REPAIR MANUAL FOR ENGINES F4GE0684F -- F4HE0684J F4GE0684F F4HE0684J Every information, illustration and specification contained in the present manual is based on the most recent information available at the time of printing. CNH America LLC r eserves the right to modify the text at any time without prior communication. Edition – June 2003 IN--1 INTRODUCTION TO THE READER - This manual was written for a skilled technician and contains all the technical information needed to repair this vehicle. - Read this manual carefully for the information concerning repairing operations. FURTHER REFERENCES PAGE NUMBER - Every page carries a number on the top right corner. Every page contains the following information: Example:: T 1 -- 2 -- 3 Progressive page number for each group Group number (if any) Section number S: Safety rules T: Technical section EW: Instruction section for engine repairing Operation principle Performance tests Fault diagnosis SYMBOLS This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages. ! This symbol regards safety. Use great care when you see this symbol because possible injuries to the personnel may occur. Strictly observe the precautions marked with this symbol. The safety warning symbol is used also to draw attention on the weight of a component or an element. Make sure you are always using the right equipment and lifting techniques when handling heavy loads, in order to prevent injuries or damages. F4GE0684F -- F4HE0684J SECTION 3 ENGINES F4GE0684F -- F4HE0684J OVERHAUL INDEX Engine coding . . . . . . . . . . . . . . . . . . . . Main engine features . . . . . . . . . . . . . . Assem ling pla specifications . . . Tightening tor ue . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graphic indications and s m ols . . . General remar s . . . . . . . . . . . . . . . . . . Engine F4GE0684F . . . . . . . . . . . . . . . . Engine F4HE0684J . . . . . . . . . . . . . . . . Description of main mechanic engine components . . . . . . . . . . . . . . . Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . Drive shaft seal rings . . . . . . . . . . . . . . . Connecting rods . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributing shaft . . . . . . . . . . . . . . . . . . . Engine F4GE0684F valve control . . . . . Engine F4HE0684J valve control . . . . . Engine F4GE0684F cylinder head . . . . Engine F4GE0684F cylinder head . . . . Engine F4GE0684F valves and valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine F4HE0684J valves and valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine F4GE0684F valve guides . . . . . Engine F4HE0684J valve guides . . . . . Valve control bridges F4HE0684J . . . . . . . . . . . . . . . . . . . . . . . . Grinding cylinder head valve seats F 4HE0684J Engine flywheel . . . . . . . . . . . . . . . . . . . . Engine F4GE0684F auxiliary component drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine F4HE0684J auxiliary component drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine F4GE0684F Lu rication . . . . . Engine F4HE0684J Lu rication . . . . . Heat exchanger . . . . . . . . . . . . . . . . . . . . Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . Engine F4GE0684F oil sump . . . . . . . . . Engine F4HE0684J oil sump . . . . . . . . . Engine F4GE0684F oil vapour recirculation . . . . . . . . . . . . . . . . . . . . . . . Engine F4HE0684J oil vapour recirculation . . . . . . . . . . . . . . . . . . . . . . . EW--3--4 EW--3--5 EW--3--8 EW--3--14 EW--3--15 EW--3--16 EW--3--17 EW--3--17 EW--3--18 EW--3--19 EW--3--19 EW--3--20 EW--3--20 EW--3--21 EW--3--22 EW--3--23 EW--3--24 EW--3--25 EW--3--26 EW--3--27 EW--3--28 EW--3--29 EW--3--30 EW--3--31 EW--3--31 EW - 3 - 31 EW--3--32 EW--3--33 EW--3--34 EW--3--35 EW--3--36 EW--3--37 EW--3--38 EW--3--39 EW--3--40 EW--3--41 EW--3--42 Engine F4GE0684F cooling . . . . . . . . . Engine F4HE0684J cooling . . . . . . . . . Water pump . . . . . . . . . . . . . . . . . . . . . . . Engine F4GE0684F mechanic in ection feeding s stem . . . . . . . . . . . Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . Mechanic fuel pump . . . . . . . . . . . . . . . . Engine F4GE0684F In ection assem l . . . . . . . . . . . . . . . . . . . . . . . . . Engine F4HE0684J fuel suppl s stem . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine F4HE0684J fuel s stem diagram . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical feed pump . . . . . . . . . . . . . . Normal operating condition . . . . . . . . . . Outlet overpressure condition . . . . . . . . Bleed conditions . . . . . . . . . . . . . . . . . . . . High pressure pump . . . . . . . . . . . . . . . . Operating principle . . . . . . . . . . . . . . . . . Engine F4GE0684F ench--overhaul Disassembling the engine . . . . . . . . . . . Replacing the seal ring . . . . . . . . . . . . . . Removing the injection pump . . . . . . . . . Removing the rocker arm assembly . . . Repair wor on c linder cluster . . . . . Checks and measurements . . . . . . . . . . Checking the surface supporting the head on the cylinder cluster . . . . . . . . . . Valve gear . . . . . . . . . . . . . . . . . . . . . . . . Distributing shaft . . . . . . . . . . . . . . . . . . . Checking the eccentric lift and the pin alignment . . . . . . . . . . . . . . . . . . . . . . . . . Bushings . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the bushings . . . . . . . . . . . . . . Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the tappets – Distributing shaft Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . Measuring the journals and crankpins . Replacing the oil pump drive gears . . . . Mounting the main bearings . . . . . . . . . . Measuring the journal assembling play Checking the drive shaft shoulder play . Connecting rod--piston assem l . . . EW--3--43 EW--3--44 EW--3--45 EW--3--46 EW--3--46 EW--3--46 EW--3--47 EW--3--48 EW--3--49 EW--3--50 EW--3--51 EW--3--52 EW--3--53 EW--3--53 EW--3--53 EW--3--54 EW--3--54 EW--3--56 EW--3--59 EW--3--59 EW--3--62 EW--3--62 EW--3--65 EW--3--67 EW--3--67 EW--3--68 EW--3--69 EW--3--69 EW--3--69 EW--3--70 EW--3--71 EW--3--71 EW--3--71 EW--3--72 EW--3--72 EW--3--75 EW--3--75 EW--3--75 EW--3--76 EW--3--77 INDEX Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring the piston diameter . . . . . . . Piston pins ...................... Conditions for correct pin/piston matching . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rings . . . . . . . . . . . . . . . . . . . . . . . . Connecting rods . . . . . . . . . . . . . . . . . . . . Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the connecting rods . . . . . . . . Checking the torsion . . . . . . . . . . . . . . . . Checking the flexion . . . . . . . . . . . . . . . . Mounting the connecting rod--piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod--piston match . . . . . . . . Mounting the piston rings . . . . . . . . . . . . Mounting the connecting rod/piston assemblies in the cylinder liners . . . . . . Measuring the crankpin assembling play Checking piston protrusion . . . . . . . . . . . Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . Distribution gearbox case . . . . . . . . . . . . Valve timing . . . . . . . . . . . . . . . . . . . . . . . Injection pump – 1st phase . . . . . . . . . . Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel cover case . . . . . . . . . . . . . . . . Engine fl wheel . . . . . . . . . . . . . . . . . . . Replacing the engine flywheel ring gear Injection pump – 2nd phase . . . . . . . . . . Mounting the injection pump – 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the oil and water pumps . . . . Mounting the oil sump . . . . . . . . . . . . . . . Mounting the water / oil heat exchanger Cylinder head . . . . . . . . . . . . . . . . . . . . . . Removing the valves . . . . . . . . . . . . . . . . Checking the cylinder head supporting surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the cylinder head water seal . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve descaling, check and grinding . . . Checking the play between the valve stem, valve guide and valve centring . . Valve guide . . . . . . . . . . . . . . . . . . . . . . . Valve seats . . . . . . . . . . . . . . . . . . . . . . . Valve seat reconditioning -- replacement Valve springs . . . . . . . . . . . . . . . . . . . . . Mounting the c linder head . . . . . . . . Reattaching the cylinder head . . . . . . . . Rocker arm assembly . . . . . . . . . . . . . . . Mounting the injectors . . . . . . . . . . . . . . . Replacing the in ectors . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembling . . . . . . . . . . . . . . . . . . . . . . Ad usting the tappets . . . . . . . . . . . . . . Roc er arm removal reassem ling . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembling . . . . . . . . . . . . . . . . . . . . . . Valve timing . . . . . . . . . . . . . . . . . . . . . . Removal of EDC7 components F4HE0684J . . . . . . . . . . . . . . . . . . . . . . . Disassembly of the engine . . . . . . . . . . . Repair interventions . . . . . . . . . . . . . . . C linder group . . . . . . . . . . . . . . . . . . . . Controls and measurements . . . . . . . . . EW--3--78 EW--3--78 EW - 3 - 79 EW--3--79 EW--3--79 EW--3--80 EW--3--81 EW--3--81 EW--3--81 EW--3--81 EW--3--82 EW--3--82 EW--3--82 EW--3--83 EW--3--83 EW--3--84 EW--3--85 EW--3--85 EW--3--85 EW--3--86 EW--3--86 EW--3--87 EW--3--88 EW--3--88 EW--3--89 EW--3--89 EW--3--89 EW--3--90 EW--3--91 EW--3--92 EW--3--92 EW--3--93 EW--3--93 EW--3--93 EW--3--94 EW--3--94 EW--3--94 EW--3--94 EW--3--94 EW--3--96 EW--3--96 EW--3--96 EW--3--97 EW--3--98 EW--3--101 EW--3--101 EW--3--101 EW--3--103 EW--3--103 EW--3--103 EW--3--103 EW--3--103 EW--3--104 EW--3--104 EW--3--113 EW--3--113 EW--3--113 Cam lift check and pin alignment check Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . Head face check on the cylinder group Timing s stem . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . Bush replacement . . . . . . . . . . . . . . . . . . Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting tappets – camshaft . . . . . . . . . . . Output shaft . . . . . . . . . . . . . . . . . . . . . . Measuring journals and crankpins . . . . Replacing oil pump control gear . . . . . . Fitting main bearings . . . . . . . . . . . . . . . . Finding journal clearance . . . . . . . . . . . . Checking output shaft shoulder clearance . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod -- piston assem l . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring piston diameter . . . . . . . . . . . Piston pin diameter. . . . . . . . . . . . . . . . . . . . . . Conditions for proper pin--piston coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . Split rings . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rods . . . . . . . . . . . . . . . . . . . . Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking torsion . . . . . . . . . . . . . . . . . . . Checking connecting rods . . . . . . . . . . . Checking bending . . . . . . . . . . . . . . . . . . Fitting connecting rod--piston assembly Connecting rod--piston coupling . . . . . . Fitting split rings . . . . . . . . . . . . . . . . . . . . Fitting connecting rod--piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . Finding crankpin clearance . . . . . . . . . . Checking piston protrusion . . . . . . . . . . . Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel housin . . . . . . . . . . . . . . . . . . . . Engine fl wheel . . . . . . . . . . . . . . . . . . . Replacing engine flywheel ring gear . . . C linder head . . . . . . . . . . . . . . . . . . . . . Removing the valves . . . . . . . . . . . . . . . . Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . Checking cylinder head supporting surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide . . . . . . . . . . . . . . . . . . . . . . . Valve seats . . . . . . . . . . . . . . . . . . . . . . . Regrinding – replacing the valve seats . Valve springs . . . . . . . . . . . . . . . . . . . . . Fitting c linder head . . . . . . . . . . . . . . . Refitting the cylinder head . . . . . . . . . . . Fitting injectors . . . . . . . . . . . . . . . . . . . . . Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker assembly . . . . . . . . . . . . . . . . . . . Tappet clearance adjustment . . . . . . . . . Harness support ................. EW--3--113 EW--3--113 EW--3--115 EW--3--115 EW--3--115 EW--3--116 EW--3--116 EW--3--116 EW--3--117 EW--3--117 EW--3--119 EW--3--119 EW--3--119 EW--3--120 EW--3--120 EW--3--121 EW--3--121 EW - 3 - 122 EW--3--122 EW--3--122 EW--3--123 EW--3--123 EW--3--124 EW--3--124 EW--3--124 EW--3--124 EW--3--124 EW--3--125 EW--3--125 EW--3--126 EW--3--127 EW--3--128 EW--3--128 EW--3--129 EW--3--129 EW--3--133 EW--3--133 EW--3--135 EW--3--134 EW--3--135 EW--3--135 EW--3--135 EW--3--135 EW--3--136 EW--3--136 EW--3--137 EW--3--138 EW--3--138 EW--3--139 EW--3--140 EW--3--140 EW--3--141 EW - 3 - 143 EW--3--3 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 1 86483 ENGINE F4GE0684F Figure 2 86484 ENGINE F4HE0684J EW--3--4 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE CODING F 4 G E 0 6 8 4 J * D + Emission level Approved rating Use Feeding / Injection D = TIER 2 Cylinder no. Cylinder pattern 0 = 4 strokes, vertical Engine Type of crankcase: B = non--structural 6 = 6--cylinder Engine group 8 = Direct injection turbo diesel with intercooler 4 = Earthmovers X Y Y X = 4 in--line, 2--valve injection pump Y = Engine model X = X= 1 4--valve Common Rail Y Y Y Y Y Manufacturing sequence number Y EW--3--5 ENGINE F4GE0684F -- F4HE0684J OVERHAUL MAIN ENGINE FEATURES A Construction Equipment Construction Equipment B F4GE0684F F4HE0684J C *D601 *D100 D 6728 cm3 E F 145 kW 2000 rpm 110 kW 2000 rpm G Direct injection H In--line injection pump I T.A.A. (Boosted by intercooler) A B C D E F G H Engine Used For Type T off engine i Engine model Number of cylinders Total displacement Max. power currently available Type of injection Injection system I Air supply system EW--3--6 ENGINE F4GE0684F -- F4HE0684J OVERHAUL MAIN ENGINE FEATURES F4GE6484F F4HE6484J *D601 *D100 Type Cycle 4--stroke diesel engine Feeding Boosted by intercooler Injection Direct Number of cylinders In--line, 6--cylinder Bore mm 11042 Stroke mm 132 Total displacement cm3 6728 cm3 Compression ratio Max. rating Max. torque kW min --1 110 2000 145 2000 Nm (kgm) min --1 675 1400 850 1400 No--load idle rpm min --1 700 No--load peak rpm min --1 -- BOOSTING Type of turbocompressor: With intercooler HOLSET HX35W Forced by means of gear pump, pressure relief valve, oil filter LUBRICATION Oil pressure with hot engine: at idle rpm at peak rpm bar bar 1.2 3.8 EW--3--7 ENGINE F4GE0684F -- F4HE0684J OVERHAUL F4GE0684F F4HE0684J *D601 *D100 Type COOLING By fluid Water pump drive: Thermostat: start of opening: REFUELLING Full filling capacity 1q 15W40 10W30 By means of belt qC 81 r 2 litres kg -- -- engine sump litres kg -- -- engine sump + filter litres kg FEEDING Bosch--type injection VE6/12F9000 L968 0q r 0q.5 Pump setting Start of delivery Type of nozzle Injection sequence Injection pressure bar High pressure Common Rail mm 1 DSLA 145 P1174 Electro--injectors 1 -- 5 -- 3 --6 --2 -- 4 245 bar 250 -- 1450 bar EW--3--8 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ASSEMBLING PLAY -- SPECIFICATIONS F4GE0684F F4HE0684J *D601 *D100 Type CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm Cylinder liners 1 104 Pistons: supplied with standard spares Measurement dimension Outer diameter Pin seat X 1 2 61 103.730 to 10.748 Piston -- cylinder liners Piston diameter Position of pistons from crankcase Piston pin -1 X 3 Piston rings Piston rings– Slots Piston rings 0.5 -- 37.994 to 38.000 0.01 to 0.022 Piston pin - Pin seat Type of piston Piston ring slots 38.016 to 38.010 X1* X2 X3 2.705 to 2.735 2.440 to 2.460 4.03 to 4.05 S1* S2 S3 2.560 to 2.605 2.350 to 2.380 3.977 to 3.990 1 2 3 0.100 to 0.175 0.010 to 0.11 0.040 to 0.083 0.5 EW--3--9 ENGINE F4GE0684F -- F4HE0684J OVERHAUL F4GE0684F F4HE0684J *D601 *D100 Type CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm Piston ring end opening in cylinder liner: X1 X2 X3 Connecting rod small--end bushing seat Connecting rod bearing seat 0.3 to 0.4 0.6 to 0.8 0.3 to 0.55 1 2 41.2797 to 41.553 72.987 to 73.013 Connecting rod small--end bushing diameter Outer 4 Inner 3 40.987 to 410.13 38.019 to 38.033 Connecting rod small--end bushing – seat 0.266 to 0.566 Piston pin – Bushing 0.019 to 0.039 Measurement dimension X -- Max. error on connecting rod axis parallelism = -- Journals Crankpins Main half bearings Connecting rod half bearings * supplied with spares Bed supports no.: n. 1--5 n. 2--3--4 1 2 S1* S2* 82.99 to 83.01 68.987 to 69.013 2.456 to 2.464 1.955 to 1.968 3 87.982 to 88.008 87.977 to 88.013 EW--3--10 ENGINE F4GE0684F -- F4HE0684J OVERHAUL F4GE0684F F4HE0684J *D6011 *D100 Type CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm Half bearings -- journals: n. 1--7 n. 2--3--4--5--6 0.041 to 0.119 0.041 to 0.103 Half bearings -- crankpins 0.033 to 0.041 Main half bearings Connecting rod half bearings + 0.250; + 0.500 Shoulder journal X1 37.475 to 37.545 Shoulder bed support X2 25.98 to 26.48 Shoulder half rings X3 37.28 to 3738 Drive shaft shoulder 0.068 to 0.410 EW--3--11 ENGINE F4GE0684F -- F4HE0684J OVERHAUL F4GE0684F F4HE0684J *D601 *D100 Type VALVE GEAR – CYLINDER ASSEMBLY Valve guide seats on cylinder head mm 1 8.019 to 8.039 70.42 to 7.062 4 D 4 D 7.96 to 7.98 60q 7.96 to 7.98 6.970 to 6.999 60 y 0.25q 6.970 to 6.999 45q 45 y 0.25q 0.052 to 0.092 0.043 to 0.092 Valves: Valve stem and respective guide Seat on head for valve seat: 1 46.987 to 47.013 34.837 to 34.863 1 43.637 to 43.668 34.837 to 34.863 Valve seat outer diameter; inclination of valve seats on cylinder head: 2 47.063 to 47.089 34.917 to 34.931 D 60q 60q 2 43.713 to 43.739 34.917 to 34.931 D 45q 45q Hollow Between the valve seat and the head Valve seats X 0.356 to 1.102 0.59 to 1.11 X 0.104 to 0.840 0.96 to 1.48 0.050 to 0.102 0.054 to 0.094 0.050 to 0.102 0.054 to 0.094 -- EW--3--12 ENGINE F4GE0684F -- F4HE0684J OVERHAUL F4GE0684F F4HE0684J *D601 *D100 Type VALVE GEAR – CYLINDER ASSEMBLY Valve spring height: free spring under a load of: 329 N (x) -- 3398 N (H) 641 N (x) -- 741 N (H) Injector protrusion mm H 63.5 47.75 H1 H2 49.02 (x) 38.20 (x) 35.33 (H) 25.2 (H) X not adjustable Seats for distributing shaft bushings no. n. 1--7 Distributing shaft seats no. 2--3--4--5--6 --- Distributing shaft support pins: 17 53.995 to 54.045 Bushing inner diameter 54.083 to 54.147 Bushings and seats in crankcase Bushings and support pins -0.038 to 0.162 Eccentric working lift: 6.045 6.45 7.239 7.582 EW--3--13 ENGINE F4GE0684F -- F4HE0684J OVERHAUL F4GE0684F F4HE0684J *D601 *D100 Type VALVE GEAR – CYLINDER ASSEMBLY 1 2 3 Seat for tappet collar in the crankcase mm 1 16.000 to 16.030 Outer diameter of tappet collar: 2 15.929 to 15.959 15.924 to 15.954 3 15.965 to 15.980 15.960 to 15.970 2 Between the tappets and the seats 0.020 to 0.065 Tappets 0.025 to 0.070 -- 1 Rocker arm shaft 1 18.963 to 18.975 21.965 to 21.977 Rocker arms 2 19.000 to 19.026 22.001 to 0027 2 Between the rocker arm and the shaft 0.025 to 0.063 0.024 to 0.377 EW--3--14 ENGINE F4GE0684F -- F4HE0684J OVERHAUL TIGHTENING TORQUE PART Cylinder y head fastening g screw 1st p phase: screws M12x1.75x70 screws M12x1.75x140 screws M12x1.75x180 nd 2 p phase: 3rdd phase: (only for screws 140 and 180 mm long) phase 1st p nd 2 p phase 3rd phase g rod cap p fastening g 1st p phase Connecting nd 2 p phase 3rd phase g y g screws p g Engine flywheel fastening pre--tighten Angle Injector fastening Sump oil drain plug Fuel filter Injection pump gear cover fastening screw Valve gear cover and case fastening screw Container fastening screw Intake manifold fastening screw Fuel pump fastening screw Exhaust manifold fastening screw Tappet cover fastening nut Rocker arm support fastening screw Nut for rocker arm adjusting screw Screw fastening the pulley on drive shaft pre--tighten Angle Distributing shaft shoulder plate fastening screw Fan support fastening screw Injection pump fastening screw Fan pulley fastening screw Turbocompressor fastening screw Heat exchanger fastening screw Oil pump and front cover fastening screw Starter motor fastening screw Alternator fastening screw Water pump fastening screw Oil filter Belt stretcher fastening screw p fastening g screws Bed cap -- Lubrication with oil COPPIA Nm 50 r 5 40 r 5 70 r 5 (kgm) (5 r 0.5) (4 r 0.5) (7 r 0.5) 90q 90q 50 r 6 (5 r 0.6) 80 r 6 (8 r 0.6) 90q r 5q 30 r 5 (3 r 0.5) 50 r 5 (5 r 0.5) 60q r 5q 30 r 5 (3 r 0.5) 60q r 5q 60 r 5 (6 r 0.5) 60 r 5 (6 r 0.5) contact + 3/4 turn 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 53 r 5 (5.3 r 0.5) 25 r 5 (2.5 r 0.5) 48 r 8 (4.8 r 0.8) 25 r 5 (2.5 r 0.5) 50 r 5 (5 r 0.5) 90q r 5q 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 12 r 5 (1.2 r 0.5) 45 r 5 (4.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 25 r 5 (2.5 r 0.5) 55 r 5 (5.5 r 0.5) 45 r 5 (4.5 r 0.5) 25 r 5 (2.5 r 0.5) contact + 3/4 turn 45 r 5 (4.5 r 0.5) EW--3--15 TOOLS TOOL No. ENGINE F4GE0684F -- F4HE0684J OVERHAUL DEFINITION 380000663 TOOL No. DEFINITION 380000988 Crankshaft Rear Seal Puller 380000664 Crankshaft Rear Seal Installer 380000665 Crankshaft Front Seal Puller 380000666 Crankshaft Front Seal Installer 380000671 Injector Puller 380000979 Injector Pump Puller Tool for Rotating the Engine Flywheel EW--3--16 ENGINE F4GE0684F -- F4HE0684J OVERHAUL GRAPHIC INDICATIONS AND SYMBOLS Detachment Disconnect Intake Reattachment Connect Exhaust Removing Disassembling Operation Mounting Assembling § ! ¸ Compression ratio Torque--tighten Tolerance Weight difference Torque--tighten + angular value Dragging torque Countersink Replacement Genuine spares Adjustment Setting Rotation Warning Note Angle Angular value Visual check Mounting position check Preload Measurement Dimension to be measured Check Revs number Equipment Temperature Surface to be machined Machining finish bar Pressure Interference Forced mounting Increase Greater than ..... Maximum Thickness Play Decrease Smaller than ..... Minimum Lubricate Moisten Grease Selection Classes Increases Sealant Temperature < 0 qC Cold Winter Air bleed Temperature > 0 qC Hot Summer EW--3--17 ENGINE F4GE0684F -- F4HE0684J OVERHAUL GENERAL REMARKS ENGINE F4GE0684F Figure 3 86485 1. Turbocompressor – 2. Fixed guide pulley – 3. Alternator -- 4. Automatic belt stretcher – 5. Water pump -- 6. Poly--V water pump and alternator drive belt– 7. Fixed guide pulley – 8. Damper flywheel – 9. Sump – 10. Diesel oil filters – 11. Rotary injection pump – 12. Blow--by -- 13. Cold start air heater EW--3--18 ENGINE F4GE0684F -- F4HE0684J OVERHAUL MOTORE F4HE0684J Figure 4 86486 1. Turboblower-- 2. Conditioner compressor -- 3. Alternator -- 4. Fixed guide pulley -5. . Automatic take--up unit -- 6. Water pump -- 7. Fixed guide pulley 8. Damper flywheel -- 9. Electronic control unit -- 10. Oil sump -- 11. Fuel oil filter -- 12. High pressure pump with fuel pump -- 13. Common rail EW--3--19 ENGINE F4GE0684F -- F4HE0684J OVERHAUL DESCRIPTION OF MAIN MECHANIC ENGINE COMPONENTS Cran case It consists of a cast--iron structure in which the following items are realized: cylinder liners (1); bed supports (5) and seats for: distributing shaft bushings (3), tappets, water/oil heat exchanger (7), water pump (2) and oil pump (4). It also incorporates the coolant circulation chambers and the engine member lubricating circuit ducts. Plate (6) is fitted to the lower part of the crankcase and ensures greater resistance to forces and stress. Figure 5 86605 EW--3--20 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Drive shaft It is made of steel and rests on seven induction--hardened supports. Inside the drive shaft are the lubricating oil ducts. The following items are force--fitted on the front shank: oil pump drive gear, phonic wheel, damper flywheel and auxiliary component drive pulley. The following items are force--fitted on the rear shank: distributing shaft drive gear and engine flywheel mounting hub. The main half bearings are made of steel with anti-friction alloy coating. The penultimate main half bearings are equipped with a shoulder to restrain the drive shaft end play. Parts (1) and (3) are mounted in an interfering manner on the rear shank and cannot be replaced. Figure 6 84037 1. Oil pump drive gear -- 2. Drive shaft -- 3. Valve gear drive gear -4. Flywheel attachment hub Drive shaft seal rings The front and rear seal rings are of the “box” type, with radial seal. EW--3--21 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Connecting rods They are steel--stamped, of the oblique cut type, with separation of the cap obtained by an advanced technology (fracture split) instead of mechanic machining. The connecting rod half bearings are made of steel, with anti--friction alloy coating. Each connecting rod is marked: - By a number (on the connecting rod body and cap) indicating its respective match and the cylinder in which it is mounted. - By a letter (on the connecting rod body) indicating the weight class of the factory--assembled connecting rod. Figure 7 84038 EW--3--22 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Pistons The combustion chamber is machined in the piston crown.The crown of the piston is cooled by the engine oil supplied by the sprayer. There are three grooves that house the compression rings; the 1st of which is V shaped and is obtained using a cast iron insert. The following references are engraved on the crown of the piston: 1. Spare part number and design change number. 2. Arrow indicating the assembly sign of the piston in the cylindrical liner; this must be facing towards the front side of the engine block. 3. Date of manufacture. 4. Stamp indicating testing of the 1st groove insert Figure 8 86549 EW--3--23 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Distri uting shaft The distributing shaft rests on seven supports in the crankcase. trics are provided for each cylinder. The supports (front and rear) are equipped with steel bushings mounted in an interfering manner and coated with anti--friction material; two control eccen- B. Exhaust valve control A. Intake valve control The distributing shaft is controlled directly by the drive shaft by means of straight--tooth gears. Figure 9 70164 84041 EW--3--24 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4GE0684F valve control Figure 10 84042 1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring – 8. Tappet – 9. Distributing shaft EW--3--25 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4HE0684J valve control Figure 11 003198t 1.Rocker arm -- 2. Shaft -- 3. Adjustment screw -- 4. Rod -- 5. Bridge -- 6. Half--cones -7. Retainer -- 8. Spring -- 9. Tappet -- 10. Timing shaft EW--3--26 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4GE0684F c linder head The seats of the following parts are obtained on the cast--iron cylinder head: Moreover, the following components are inserted on the heads: - inserted valve seats (4); - single--block exhaust manifold (1); - injectors (6); - intake manifold (2) with seat for cold start air heater (3). - thermostat (5); Figure 12 84043 DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS EW--3--27 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4GE0684F c linder head The seats of the following parts are obtained on the cast--iron cylinder head (8): Moreover, the following components are inserted on the heads: - inserted valve seats (10); - exhaust manifold (1) in two parts; - injectors (2); - intake manifold (5) with seat for cold start air heater (6); - thermostat (4); - support (7) with injector harness (3). Figure 13 86487 EW--3--28 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4GE0684F valves and valve seats Figure 14 84044 1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side The valve seats inserted on the cylinder head have the following inclination: - 45q (exhaust valves) - 60q (intake valves). The exhaust valves (2) differ from intake valves in that they have only one notch at the stem end. Figure 15 84045 Figure 15, shows the oil seals mounted on valve stems. EW--3--29 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4HE0684J valves and valve seats Figure 16 70319 1. Intake valves - 2. Exhaust valves - A . Intake side - S . Exhaust side. The angles of the valve seats are as follows: - 45q for the exhaust valves - 60q for the intake valves The exhaust valves 2 have a distinctive hollow at the center of the mushroom. Figure 17 70334 The figures shows the oil gaskets fitted on the valve rods EW--3--30 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4GE0684F valve guides Figure 18 INTAKE EXHAUST 84046 DETAIL OF VALVE GUIDES AND SEATS EW--3--31 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4HE0684J valve guides The valve guides are not shown. Figure 19 INTAKE EXHAUST 70328 Valve control ridges F4HE0684J engine When re--assembling the cylinder head, observe the direction of the valve control bridges. The bridges must be positioned with the notches (o)facing towards the exhaust manifold. Figure 20 70345 1. Bridge -- 2. Rod Grinding of the F4HE0684J c linder head not exceed 0.13 mm. A single thickness gasket is available as spare part The nominal thickness of the cylinder head is 105 r 0,25 mm mm; maximum metal removal must Figure 21 70325 EW--3--32 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine fl wheel The flywheel (1) does not need being positioned in a fixed manner on the drive shaft, since it does not bear any stamping, notch or reference hole for sen- sors or timing. The equidistance of fastening screw holes (2) allows it to be mounted in any position. Figure 22 86454 ENGINE FEHE0684J Figure 23 86488 ENGINE F4GE0684F EW--3--33 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4GE0684F au iliar component drive A Poly--V belt (4) transmits the motion of drive shaft (5) to water pump (1) and alternator (2). The belt is stretched by means of automatic belt stretcher (3). Figure 24 86489 1. Water pump -- 2. Alternator -- 3. Automatic belt stretcher -- 4. Poly--V belt -- 5. Drive shaft EW--3--34 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4HE0684J au iliar component drive A Poly--V belt (4) transmits the motion of drive shaft (5) to water pump (1) and alternator (2). The belt is stretched by means of automatic belt stretcher (3). Figure 25 86490 1. Conditioner compressor -- 2. Alternatore -- 3. Water pump -- 4. Automatic belt stretcher -- 5. Poly--V belt -- 6. Drive shaft EW--3--35 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE F4GE0684F LUBRICATION Forced circulation lubrication is performed by the following components: - rotor--equipped oil pump housed in the crankcase front part, controlled by the straight--tooth gear force--fitted on the drive shaft shank; - water / oil heat exchanger housed in the engine crankcase, - oil pressure control valve; - by--pass valve for clogged oil filter cut--off, built into the oil filter adapter; - cartridge--type oil filter. Figure 26 86491 Oil return drop--type path Pressure oil path EW--3--36 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE F4HE0684J LUBRICATION Forced circulation lubrication is afforded by the following components: - vane type oil pump (5), housed in the front part of the engine block, controlled by the straight-toothed gear splined on the tail of the crankshaft; - water/oil heat exchanger (3), housed in the engi- ne block, with oil filter support; - oil pressure regulation valve (1 incorporated in the filter support; - by--pass valve (4) to bypass the clogged oil filter, incorporated in the filter support; - cartridge type oil filter (2). Figure 27 Pressure oil path Oil return drop--type path Introduction oil 86492 EW--3--37 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Heat e changer Figure 28 1 2 3 4 86458 1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between exchanger unit and engine block EW--3--38 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Oil pump Figure 29 84052 Figure 30 70150 1. Drive shaft with oil pump drive gear EW--3--39 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4GE0684F oil sump The oil sump (1) is secured elastically to the crankcase by means of an aluminium plate (3), Figure 32. The C--section rubber gasket (2), fitted onto the oil sump leading profile, enhances sealing properties and also deaden noise. This type of gasket can only be replaced in case of deterioration or break, and not necessarily at every single disassembling operation. Figure 31 84054 Figure 32 84055 EW--3--40 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4HE0684J oil sump The sump is bolted to the engine block with a thin gasket Figure 33 003202t 003203t EW--3--41 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4GE0684F oil vapour recirculation Oil vapour recirculation takes place by means of valve (1) placed above the tappet cover (2). The vapour condensed therein fall below the tappet cover (2) due to gravity, whereas the remaining vapour is recovered by vent (3) and properly conveyed to the intake phase. Figure 34 86460 EW--3--42 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Engine F4HE0684J oil vapour recirculation A pre--separator (1) is housed in the tappet cover, whose shape and position determine an increase in the outfeed speed of the oil vapors and, at the same time, condense part of these. The condensed oil returns to the oil sump while the remaining vapors are routed, collected and filtered in the blow--by (3). In the blow--by (3), part of the vapors condense and return to the oil sump while the remaining vapors are recycled through suction via the hose (2). Figure 35 not exceed 0.13 mm. oil condensation oil vapors 1. Pre--separatore -- 2. Suction recycling -- 3. Filter -- 4. Return to the engine 000966t EW--3--43 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE F4GE0684F COOLING The engine cooling system is of the forced, closed-circuit circulation type and is made up of the following components: - centrifugal water pump, housed in the engine crankcase front part; - heat exchanger, used to cool the lubricating oil; - thermostat, used to regulate coolant flow. Figure 36 86493 Water flowing out Water recirculating Water flowing in EW--3--44 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE F4HE0684J COOLING The forced circulation, closed loop engine cooling system comprises the following components: - a centrifugal type water pump housed in the front part of the engine block; - a heat exchanger to cool the lubrication oil (see lubrication); - a thermostat that regulates circulation of the cooling fluid. Figure 37 86494 Water in output from the thermostat Water recirculating in the engine Water supplied to the pump EW--3--45 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Water pump The water pump is housed in a seat obtained from the crankcase and is controlled by means of a poly--V belt. The nearly total absence of outer pipes, sleeves and clamps eliminates many connections, thus reducing possible leak points. The engine temperature is controlled by a thermostat. The coolant flows also in the oil heat exchanger. Figure 38 84058 Figure 39 84059 EW--3--46 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE F4GE0684F MECHANIC INJECTION FEEDING SYSTEM Fuel prefilter The filter support (1) incorporates: manual priming pump (4), screw (2) used to blow air off the system, and cartridge (3). Figure 40 84060 Fuel filters The support (2) incorporates: fuel temperature sensor (1), heater resistors (4), air bleeding screws (3) and filter (5). Degree of filtration of cartridge: 10 micron. Figure 41 Maximum working pressure: 5 bar. Working temperature: --25 qC to + 90 qC. 84061 EW--3--47 ENGINE F4GE0684F -- F4HE0684J OVERHAUL MECHANIC FUEL PUMP Displacement pump mounted on the injection pump left side; it is used to feed the injection pump. Figure 42 84062 1. Injection pump -- 2. Fuel outflow to the filter -- 3. Fuel pump -- 4. Fuel inflow from the tank -- 5. Manual control lever EW--3--48 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE F4GE0684F INJECTION ASSEMBLY Figure 43 9 86495 1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for fuel discharge from injectors -- 6. Injector 5 fuel pipe -- 7. Injector 6 fuel pipe -- -- 8. Injection pump -9. Injector EW--3--49 ENGINE F4GE0684F -- F4HE0684J OVERHAUL \ ENGINE F4HE0684J FUEL SUPPLY SYSTEM The Common Rail system features a special pump that maintains the fuel constantly at high pressure regardless of the phase and of the cylinder to be injected and accumulates it in a duct common to all the electro--injectors. This means that fuel at the injection pressure calculated by the electronic control unit is always available at the infeed to the electro--injectors. When the solenoid valve of an electro--injector is energized by the electronic control unit, fuel tapped directly from the rail is injected in the related cylinder. Figure 44 High pressure Low pressure Fuel drainage 003205t 1.Electro--injector -- 2. Common Rail -- 3. Pressure limiting device for fuel return -4.Common Rail overpressure valve -- 5.Prefilter fitted on the chassis -- 6.High pressure pump -- 7. Mechanical vane pump -- 8. Fuel filter The hydraulic system consists of a low pressure circuit and a high pressure circuit. - suction pipe of the fuel from the tank to the prefilter; The high pressure circuit comprises the following pipes: - pipes that supply the mechanical fuel pump through the heat exchanger of the control unit, the manual priming pump and the prefilter; - pipe connecting the outlet of the high pressure pump to the Common Rail; - pipes that supply the electro--injectors from the Common Rail. The low pressure circuit comprises the following pipes: - pipes that supply the high pressure pump through the fuel filter. The supply system also includes the fuel drainage system from the Common Rail, from the injectors and the cooling circuit of the high pressure pump EW--3--50 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE F4HE0684J FUEL SYSTEM DIAGRAM Figure 45 E haust Inta e (low pressure) High pressure pump suppl (low pressure) Alta pressure Inta e (low pressure) 000909t 1. High pressure pump -- 2. Limiting valve on the high pressure pump, 5 bar -- 3. Regulating valve fitted on the fuel return from the electro--injectors, 1,3 -- 2 bar-- 4. Common Rail overpressure valve -- 5. Common Rail -- 6. Pressure sensor -- 7. Electro--injector -- 8. Return pipe -- 9.Heat exchanger of the control unit -- 10.Mechanical priming pump -- 11. Prefilter fitted on chassis -- 12. Fuel tank -- 13. Mechanical fuel pump -- 14.Fuel filter -- 15. Pressure regulator -- 16. . Return pipe from high pressure pump -- 17. By--pass valve -- 18. By--pass valve The pressure regulator located ahead of the high pressure pump regulates the flow of fuel required on the low pressure system. Subsequently, the high pressure pump supplies the Common Rail correctly. This solution, which pressurizes only the fuel required, improves energy efficiency and restricts heating of the fuel in the system. The limiting valve (2), fitted on the high pressure pump, maintains a constant pressure of 5 bar at the infeed to the pressure regulator. The limiting valve (3) housed on the cylinder head, fitted on the return of the electro--injectors, regulates return flow of the fuel from the electro--injectors to a pressure of 1.3 P 2 bar. Two by--pass valves are installed in parallel with the mechanical fuel pump. By--pass valve 18 permits return of the fuel from the outlet of the mechanical pump to its infeed when the pressure at the entrance to the fuel filter exceeds the permitted limit. By pass valve 17 makes it possible to fill the fuel system through the manual priming pump (10). EW--3--51 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Fuel prefilter The high water separation type fuel filter is fitted on the base of the cartridge (3), with the sensor (4) that indicates the presence of water in the fuel. The manual priming pump (5) and the system air vent screw (2) are present on the filter support. IMPORTANT -- If the light switches on, ta e action immediately in order to remove the cause the presence of water or impurities in the fuel causes fast downgrading of Common ail system components. Figure 46 000910t EW--3--52 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Fuel filter Located on the engine block in the circuit between the fuel pump and the high pressure pump (CP3). The fuel temperature sensor and the resistor of the heater are located on the support The heater is activated if the temperature of the fuel is < = 0 qC and continues to heat until a temperature of 5 qC. is reached. The temperature of the fuel, communicated to the EDC 7 control unit by the related sensor, permits very precise calculation of the amount of fuel to be injected in the cylinders. Figure 47 003206t 1. Fuel filter support -- 2. Heater connector -- 3. electric fuel heater -4.Fuel filter -- 5. Fuel temperature sensor -- A. Outlet fitting to the high pressure pump -- B. Inlet fitting fuel drainage from the Common Rail and from the cylinder head (injectors) -C. Drainage fitting from high pressure pump -- D.Inlet fitting from fuel pump -E. Outlet fitting fuel drainage to the tank EW--3--53 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Mechanical feed pump Normal operating condition Gear pump fitted on the rear part of the high pressure pump, with the function of supplying this. It is controlled by the shaft of the high pressure pump. In normal operating conditions, the flow of fuel inside the mechanical pump is shown in the figure Figure 48 001237t A. Fuel infeed from tank -- B. Fuel outfeed to the filter 1 -- 2. By--pass valves in closed position Outlet overpressure condition The by--pass valve (1) is tripped in the case of overpressure in outfeed (B). The pressure present, overcoming the elastic resistance of the spring (1), puts the outfeed and infeed in communication through the duct (2). 001238t EW--3--54 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Bleed conditions The by--pass valve (2) is tripped when, with the engine off, the fuel system is to be filled through the priming pump. In this situation, the by--pass valve (2) opens, due to the effect of the inlet pressure and the fuel flows out (B). Figure 49 001239t High pressure pump The pump with 3 radial pumping elements, controlled by a timing gear, does not require phasing. The mechanical fuel pump controlled by the shaft of the high pressure pump is fitted on the rear side of the high pressure pump. Figure 50 001250t 1. Fuel outlet fitting to the rail-- 2. High pressure pump -- 3. Pressure regulator -- 4. Fuel inlet fitting from filter -- 5. Fuel outlet fitting to the filter support -- 6. Fuel infeed fitting from the heat exchanger of the control unit --7. Fuel outlet fitting from mechanical pump to the filter -- 8. Mechanical fuel pump. EW--3--55 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 51 001967t 1. Mechanical fuel pump -- 2. Fuel return from high pressure pump -3. Delivery valve to the Common Rail-- 4. Single pumping element -- 5. By--pass valves on fuel pump -6. Pump shaf -- 7. Fuel inlet from filter -- 8.Limiting valve 5 bar --9. Pressure regulator EW--3--56 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Operating principle Figure 52 0021111t SEZ. B -- B 001242t 1. Outlet for delivery to the rail -- 2. Delivery valve to the rail -- 3. Pumping element -- 4. Pump shaft -5. Pumping element supply duct -- 6. Pressure regulator supply duct -7. Pressure regulator The pumping element (3) rests on the cam present on the shaft of the pump. In the suction phase, the pumping element is supplied through the supply duct (5). The amount of fuel to be sent to the pumping element is established by the pressure regulator (7). According to the PWM command received from the control unit, the pressure regulator partializes the flow of fuel to the pumping element. During the compression phase of the pumping element, the fuel, reaching a pressure sufficient to open the delivery valve to the Common Rail (2), supplies this through the outlet (1). EW--3--57 ENGINE F4GE0684F -- F4HE0684J OVERHAUL The figure illustrates the paths of the low pressure fuel present inside the pump showing the main pumping element supply duct (4), the pumping element supply ducts (1 -- 3 -- 6), the ducts used for lubrication of the pump (2), the pressure regulator (5), the 5 bar limiting valve (8) and the fuel drain (7). The shaft of the pump is lubricated by the fuel through the delivery and return ducts (2). The pressure regulator (5) establishes the amount of fuel to be supplied to the pumping elements; any excess fuel flows out through the duct (9). In addition to acting as manifold for fuel drainage, the 5 bar limiting valve also maintains a constant pressure of 5 bar at the infeed of the regulator. Figure 53 SEZ. C -- C 001244t 001244t 1--3--6. Infeed to the pumping element -- 2. Pump lubrication ducts -- 4. Pumping element main supply ducts -- 5. Pressure regulator -- 7. Drainage duct of the regulator -8. bar limiting valve -- 9. Fuel drainage from regulator inlet. EW--3--58 ENGINE F4GE0684F -- F4HE0684J OVERHAUL The figure shows the flow of high pressure fuel through the outfeed ducts of the pumping elements. Figure 54 001240t 001241t SEZ. A -- A 1. 2. Fuel outfeed ducts -- 3. Fuel outfeed from the pump with fitting for high pressure pipe for the common rail. EW--3--59 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE F4GE0684F BENCH--OVERHAUL Disassem ling the engine - Disconnect electric wiring; - drain the engine oil by taking the cap off the sump and the oil filling cap off the head cover; - fit bracket (which fastens the engine to the overhaul stand) to the crankcase; - disconnect the engine oil vapour recovery pipe from blow--by (2); - take off tappet covers (3); - disconnect quick--coupling pipes (9) by following the indications given in Figure 56; - take off fuel filters (8); - take off fuel filter support (10). - disconnect injector feed pipes (4) from injection pump (6); remove the brackets fastening pipe (7), and (11) unit on the cylinder head; - take off intake manifold unit (1); - take off injection pump lubrication pipes; - disconnect the piping from L.D.A. system (5); - take off oil level check piping. Figure 55 86496 EW--3--60 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 56 Figure 58 70126 Act on fork (1) as shown in the figure (detail A), then remove the adapter. To avoid deformations, bring fork (1) back to the locking position (detail B) after the adapter has been removed. 86464 - Take off the feed pipe assembly from injectors (1). - Take off the pipe (2) for discharging fuel from the injectors by removing screw (4) and gasket (3). Figure 59 Figure 57 86465 5 - Remove screws (3 and take off turbine (1). - Remove the exhaust manifold (2). Figure 60 4 86463 In order to be able to fit bracket 75301886 to the engine crankcase on the right side, it is necessary to remove: - the fastening bracket (2) of the harness (1); - the harness (1); - the starter motor (3); - take off turbine lubrication delivery pipe (5); - detach the heat exchanger assy with the oil filter (4). Secure the engine to rotary stand. 84068 Apply suitable tool (1) to the flywheel cover case to stop flywheel rotation. EW--3--61 ENGINE F4GE0684F -- F4HE0684J OVERHAUL - Remove automatic belt stretcher (5). Remove Poly--V belt (70). Remove alternator fastening bracket (1). Remove the alternator (2), the water pump (4), the guide pulleys (3) and (6). - Remove engine cooling system adapter from the crankcase. - Remove damper flywheel (8) with underlying pulley (9). Figure 61 86467 EW--3--62 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 62 Figure 64 84237 Remove screws (1) and take off gear oil pump. 78256 Apply seal tool (4) on drive shaft front shank (2). Drill inner seal ring (1), through tool (4) guide holes, with an inset ( 3.5 mm) down to a depth of 5 mm. Secure tool (4) to ring (1) by screwing the six screws (5) provided. Take off ring (1) by fastening screw (3). IMPORTANT -- Oil pump tioned. cannot be recondi- Removing the in ection pump Figure 65 Figure 63 84071 Prior to removing the injection pump, take off the flywheel locking tool described in Figure 60. 78257 Apply the proper tension rod (3) of tool to outer seal ring (2) as shown in the figure, then take the same off front cover (1) by means of lever (4). Remove the front cover. Rotate the drive shaft until it reaches the condition of 1q cylinder at top dead centre. Such condition is obtained when, by pushing pin (1) shown by the arrow, it is housed in its own seat obtained on distributing shaft drive gear (2). EW--3--63 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 66 Figure 68 84261 84260 To correctly preset the injection pump prior to removing it, loosen screw (2) and remove L--shaped spacer (1). Fasten again screw (2) to its abutting end. Loosen the three nuts (2) (4) (5) securing the injection pump (1) to the flywheel covering case (3), then take the pump out of its housing by means of tool through proper application to gear (4) in Figure 67B. Figure 69 IMPORTANT -- Carefully store the L--shaped spacer with the pump body. 84075 Apply tool (2) to unlock screws (3). Remove tool (2). Figure 67 Remove screws (3) fastening engine flywheel (4) to the drive shaft. Figure 70 84073 - Remove cover (1) from gear covering case (2). - Lock the engine flywheel as described in Figure 60. - Loosen nut (3) securing the injection pump drive gear (4). 84076 Screw two pins (2) of adequate length into drive shaft holes (3). Take out engine flywheel (1) so that it can be harnessed by means of a hoist and placed into its own container. EW--3--64 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 71 Figure 73 84077 Remove screws (2) and take off rear cover (1). 78258 Apply seal tool (3) on drive shaft rear shank (5). IMPORTANT -- Ta e note of the mounting position of screws , due to the different si e of the latter. Drill inner seal ring (1), through tool (3) guide holes, with an inset ( 3.5 mm) down to a depth of 5 mm. Secure tool (3) to ring (1) by screwing the six screws (4) provided. Take off ring (1) by fastening screw (2). Figure 72 Figure 74 78257 Apply the proper tension rod (3) of tool to outer seal ring (2) as shown in the figure, then take the same off flywheel cover case (1) by means of lever (4). 84078 Turn the engine upside down, remove screws (2), take off both plate (3) and oil sump (1). EW--3--65 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 75 Figure 78 86516 Remove screws (1) and (4) and dismantle oil suction strainer (5). 84082 Take out injectors (2) by means of tool (1). Remove screws (2) and dismantle stiffening plate (3). Figure 76 Figure 79 70156 Remove screws (1) and take gear (3) off distributing shaft (2). Removing the roc er arm assem l Figure 77 84083 Remove screws (1) securing the head to the crankcase. Figure 80 84081 For each cylinder, remove rocker arm assembly (1), loosen adjusting nuts (3), unscrew registers (2) and remove screws (4). 84084 Hook the wire ropes to brackets (1) and (2), then separate the cylinder head from the crankcase by means of a hoist. EW--3--66 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 81 Figure 84 84085 70160 Remove screws (2) and take off timing gear case (1). The penultimate bed cap (1) and its respective support have half bearing (2) provided with shoulder. IMPORTANT -- Ta e note of the mounting position of screws , due to the different si e of the latter. IMPORTANT -- Ta e note of the mounting position of lower and upper half bearings in fact, if they have to be used again, they must be mounted in the same position they had prior to being ta en off. Figure 82 Figure 85 70158 Remove connecting rod cap (2) fastening screws (1), then take off the caps. Remove the pistons (complete with connecting rods) from the crankcase upper part. IMPORTANT -- alf bearings must be ept in their respective housings in fact, if they have to be used again, they must be mounted in the same position they had prior to being ta en off. 84086 Remove drive shaft (2) from crankcase by means of suitable lifting device (1) and a hoist. Figure 86 Figure 83 70162 70159 Remove screws (1) and take off bed caps (2). Take off main half bearings (1). Remove screws (2) and take off oil nozzles (3). EW--3--67 ENGINE F4GE0684F -- F4HE0684J OVERHAUL REPAIR WORK ON CYLINDER CLUSTER Figure 87 Chec s and measurements After the engine has been dismantled, clean the crankcase--cylinder cluster thoroughly. Use proper rings to move the cylinder cluster. Check the crankcase carefully for cracks. Check the condition of working caps. They must be replaced if they are rusty or their sealing properties are in doubt. Inspect the cylinder liner surfaces; they must not show traces of seizing, scoring, out--of--roundness, taper and excessive wear. 70163 Remove screws (1) and take off distributing shaft (3) retaining plate (2). IMPORTANT -- Ta e note of plate position. Figure 90 mounting Figure 88 84087 70164 Carefully remove distributing shaft (1) from the engine crankcase. Figure 89 70165 Remove tappets (1) from the engine crankcase. The check of cylinder liner inner diameter (in order to measure the amount of out--of--roundness, taper and wear) is carried out by means of bore gauge (1) equipped with a comparator previously reset on the ring gauge (2) of the cylinder liner diameter. NOTE -- If no ring gauge is available, use a micrometer to perform reset. EW--3--68 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Chec ing the surface supporting the head on the c linder cluster Figure 91 Figure 93 70167 Measurements must be taken for each single cylinder, at three different heights of the liner and on two planes perpendicular to each other: one parallel to the engine longitudinal axis (A), the other perpendicular (B); the greatest amount of wear is usually found on the latter plane and during the first measurement. When detecting out--of--roundness, taper or wear, the cylinder liners must be bored and refaced. Cylinder liner reconditioning must be performed with regard to the spare piston diameter increased by 0.5 mm of the rated value, and to the prescribed assembling play. Figure 92 84088 Verify that the head supporting plane on the cylinder cluster does not show deformations. This check can be carried out by taking off dowels (4) by means of a gauged rule (2) and thickness gauge (3). After detecting the deformed areas, flatten the supporting surface by means of a grinder. The flatness error must not be greater than 0.075 mm. NOTE -- Cran case flattening may be carried out only after ma ing sure, when the repair wor has been completed, that the protrusion of the piston from the cylinder liner is not greater than the specified value. Check the condition of cylinder cluster working caps (1); they must be replaced if they are rusty or their sealing properties are in doubt. After flattening, restore the cylinder liner countersink, as shown in Figure 92. 80585 IMPORTANT -- In case of reconditioning, all the liners must be machined to the same increase . mm . Check the main bearing seats as follows: - mount the bed caps on the supports without bearings; - tighten the fastening screws to the specified torque; - check, by means of an adequate internal comparator, that the seat diameter is the same as the specified value. If a greater value is found, replace the crankcase. EW--3--69 ENGINE F4GE0684F -- F4HE0684J OVERHAUL VALVE GEAR Distri uting shaft Figure 94 84089 MAIN FEATURES OF DISTRIBUTING SHAFT The features described given below refer to the normal diameter of pins. The shaft support pin and eccentric surfaces must be perfectly smooth; if, on the contrary, they show traces of seizing and scoring, it is advisable to replace the shaft and its respective bushings. Figure 95 Chec ing the eccentric lift and the pin alignment Place the shaft on back centres and check, by means of a centesimal comparator placed on the middle support, that the alignment error is not greater than 0.04 mm; otherwise, replace the shaft. Also check the eccentric lift, which must be equal to 7.239 mm (for exhaust eccentrics) and 6.045 mm (for intake eccentrics). If different values are found, replace the shaft. 70171 Check the diameter of distributing shaft support pins (2) by means of a micrometer (1) on two axes perpendicular to each other. EW--3--70 ENGINE F4GE0684F -- F4HE0684J OVERHAUL BUSHINGS Figure 96 The distributing shaft bushings (2) must be force-fitted into their respective seats. The inner surfaces must show no traces of seizing or wear. Use bore gauge (3) to measure the diameter of front and rear bushings (2) and of distributing shaft intermediate seats (1). Measurements must be taken on two axes perpendicular to each other. 70172 Figure 97 sec. A-A 70173 MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS * Dimension to be obtained after driving the bushings EW--3--71 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Replacing the ushings Figure 101 Figure 98 70174 To replace front and rear bushings (1), use beater (2) and handle (3) to remove and reassemble the bushings. 70164 Lubricate the distributing shaft support bushings and mount distributing shaft (1) taking care not to damage the bushings or supporting seats. IMPORTANT -- Bushings must, upon mounting, be turned in such a way that the lubricating holes match with the holes available on the cran case seats. Tappets Figure 99 84053 MAIN FEATURES OF TAPPETS AND THEIR RESPECTIVE SEATS ON THE CRANKCASE Figure 102 Mounting the tappets – Distri uting shaft Figure 100 70238 70176 Lubricate tappets (1) and fit them to their respective seats of the crankcase. Place distributing shaft (3) retaining plate (1) with the slotted hole facing the crankcase upper side and the stamping facing the operator, then fasten screws (2) to the specified torque. EW--3--72 ENGINE F4GE0684F -- F4HE0684J OVERHAUL DRIVE SHAFT Figure 103 Measuring the ournals and cran pins Figure 105 70179 Check the distributing shaft end play (1). 70182 If traces of excessive seizing, scoring or out--of-roundness are found on journals and crankpins, it is necessary to reface the pins by grinding. Prior to grinding pins (2), measure the journals by means of a micrometer (1) so as to determine the amount (diameter) by which the pins have to be reduced. Figure 104 NOTE -- It is advisable to write down the measured values on a table. ee Figure . Reduction classes are 0.250 and 0.500 mm. 70180 Mount nozzles (2) and tighten fastening screws (1) to the specified torque. IMPORTANT -- ournals and cran pins must always be ground to the same reduction class. The reduction carried out on ournals and cran pins must be mar ed with a special stamping made on the side of cran arm . For reduced cran pins, use letter . For reduced ournals, use letter B. For reduced cran pins and ournals, use letters B. EW--3--73 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 106 84090 DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE WRITTEN DOWN * Rated value EW--3--74 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 107 84091 MAIN TOLERANCES OF DRIVE SHAFT TOLERANCES CONCERNING: SHAPE ORIENTATION POSITION OSCILLATION TOLERANCE--RELATED FEATURE GRAPHIC SYMBOL f /f/ // Roundness Cylindricality Parallelism Perpendicularity Straightness Concentricity or coaxiality Circular oscillation Total oscillation Taper CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL ¤ CRITICAL IMPORTANT SECONDARY Figure 108 BEARINGS ON TIMING SIDE INTERMEDIATE BEARINGS FIRST BEARING ON UPPER SIDE 84275 EW--3--75 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Measuring the ournal assem ling pla Replacing the oil pump drive gears Figure 109 Figure 111 70184 Verify that the teeth of gear (1) are not damaged or worn; otherwise, proceed with removal by means of a suitable extractor (3) foce--fitted on drive shaft (2). When fitting the new gear, the latter must be heated for 10 minutes in a small furnace at a temperature of 180 qC and force--fitted onto the drive shaft by putting the key in between. 84092 Mount drive shaft (1). Check the play between the drive shaft journals and their respective bearings by following the procedure below: Mounting the main earings Figure 110 Figure 112 70185 IMPORTANT -- If main bearings do not need replacing, they must be fitted in the same order and positions they had prior to being ta en off. Main bearings (1) are supplied as spares reduced on their inner diameter by 0.250 – 0.500 mm. IMPORTANT -- o matching operation must be carried out on bearings. Clean thoroughly the main half bearings (1) provided with lubrication holes, then fit them to their seats. The penultimate main half bearing (1) is provided with shoulder half rings. 70186 Check the play between the drive shaft journals and their respective bearings by following the procedure below: - clean thoroughly the parts and eliminate traces (if any) of oil; - place a piece of gauged wire (3) (parallel to the longitudinal axis) on drive shaft pins (4); - mount caps (1), complete with half bearings (2), on their respective supports. EW--3--76 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 113 Figure 115 70187 Fasten pre--lubricated screws (1) by tightening them in three subsequent phases. - 1st phase with a torque wrench at 50 r 6 Nm. - 2nd phase with a torque wrench at 80 r 6 Nm. 70189 - take the caps off the supports. The play between the main bearings and their respective pins can be measured by comparing the width taken on by gauged wire (2) at the point where it is flattened most, with the scale graduation shown on gauged wire envelope (1). The numbers shown on the scale indicate the matching play (mm). If the measured play is different from the specified one, replace half bearings and repeat the check; once the prescribed play has been obtained, lubricate main bearings and mount the supports definitely by tightening the fastening screws as described above. Chec ing the drive shaft shoulder pla Figure 116 Figure 114 § 70190 The shoulder play is checked by placing a magnetic comparator (2) on drive shaft (3) as shown in the figure: normal assembling play is 0.068 to 0.410 mm. 70188 - 3rd phase with tool (1) placed as shown in the figure: tighten screws (2) further to an angle of 60q r 5q. If a greater play is found, replace the main thrust half bearings of the penultimate support (1), then check again the play between the drive shaft pins and the main half bearings. EW--3--77 ENGINE F4GE0684F -- F4HE0684J OVERHAUL CONNECTING ROD--PISTON ASSEMBLY Figure 117 70191 PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY 1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod -8. Bushing NOTE -- istons are supplied as spares increased by . mm. Figure 118 Figure 119 84093 Taking piston rings (1) off piston (2) by means of pliers (3). 84094 The piston rings (2) retaining the piston pin (1) are removed by means of a mark scraper (3). EW--3--78 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 120 86497 MAIN DATA OF PISTON Pistons Measuring the piston diameter Figure 121 Figure 122 84096 Measuring the piston diameter (1) by means of a micrometer (2) to determine the assembling play. NOTE -- The diameter must be measured from the piston s irt base. mm far 70192 The play between the piston and the cylinder liner can also be measured by means of a thickness gauge (1) as shown in the figure. EW--3--79 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Piston pins Figure 126 Figure 123 84097 Measuring the gudgeon pin diameter (1) by means of a micrometer (2). Conditions for correct pin piston matching 84100 Use a thickness gauge (1) to check the play between the seal rings (3) of the 3rd slot and the respective seats on piston (2). Figure 124 Figure 127 84098 Lubricate pin (1) and its respective seat on piston hubs with engine oil; the pin must be inserted into the piston by pressing with your fingers slightly and must not come out of the same due to gravity. Piston rings Figure 125 84101 SCHEME FOR MEASURING PLAY X FOR THE TRAPEZOIDAL RING Due to the peculiar shape of the two trapezoidal cross--sectioned seal ring, the play between the slot and the ring itself must be measured as follows; allow piston (1) to protrude from the crankcase so that ring (2) at issue comes out of about half from cylinder liner (3). 84099 Check the thickness of seal rings (2) by means of a micrometer (1). In this position, check, by means of a thickness gauge, the play (X) between the ring and the slot: it must correspond to the specified value. EW--3--80 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 128 Figure 130 70194 Measuring the play between the ends of piston rings (2) inserted into cylinder liner (3), by means of a thickness gauge (1). Connecting rods Figure 129 80339 IMPORTANT -- Each connecting rod is mar ed as follows - By a number on the body and cap which indicates the connecting rod match and the cylinder on which it is mounted. In case of replacement, it is therefore necessary to number the new connecting rod with the same number as the replaced one. - By a letter on the connecting rod body which indicates the weight class of the factory--assembled connecting rod -- , to mar ed in yellow -- , to mar ed in green -- , to mar ed in blue eplacement rods are supplied class mar ed in green . aterial removal is not permitted. 86498 MAIN DATA OF CONNECTING ROD, GUDGEON PIN BUSHING AND HALF BEARINGS * Dimension of inner diameter to be obtained after driving into the connecting rod small--end and refacing by means of a reamer. ** This dimension cannot be measured in a free state. IMPORTANT -- The connecting rod--connecting rod cap matching surfaces are nurled to ensure better match. Therefore, it is recommended not to remove nurls. and EW--3--81 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Bushings Verify that the bushing in the connecting rod small-end is not loosened and does not show traces of scoring or seizing. Otherwise, replace it. Chec ing the torsion Figure 132 Removing and reassembling are carried out with the same suitable beater. When driving, take the greatest care that the holes allowing oil to flow onto the bushing and the connecting rod small--end correspond to each other. Use a reamer to reface the bushing so as to obtain the required diameter. Chec ing the connecting rods Figure 131 61694 Check connecting rod torsion (5) by comparing two points (A and B) of pin (3) on the horizontal plane of the connecting rod axis. Place comparator (2) support (1) so that the comparator is preloaded by ~ 0.5 mm on pin (3) at point A, then set comparator (2) to zero. Move spindle (4) with connecting rod (5), then compare the deviation (if any) on opposite side (B) of pin (3): the difference between A and B must not be greater than 0.08 mm. Chec ing the fle ion Figure 133 61696 Check the parallelism of connecting rod axes (1) by means of device (5). Proceed as follows: - mount connecting rod (1) on tool (5) spindle, then secure it by means of screw (4); - place spindle (3) on V--shaped block squares by putting connecting rod (1) on stop bar (2). 61695 Check connecting rod flexion (5) by comparing two points C and D of pin (3) on the vertical plane of the connecting rod axis. Place comparator (2) vertical support (1) so that the comparator rests on pin (3) at point C. Swing the connecting rod to and fro, looking for the highest position of the pin; under such condition, set comparator (2) to zero. Move the spindle with connecting rod (5) and repeat the highest point check on opposite side (D) of pin (3). The difference between points C and D must not be greater than 0.08 mm. EW--3--82 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Mounting the connecting rod--piston assem l Figure 136 Connecting rod--piston match Figure 134 72705 Insert pin (1) fastening piston rings (2). 86550 The following references are engraved on the crown of the piston: 1. Spare part number and design change number. 2. Arrow indicating the assembly sign of the piston in the cylindrical liner; this must be facing towards the front side of the engine block. 3. Date of manufacture. 4. Stamp indicating testing of the 1st groove insert Mounting the piston rings Figure 137 Figure 135 84093 Use pliers (3) to fit piston rings (1) on piston (2). The rings must be mounted with the writing “TOP” facing upwards; moreover, the ring apertures must be turned in such a way that they are offset to each other by 120q. 86551 Connect piston (2) to connecting rod (4) by means of pin (3) so that reference inscription (1) for mounting piston (2) in the cylinder liner and the numbers stamped on connecting rod (4) can be seen as shown in the figure. IMPORTANT -- pare piston rings are supplied in the following dimensions -- standard, mar ed with yellow paint -- increased by . mm, mar ed with yellow green paint EW--3--83 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 138 Figure 140 70200 Mount half bearings (1) both on the connecting rod and the cap. IMPORTANT -- If connecting rod bearings do not need replacing, they must be fitted in the same order and positions they had prior to being ta en off. o matching operation must be carried out on half bearings. Mounting the connecting rod piston assem lies in the c linder liners 84040 SCHEME FOR MOUNTING THE CONNECTING ROD--PISTON ASSEMBLY INTO THE TUNNEL - the piston ring apertures are offset to each other by 120q; - all the connecting rod/piston assemblies weigh the same; - the writing stamped on the piston crown faces the crankcase front side, or the notch obtained on the piston skirt corresponds to the position of oil nozzles. Measuring the cran pin assem ling pla Figure 141 Figure 139 70201 70203 Lubricate thoroughly the pistons, including the piston rings and the cylinder liner inside. The play can be measured by following the procedure below: Use band (2) to mount the connecting rod--piston assemblies (1) into the cylinder liners; moreover, verify that: - clean thoroughly the parts and eliminate any trace of oil; - place a piece of gauged wire (2) on drive shaft pins (1); - the number of each connecting rod corresponds to the cap matching number. - mount the connecting rod caps (3) with their respective half bearings (4). EW--3--84 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 142 Figure 145 70204 - tighten screws (1) (previously lubricated with engine oil) to the specified torque by means of a torque wrench (2); Figure 143 70207 If the measured play is different from the specified one, replace half bearings and repeat the check. Once the specified play has been obtained, lubricate the connecting rod half bearings and mount them definitely by tightening the connecting rod cap fastening screws as described. IMPORTANT -- rior to mounting the connecting rod cap fastening screws definitely, verify that the diameter of the same as measured at the middle of the thread length is not smaller than . mm of the diameter measured at about mm from the screw end. § Check manually that connecting rods (1) run axially on the drive shaft pins, and that the end play of the same (as measured by means of a thickness gauge (2)) is 0.10 to 0.33 mm. 70205 - Apply tool (1) on the compass wrench, then tighten screws (2) further in a criss-cross sequence. Figure 144 70206 - take off the cap and calculate the existing play by comparing the width of gauged wire (1) with the scale graduation shown on the wire envelope (2). Chec ing piston protrusion Figure 146 70208 After the connecting rod--piston assemblies have been mounted, check, by means of comparator (1) equipped with base (2), the protrusion of pistons (3) at the top dead centre relative to the crankcase upper plane. Said protrusion must be 0.28 to 0.52 mm. EW--3--85 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Valve gear Figure 148 Distri ution gear o case Figure 147 84105 SCHEME FOR SEALANT LOCTITE 5999 APPLICATION AREA Clean thoroughly distribution gearbox case (1) and the engine crankcase. Cleaning the surface to be sealed is necessary and unavoidable in order to ensure optimum seal. 84106 SCHEME FOR REAR GEARBOX CASE FASTENING SCREW TIGHTENING SEQUENCE Reassemble case to the crankcase. Tighten the fastening screws in the same positions they had prior to being taken off, then fasten the screws to the specified torque. Apply sealant LOCTITE 5999 on the case so as to make a bead with a diameter of a few millimetres. The bead must be smooth (no lumps) and free from air bubbles, thin areas or gaps. Any defect must be corrected as soon as practicable. Avoid using excess material to seal the joint. An excessive amount of sealant tends to come out on both sides of the joint and obstruct lubricant flowing passages. After completing sealant application, the joints must be mounted immediately (within 10 -- 20 minutes). Valve timing Figure 149 70211 Mark, with a felt--tip pen, the tooth of drive gear (1) mounted on drive shaft (2), the side surface of which bears a stamped notch (o) for timing. EW--3--86 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 150 Figure 153 84273 84107 Turn drive shaft (4) and distributing shaft (2) in such a direction that when mounting driven gear (1) on the distributing shaft, the stamped marks on gears (1 and 3) correspond to each other. Figure 151 Mount the injection pump body (1) in the gearbox seat (2), then secure it by means of screws (3). 70213 Tighten gear (2) fastening screws (1) to distributing shaft (3), then fasten them to the specified torque. In ection pump – 1st phase Timing Figure 152 Figure 154 84071 Bring cylinder 1 to the top dead centre. This condition occurs when pin (1) (shown by an arrow) is housed in the seat available on distributing shaft drive gear (2). 84108 Force--fit gear (1) transmitting the motion to the pump, then fasten nut (2) by hand. EW--3--87 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Fl wheel cover case Figure 156 Figure 155 § 84109 84110 SCHEME FOR SEALANT LOCTITE 5999 APPLICATION AREA SCHEME FOR FLYWHEEL COVER CASE FASTENING SCREW TIGHTENING SEQUENCE Clean thoroughly the attaching surfaces of flywheel case (1) and distribution gearbox case. Cleaning the surface to be sealed is necessary and unavoidable in order to ensure optimum seal. Fit case (1) back to the crankcase, tighten the fastening screws in the positions they had prior to being taken off, then fasten them to the specified torque. Apply sealant LOCTITE 5999 on the case (1) so as to make a bead with a diameter of a few millimetres. - M12 x 1.75 x 100 - M16 x 1.50 x 80 80 r 10 Nm 200 r 20 Nm The bead must be smooth (no lumps) and free from air bubbles, thin areas or gaps. Any defect must be corrected as soon as practicable. - M12 x 1.75 x 78 80 r 10 Nm Screws: Avoid using excess material to seal the joint. An excessive amount of sealant tends to come out on both sides of the joint and obstruct lubricant flowing passages. Figure 157 After completing sealant application, the joints must be mounted immediately (within 10 -- 20 minutes). 70216 Apply part (5) of tool on drive shaft rear shank (6), secure it by means of screws (4) and force--fit the new seal ring (3) on the same. Position part (1) on part (5), then screw nut (2) to fully mount seal ring (3) in flywheel cover case (7). EW--3--88 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE FLYWHEEL Figure 160 Figure 158 84111 Check the clutch disc supporting surface and turn it if scoring is detected. NOTE -- The rated thic ness of the engine flywheel is r . mm. 84075 Apply tool (2) to the flywheel cover case (1) to stop engine flywheel (3) rotation. Tighten screws (4) fastening engine flywheel (3) to the drive shaft. Replacing the engine fl wheel ring gear Check the condition of ring gear (2) teeth. If breaks or excessive tooth wear is found, remove the ring gear from the engine flywheel (1, Figure 158) by using a normal beater, then mount the new gear ring after previously heating it to 150 qC for 15’ to 20’; the countersink made on the gear ring inner diameter must face the engine flywheel. Figure 161 § Figure 159 84114 Tighten engine flywheel (2) fastening screws (1) in two separate phases: - 1st phase: tighten to a torque of 30 r 5 Nm by means of a torque wrench; - 2nd phase: angle--tighten to 60q r 5q. 84076 Screw down two pins (2) of adequate length into the shaft holes (3), then remove the engine flywheel (1) by means of suitable harnesses and a hoist. EW--3--89 ENGINE F4GE0684F -- F4HE0684J OVERHAUL In ection pump – 2nd phase Mounting the oil and water pumps Figure 165 Mounting the in ection pump – 2nd phase Figure 162 84115 Torque--tighten nut (1) by means of torque wrench (2). Figure 163 70220 Mount oil pump (1). Screw down fastening screws (2) and tighten them to the specified torque. Figure 166 84116 Apply sealant (1) as shown in the figure, then put on small cover (2), then tighten screws to the specified torque. Figure 164 70221 Apply a new seal ring (2) onto water pump (1). Figure 167 84072 Remove plug (1) from the distribution gear seat Figure 43. Remove presetting screw (2) and insert L--shaped spacer (1). Fasten again the screw to its abutting end. 70222 Mount water pump (1). Fasten screws (2) and tighten them to the specified torque. EW--3--90 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 168 Figure 170 70223 Take seal ring (2) off front cover (1), clean thoroughly the attaching surface and apply sealant LOCTITE 5999 onto the same. 70225 Apply part (5) of tool on drive shaft front shank (6), secure it by means of screws (4) and force-fit the new seal ring (3) onto the same. Position part (1) on part (5), then screw nut (2) to fully mount seal ring (3) in front cover (7). Mounting the oil sump Figure 169 Figure 171 70224 Clean thoroughly the surface of front cover (2) attaching base, then mount front cover. Fasten screws (1) and tighten them to the specified torque. 86516 Mount plate (3) and strainer (5), then screw down fastening screws (2) and (4) and tighten them to the specified torque. EW--3--91 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 172 Figure 174 § 84117 Place gasket (1) on oil sump (2). IMPORTANT -- The gas et can be used again, provided it is not damaged. 86514 Force--fit pulley (3) with damper flywheel (4) onto the drive shaft, then torque--tighten and angle--tighten the screws by means of tool Secure guide pulley (1) to the front cover by means of screws (2) and tighten them to the specified torque. Figure 173 Mounting the water oil heat e changer Figure 175 84118 Mount oil sump (1) and apply plate (3) on the same. Fasten screws (2) and tighten them to the specified torque. Screws: - M10 x 1.50 x 90 70 r 5 Nm - M10 x 1.50 x 45 50 r 5 Nm - M10 x 1.50 x 190 - M10 x 1.50 x 125 70 r 5 Nm 70 r 5 Nm 84175 Mount the following items on the crankcase: a new gasket (1), heat exchanger (2), a new gasket (3), and oil filter support (4). Fasten screws (5) and tighten them to the specified torque. Applicare la nuova cartuccia filtro olio. EW--3--92 ENGINE F4GE0684F -- F4HE0684J OVERHAUL C linder head Figure 176 Removing the valves Figure 178 84177 Position alternator support (1) in such a way that pins (3 and 4) are placed against the engine crankcase. Fasten screws (2) and tighten them to the specified torque. 84179 Valves can be removed by means of tool (1) by pressing slightly on collar (3) so that lock cones (2) can be removed by compressing springs (4). Then remove collar (3) and springs (4). Repeat the operation on all valves. Figure 179 Figure 177 84180 84178 Fit alternator (1) back to alternator support (3). Fasten screws (2) without torque--tightening them. Fit automatic belt stretcher (4) back to alternator support (3). Take off oil seals (1) fitted to the valve stems. To remove the valves, properly turn the head upside down. IMPORTANT -- ar the exhaust and inta e valves prior to removing them. EW--3--93 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Chec ing the c linder head water seal Figure 180 Check the water seal by means of suitable equipment. Use a pump to feed water heated to a 90 qC at a pressure of 2 to 3 bar. If leaks are detected from the caps, the latter must be replaced by using a suitable beater for disassembling/ assembling operations. IMPORTANT -- rior to mounting the caps, apply water--repellent sealant on the sealing surface of the same. INTAKE EXHAUST 84181 In addition to the head dimensions, the exhaust valves differ from intake valves in that they are equipped with a supplementary notch (1) obtained on the stem for intake valves. If leaks are detected from the cylinder head, the latter must be replaced. Figure 183 Figure 181 84184 The rated thickness A of the cylinder head is 95 r 0,25 mm; maximum allowed metal removal must not exceed thickness B by 0.13 mm. 84182 Remove the thermostat unit (2) and brackets (1) and (3). Chec ing the c linder head supporting surface Figure 182 IMPORTANT -- After reconditioning, chec valve hollow and recondition, if necessary, the valve seats to obtain the prescribed hollow. VALVES Figure 184 EXHAUST VALVE INTAKE VALVE 84183 The plane of the supporting surface of head (1) to cylinder cluster is checked by means of a ruler (2) and a thickness gauge (3). The deformation found on the entire length of the cylinder head must not be greater than 0.20 mm. If greater values are found, reface the cylinder head according to the values and instructions given in the next figure. 84185 MAIN DATA OF INTAKE AND EXHAUST VALVES EW--3--94 ENGINE F4GE0684F -- F4HE0684J OVERHAUL VALVE GUIDE Valve descaling chec and grinding Figure 185 Figure 188 84186 Remove the carbon deposits from the valves by means of the special metal brush. Verify that the valves do not show traces of seizing, crimping or burns. Reface, if necessary, the valve seats by means of grinder, by removing as less material as possible. Figure 186 INTAKE EXHAUST 84046 Use a bore gauge to measure the valve guide inner diameter, which must be equal to the value shown in the figure. 84187 Use a micrometer (2) to measure valve stem (1), which must be equal to 7.96 to 7.98. Chec ing the pla etween the valve stem valve guide and valve centring Figure 187 VALVE SEATS Valve seat reconditioning -- replacement Figure 189 84188 Check can be made by means of a magnetic comparator (1) placed as shown. Assembling play must be equal to 0.039 to 0.079 mm. Check, by making valve (2) rotate, that the centring error is not greater than 0.03 mm. 84189 Check valve seats (2). If slight burns or scoring are found, proceed with reconditioning by means of tool (1) according to the inclination values shown in Figure 190. EW--3--95 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 190 EXHAUST INTAKE 84190 VALVE SEAT DIMENSIONS Figure 191 EXHAUST INTAKE 86591 VALVE SEAT HOUSING DIMENSIONS If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By using the same tool (1, Figure 189) and taking care not to indent the cylinder head, remove as much material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch. Heat the cylinder head to 80 to 100 qC, then mount the new valve seats (previously cooled) onto the head by means of a suitable beater. Recondition the valve seats by means of tool according to the values shown in Figure 190. EW--3--96 ENGINE F4GE0684F -- F4HE0684J OVERHAUL MOUNTING THE CYLINDER HEAD Figure 192 Figure 194 84180 84192 After the reconditioning operations, verify, by means of base (2) and comparator (1), that valve hollow (3) corresponds to the specified value. Lubricate the valve stem and insert into the respective valve guide according to the position marked upon disassembling. Mount seal rings (1) onto the valve guide. Figure 195 VALVE SPRINGS Figure 193 84179 Position spring (4) and upper collar (3) on the cylinder head: use tool (1) to compress spring (4) and link the parts to the valve by means of lock cones (2). Reattaching the c linder head Figure 196 84193 MAIN DATA FOR INTAKE AND EXHAUST VALVE SPRING CHECK Prior to mounting, check the valve spring flexibility by means of suitable tool. Compare the elastic strain and load data with those relative to the new springs shown in the table below. 84113 Verify that the cylinder head attaching plane and the crankcase attaching plane are both clean. Height mm H (free) 63.50 H1 49.02 H2 38.20 Under a load of N No load P1 329 P2 641 Do not spoil the cylinder head gasket. IMPORTANT -- rior to reusing the cylinder head fastening screws, verify that they do not show traces of wear or deformations otherwise, replace them. EW--3--97 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 200 Figure 197 84194 Mount the cylinder head on the crankcase by fastening screws (1) without torque--tightening them. 84196 MAIN DATA OF ARBOUR--ROCKER ARM Verify that the arbour/rocker arm matching surfaces do not show excessive wear or damages. Figure 198 Figure 201 84209 Prior to inserting the pushrods, verify their state of preservation: the spherical seats in contact with the rocker arm adjusting screw and tappet (arrows) must not show traces of seizing or wear; otherwise, the seats must be replaced. The rods controlling the intake and exhaust valves are identical and, therefore, they are interchangeable. Roc er arm assem l Figure 199 84197 Verify that the tappet adjusters are unscrewed to prevent the latter from crawling on the rods when the rocker arm assembly (1) is mounted. Mount the rocker arm assembly made up of the arbours and rocker arm support, then secure them to the head without torque--tightening screws (2). Figure 202 84195 PARTS MAKING UP THE ROCKER ARM ASSEMBLY: 1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws 84198 Fasten the head screws (1) according to the instructions given Figure 203. EW--3--98 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Mounting the in ectors Figure 203 Figure 205 § 84199 Scheme of cylinder head fastening screw tightening sequence: - 1st phase: pre--fastening by means of a torque wrench: screw M12 x 1.75 x 70 > @ 50 Nm r 5 Nm; screw M12 x 1.75 x 140 > @ 40 Nm r 5 Nm; screw M12 x 1.75 x 180 > @ 70 Nm r 5 Nm; - 2nd phase: angle tightening: 90q 84201 s - 3rd phase: angle tightening only for screws 140 and 180 mm long: 90q. Figure 204 Mount a new seal ring (2) lubricated with petrolatum and a new seal washer (3) on injector (1). Mount the injectors on their seats on the cylinder head, then tighten them by means of a torque wrench. Figure 206 84200 Ad just the play between the rocker arms and the valves by means of an Allen wrench (2), box wrench (3) and thickness gauge (1). The operation play is: -intake valves: 0,25 r 0,05 mm -exhaust valves: 0,50 r 0,05 mm. Take the cylinder where clearance must be adjusted to the bursting phase; its valves are closed while balancing the symmetric cylinder valves. Symmetric cylinders are 1--6, 2--5 and 3--4. FIRING ORDER 1--5--3--6--2--4 Adjuting cylinder valve no. Adjusting clearance of cylinder valve no. 1 5 3 6 2 4 6 2 4 1 5 3 84202 Mount the injector feeding pipe assembly (1). Mount the pipes for fuel discharge (2) from injectors, by using gaskets (3) and by tightening screws (4). EW--3--99 ENGINE F4GE0684F -- F4HE0684J OVERHAUL - Mount tappet covers (3); - mount intake manifold unit (1); - connect the engine oil vapour recovery pipe to blow--by (2); - mount injection pump (6); - mount fuel filter support (10); - mount fuel filters (8); - mount the injector feed pipes to injection pump (6), then secure brackets (7) and (11) fastening the pipe assembly onto the cylinder head; - mount injection pump lubricating pipes; - mount oil level check pipe; - mount L.D.A. system piping (5); - mount quick coupling pipes (9) by following the indications given in Figure 208. Figure 207 86496 EW--3--100 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 208 Figure 210 70126 86478 Act on fork (1) as shown in the figure (detail A), then remove the adapter. To avoid deformations, bring fork (1) back to the locking position (detail B) after the adapter has been removed. Figure 209 - montare la staffa fissaggio (2) ed il cablaggio (1). Figure 211 86465 - Mount exhaust manifold (2). - Mount turbine (1) by means of screws (3). - Mount starter motor (3); 86479 - Mount thermostat unit (1) to cylinder head (3) by torque--tightening screws (2). - Mount water temperature sensor (4) by fastening with a torque wrench. EW--3--101 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 212 Figure 214 ???? 84082 Remove injectors (2) by means of tool (1) and take them off the cylinder head. 86481 Fit the Poli--V belt (1) on the crankshaft pulley, on the guide pulleys, on the water pump and on the alternator; stretch the belt using the automatic take--up unit (2). Reassem ling Figure 215 REPLACING THE INJECTORS Removal Figure 213 86515 Place the vehicle in safe conditions. Lift the engine compartment cover, disconnect the battery cables and proceed as follows: - disconnect engine oil vapour recovery pipe (2) from blow--by; - take off tappet cover (1); - disconnect the fuel manifold pipes from injectors (3). 84201 Mount a new seal ring (2) lubricated with petrolatum and a new seal washer (3) on injector (1). Mount the injectors on their seats on the cylinder head, then tighten them by means of a torque wrench. EW--3--102 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Mount new seal rings (1) on fuel manifolds (2). Reassemble the tappet cover. Connect the manifolds to the injectors, by tightening the fastening nuts to a torque of 50 Nm. Re--connect the engine oil vapour recovery pipe to the blow--by. Figure 216 86499 EW--3--103 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ADJUSTING THE TAPPETS ROCKER ARM REMOVAL/REASSEMBLING Figure 217 Removal Figure 218 84200 Ad just the play between the rocker arms and the valves by means of an Allen wrench (2), box wrench (3) and thickness gauge (1). The operation play is: -r 0,05 mm 84081 Loosen tappet adjuster fastening nuts (3), then unscrew adjusters (2). Remove screws (4) and dismount rocker arm assembly (1) made up of the rocker arm support and arbours, then take off valves. – intake valves: 0,25 r 0,05 mm Reassembling -- exhaust valves: 0,50 r 0,05 mm. Verify that the tappet adjusters are unscrewed to prevent the latter from crawling on the rods when the rocker arm assembly is mounted. Take the cylinder where clearance must be adjusted to the bursting phase; its valves are closed while balancing the symmetric cylinder valves. Symmetric cylinders are 1--6, 2--5 and 3--4. FIRING ORDER 1--5--3--6--2--4 Adjuting cylinder valve no. Adjusting clearance of cylinder valve no. 1 5 3 6 2 4 6 2 4 1 5 3 Mount the rocker arm assemblies made up of rocker arm support and arbours, then secure them to the cylinder head by tightening the fastening screws to a torque of 36 Nm. Ad just the tappets as described above. VALVE TIMING Valve timing control is obtained by means of a straight--tooth gear force--fitted onto the drive shaft rear shank which engages with the one fixed to the distributing shaft. Timing is obtained by making marks () (stamped on the same) to match. Figure 219 84210 EW--3--104 ENGINE F4GE0684F -- F4HE0684J OVERHAUL ENGINE OVERHAUL AT THE BENCH F4HE0684J Disassembly of the engine Figure 222 - Drain the engine oil removing the cap from the sump. Figure 220 86500 Disconnect the fuel hose (1) from the rail and from the high pressure pump (5) and detach it removing the lock screws (2). 70125 In order to apply to the engine block the engine fixing brackets to the stand for the overhaul, operating on the engine left side, it is necessary: IMPORTANT -- hen unloc ing the pipe union , it is necessary to prevent the union rotation of the high--pressure pump , by using the proper wrench. - to remove the fuel filter (5) from the support (1) by means of suitable tool; - to remove the low pressure fuel pipe (2--3--4) from the support (1); On the right side - to remove the support (1) bracket from the block. Figure 221 Figure 223 70126 IMPORTANT -- In order to remove the low--pressure fuel pipe -- -- , Figure from the relevant connection unions, it is necessary to press the fastener as shown in figure B. After removing the pipe, position the fastener into its loc position, figure A, in order to avoid possible deformations. 70128 Remove the screws (2) and remove the oil pipe (3) from the supercharger pipe (1) and from the engine block. Remove the starting engine (5) from the flywheel cover (4). Apply to the block the bracket and fix by means of these latter the engine to the revolving stand EW--3--105 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 224 70129 1. Connections for injectors -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor -- 4. Engine oil pressure and temperature sensor -- 5. Engine shaft sensor -- 6. Injector -- 7. Temperature--air pressure sensor -- 8. Timing phase sensor -- 9. Fuel temperature sensor and fuel heater -- 10. Pressure adjuster -- 11. Control unit EDC7 Disconnect the engine wire by disconnecting the connectors: (1) from the injector harness (6); (7) air temperature /pressure sensor: (3) fuel pressure sensor; (11) control unit; (10) high pressure pump sensor; (8) timing phase sensor; (2) engine coolant temperature sensor on thermostat (5) rpm sensor; Figure 225 (Demonstration) 70236 Remove from the rail: the fuel pipe (7) according to the procedures described in Figure 4. Remove the fuel pipe (5) from the rail (2) and from the manifolds (6) for injectors. IMPORTANT -- uring the unloc ing operation of the pipe fixing unions from the rail , it is necessary to prevent the possible flow limiting device rotation by means of a proper wrench. Remove the screws (1) and the rail (2). EW--3--106 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 226 Figure 228 70130 Remove from the fuel return pressure limiting device (1), the pipe (2) as described in Figure 221. Remove the pipe (4) from the air supercharger (3) and from the union (5). Remove the nut (10) Loosen the elastic hose clamp (6) and remove the oil vapor pipe (9).Remove the unions (13--11) and remove the pipe (12). Remove the nuts (7) and remove the tappet (8) cover complete of gasket. 70132 Loosen the tappet adjuster fixing nuts (1) and unscrew the adjuster. Remove the screws (2), remove the equalizer unit (3) composed by the support (6), equalizers (4), shafts (5) and remove the bonds (7) from the valves. Remove the rods (8) Figure 227 Figure 229 86501 Remove the nuts (7) and disconnect the electric wires from the injectors (8). Remove the screws (1) and remove the injector harness support (2) complete of gasket. Remove the screws (5) and remove the air pressure/temperature sensor (6). Remove the nuts (3) and withdraw the fuel manifolds (4). IMPORTANT -- The removed fuel manifold shall not be used again and they must be replaced by new ones. 70133 Remove the injector fixing screws and by means of tool 380001099 (1) withdraw the injectors (2) from the cylinder head. EW--3--107 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 230 Figure 231 86502 Detach the conveyor (5) from the turboblower (1). Disconnect the oil hose from the heat exchange/oil filter support. 70511 Remove the lock screws (1) and detach the exhaust manifold in two parts (2--3) with the related gaskets Remove the nuts (2) and detach the turboblower (1) from the exhaust manifold (3). Figure 232 86503 - Remove the automatic take--up device (5); - remove the Poly--V belt (4); - remove the conditioner compressor (1), the alternator (3) and the fixed guide pulley (2); - remove the fitting of the engine cooling system from the engine block; - remove the damper flywheel (6) with the pulley underneath (7); - remove the phonic wheel (8). EW--3--108 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 233 Figure 236 86504 Remove the screws (1) and detach the air conveyor (2) c/w heater. Remove the screws (4), remove the cover (3) and the thermostat below. Remove the cylinder head (6) lock screws (5). 72504 Using suitable tool, remove the oil filter (1) . Figure 237 IMPORTANT -- The outside screws highlighted are shorter. Figure 234 (Demonstration) 70141 Remove the screws (4) and disassemble the oil temperature pressure sensor (3). 70137 Attach the brackets (1) using metal ropes and using the lifting device detach the cylinders head (2) from the engine block. Remove the screws (1) and disassemble the support (2) oil filter heat exchanger , intermediate plate (6) and related gaskets. Remove the oil level sensor (5). Figure 238 Figure 235 72498 Remove the cylinder head gasket (1). 70142 Remove the screws (1) and detach the electronic control unit (2) c/w heat exchanger. EW--3--109 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 239 Figure 242 70145 Remove the nut (1) and disassemble the phase sensor (2). Remove the nuts (3) and detach the high pressure pump (4) c/w fuel pump (5). 70149 Remove the screws (1) and detach the front cover (2). IMPORTANT -- ote the assembly position of the screws as they are of different length. Figure 240 Figure 243 70146 Apply tool (2) to the flywheel cover box (1) in order to block rotation of the flywheel (3). Loosen the screws (4). 70150 Remove the screws (1) and detach the oil pump (2). IMPORTANT -- The oil pump ced. Figure 241 cannot be servi- Figure 244 70148 Remove the screws (1) and detach the water pump (2). Remove the screw (3) and disassemble the roller (4). Remove the screw (5) and detach the engine speed sensor (6). 70151 Remove tool (2). Remove the screws (1) that fasten the engine flywheel (3) to the crankshaft (4). EW--3--110 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 245 Figure 248 70152 Screw two pins (2) of suitable length in the holes of the crankshaft (3). Slide out the engine flywheel (1) so that it can be rigged using the lifting device and place it in the container. 86506 Remove the screws (1) and (4) and disassemble the oil suction rose (5). Remove the screws (2) and disassemble the reinforcement plate (3). Figure 249 Figure 246 70156 70153 Remove the screws (1) and detach the rear cover (2). IMPORTANT -- ote the assembly position of the screws as they are of different si e Remove the screws (1) and disassemble the gear (3) from the camshaft (2). Figure 250 Figure 247 70157 Remove the screws (2) and detach the timing gear box (1). 86505 Turn the engine over, remove the screws (2) and detach the oil sump (1) with the gasket underneath. IMPORTANT -- ote the assembly position of the screws as they are of different si e EW--3--111 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 253 Figure 251 70158 70160 Remove the screws (1) that fasten the con--rod caps (2) and disassemble these. Slide out the pistons c/w con--rods from the upper part of the engine block. The last but one main bearing cap (1) and the related support have the bearing halves (2) with shoulder IMPORTANT -- Leave the bearing halves in their respective housings as, if these are re--used, they must be fitted in the position found during disassembly IMPORTANT --Note the assembly position of the lower and upper bearing halves as, if these are re-used, they must be fitted in the position found during disassembly. Figure 252 Figure 254 84086 70159 Remove the screws (1) and disassemble the main bearing caps (2). Using suitable lifting device (1) and hoist, remove the crankshaft (2) from the engine block. EW--3--112 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 255 Figure 257 70164 70162 Disassemble the main bearing halves (1). Remove the screws (2) and disassemble the oil sprayers (3). Remove the camshaft (1) carefully from the engine block. Figure 258 Figure 256 70165 70163 Remove the screws (1) and disassemble the camshaft (3) retention plate (2). IMPORTANT -- ote the assembly position of the plate . Remove the tappets (1) from the engine block. EW--3--113 ENGINE F4GE0684F -- F4HE0684J OVERHAUL REPAIR INTERVENTIONS CYLINDER GROUP Cam lift check and pin alignment check Position the shaft on counterpoints and, by means of a centesimal gauge, located on the central support, check that the alignment error is not higher than 0.04 mm: on the contrary, replace the shaft. Then, check the cam lifting: it must result of 6.045 mm for the exhaust ones and of 7.582 mm for the suction ones; if you detect different values, replace the shaft. Controls and measurements Figure 259 s Figure 261 70166 Carefully clean the cylinder--block group, when performed the engine disassembly.Use the proper rings to transfer the cylinder group. Carefully check that the block does not present any cracks. Check the working plug conditions. Replace them if they are rusty or in case of doubt about their conditions. Examine the cylinder barrel surfaces; they must not present any seizing, scoring, ovalization, taper, and excessive wearing traces. The internal diameter check of the cylinder barrels, to verify the ovalization, taper and wearing entity, is performed by means of bore meter (1) equipped with comparator previously set to zero on the ring gauge (2) of the cylinder barrel diameter. IMPORTANT -- If you do not have at your disposal the ring gauge, use a micrometer for the ero setting operation. 70171 Check the camshaft (2) support pin diameter by means of a micrometer (1) on two perpendicular surfaces. BUSHES Figure 262 Figure 260 70167 The measurements must be performed for each individual cylinder at three different heights from the barrel and on two perpendicular surfaces: one parallel to the longitudinal engine axis (A) and the other one perpendicular (B); usually the max wear is detected on this latter surface and in correspondence with the first measurement.If you detect any ovalization, taper or wear, ream and grind the cylinder barrels. The cylinder barrel regrinding must be performed in relation to the diameter of the spare pistons oversized of 0.5 mm in respect of the nominal value and prescribed assembling clearance. 70172 The camshaft bushes (2) must result forced in their relevant seats. The inner surfaces must result without seizing and wearing traces. By means of a bore meter (3), measure the diameter of the rear and front bushes (2) and intermediate seats (1) for camshaft. The measurements must be performed on two perpendicular axes. EW--3--114 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 263 sez. A-A * 79460 MAIN DATA OF THE CAMSHAFT BUSHES AND RELEVANT SEATS * Dimensions to be obtained after the bush driving EW--3--115 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Head face chec on the c linder group Figure 264 Figure 265 § 84088 80585 IMPORTANT -- In the event of grinding operation, all the barrels must result of the same oversi e . mm Check that the head face, on the cylinder group, does not present deformations. This check can be carried out, after a previous grains (4) extraction by means of a calibrated ruler (2) and feeler gauge (3). After verified the deformation areas, perform the flattening of the face by means of grinding machine. The flatness error must not be higher than 0.075 mm. Check the bench bearing seats, proceeding as follows: IMPORTANT -- The block flattening could be performed only after you have chec ed that, at finished wor , the piston pro ection from the cylinder barrel is not higher than the value prescribed. - mount the bench caps on the supports without bearings; - screw the fixing screws to the torque prescribed; Check the conditions of the working plugs (1) of the cylinder groups; replace them if rusty or in case of doubt about their conditions. - by means of an adequate gauge, verify that the internal diameter of the seats correspond to the value prescribed. If you detect a higher value, replace its block. When flattening is finished, restore the cylinder barrel bevel as shown in Figure 264. TIMING SYSTEM Camshaft Figure 266 79459 CAMSHAFT MAIN DATA The data listed are refereed to the standard pin diameter. The surfaces of the camshaft support pins and cams must be very smooth; if they present seizing and scoring traces, it is better to replace the shaft and relevant bushes. EW--3--116 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Bush replacement Fitting tappets – camshaft Figure 267 Figure 269 70174 To replace front and rear bushes (1), use for their removal and refitting the tool (2) and handgrip (3). 70176 Lubricate the tappets (1) and fit them into the relevant housings on the engine block. Figure 270 IMPORTANT -- hen refitting bushes direct them so that lubrication holes coincide with engine bloc housing holes. 70164 Lubricate the camshaft bushes and fit the camshaft (1) taking care not to damage the bushes or the housings. Tappets Figure 268 Figure 271 70238 86507 MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque. EW--3--117 ENGINE F4GE0684F -- F4HE0684J OVERHAUL OUTPUT SHAFT Figure 272 Measuring ournals and cran pins Figure 274 70179 Check camshaft end float (1). It shall be 0.23 r 0.13 mm. 70182 Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground. Figure 273 IMPORTANT -- It is recommended to insert the found values in the proper table. ee Figure . Undersize classes are: 0.250 – 0.500 mm 70180 Fit nozzles (2) and tighten the fastening screws (1) to the specified torque. IMPORTANT -- ournals and cran pins shall always be ground to the same undersi e class. ournals and cran pins undersi e shall be mar ed on the side of the cran arm o. . For undersi ed cran pins letter For undersi ed ournals letter B For undersi ed cran pins and ournals letters B Figure 275 70514 FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES EW--3--118 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 276 84091 MAIN TOLERANCES OF DRIVE SHAFT TOLERANCES CONCERNING: SHAPE ORIENTATION POSITION OSCILLATION TOLERANCE--RELATED FEATURE GRAPHIC SYMBOL f /f/ // Roundness Cylindricality Parallelism Perpendicularity Straightness Concentricity or coaxiality Circular oscillation Total oscillation Taper CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL ¤ CRITICAL IMPORTANT SECONDARY Figure 277 BEARINGS ON TIMING SIDE INTERMEDIATE BEARINGS FIRST BEARING ON UPPER SIDE 84275 EW--3--119 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Replacing oil pump control gear Finding ournal clearance Figure 278 Figure 280 84092 70184 Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3). When fitting the new gear, heat it to 180qC for 10 minutes in an oven and then key it to the output shaft. Mount drive shaft (1). Check the play between the drive shaft journals and their respective bearings by following the procedure below: Figure 281 Fitting main earings Figure 279 70186 - clean accurately the parts and remove any trace of oil; - position a piece of calibrated wire (3) on the output shaft pins (4) so that it is parallel to the longitudinal axis; - fit caps (1), including the half bearings (2) on the relevant supports. Figure 282 70185 IMPORTANT -- efit 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 undersize on the internal diameter. IMPORTANT -- o not try to adapt the bearings. Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings. The second last main half bearing (1) is fitted with shoulder half rings. 70187 Tighten the pre--lubricated screws (1) in the following three successive stages: - 1st stage, with dynamometric wrench to 50 r 6 Nm. - 2nd stage, with dynamometric wrench to 80 r 6 Nm. EW--3--120 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Chec ing output shaft shoulder clearance Figure 283 Figure 285 § 70188 - 3rd stage, with tool (1) set as shown in the figure, tighten the screws (2) with 90q r 5q angle. 70190 This check is performed by setting a magnetic--base dial gauge (2) on the output shaft (3) as shown in the figure, standard value is 0.068 – 0.41. If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between output shaft pins and main half bearings. Figure 284 CONNECTING ROD – PISTON ASSEMBLY Figure 286 70189 - Remove caps from supports. 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 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 tightening the fastening screws as previously described. 70191 CONNECTING ROD – PISTON ASSEMBLY COMPONENTS 1. Stop rings -- 2. Pin -- 3. Piston -- 4. Split rings -5. Screws -- 6. Half bearings -- 7. Connecting rod -8. Bush IMPORTANT -- istons are supplied spare with . mm oversi e. EW--3--121 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Pistons Measuring piston diameter Figure 290 Figure 287 32613 Remove split rings (1) from piston (2) using pliers (3). Figure 288 32615 Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance. IMPORTANT -- The diameter shall be measured at mm from the piston s irt. Figure 291 32614 Piston pin (1) split rings (2) are removed using a scriber (3). 70192 The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure. Figure 289 86497 MAIN DATA CONCERNING PISTON, PINS AND SPLIT RINGS * Value measured on 99 mm diameter EW--3--122 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 295 Piston pin diameter Figure 292 32620 18857 To measure the piston pin (1) diameter use the micrometer (2). Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1). Conditions for proper pin--piston coupling Figure 293 Figure 296 32619 Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity. Split rings Figure 294 41104 DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half--way from the cylinder barrel (3). 16552 Use a micrometer (1) to check split ring (2) thickness. In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one. EW--3--123 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 297 Figure 299 70194 Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3). Connecting rods Figure 298 80339 IMPORTANT -- Every connecting rod is mar ed as follows - On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mar the new connecting rod with the same numbers of the replaced one. - On body with a letter showing the weight of the connecting rod assembled at production S S S , -- yellow mar ing , -- green mar ing , -- blue mar ing pare connecting rods are of the green mar ing . class with aterial removal is not allowed. Bushes 86498 MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS * Value for inside diameter to be obtained after driving in connecting rod small end and grinding ** Value not measurable in released condition IMPORTANT -- To obtain best coupling the connecting rod--cap coupling surfaces are nurled. It is therefore recommended to not remove nurling. Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter. EW--3--124 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Chec ing connecting rods Figure 300 Chec ing ending Figure 302 61696 Check that the axes of the connecting rods (1) are parallel using tool 99395363 (5) as follows: - fit the connecting rod (1) on tool (5) spindle and lock it with screw (4); - set the spindle (3) on V--blocks by resting the connecting rod (1) on the stop bar (2). Chec ing torsion 61695 Check connecting rod (5) bending by comparing two points C and D of the pin (3) on the vertical plane of the connecting rod axis. Position the vertical support (1) of the dial gauge (2) to rest the latter on pin (3), point C. Move the connecting rod forwards and backwards to find pin top position, then in this condition reset the dial gauge (2). Move the spindle with the connecting rod (5) and repeat the check of the top point on the opposite side D of the pin (3). The difference between point C and point D shall not exceed 0.08 mm. Figure 301 Fitting connecting rod--piston assem l Connecting rod--piston coupling Figure 303 86550 61694 Check connecting rod (5) torsion by comparing two points (A and B) of pin (3) on the horizontal plane of the connecting rod axis. Position the dial gauge (2) support (1) to obtain a preload of approx. 0.5 mm on the pin (3) in point A and then set the dial gauge (2) to zero. Move the spindle (4) with the connecting rod (5) and compare any deviation on the opposite side (B) of the pin (3): the difference between A and B shall not exceed 0.08 mm. The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block; 3. Manufacturing date. 4. Marking showing 1st slot insert testing; EW--3--125 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 304 IMPORTANT -- plit rings are supplied spare with the following si es - standard, yellow mar ing . mm oversi e, yellow green mar ing Figure 307 86551 Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers marked on the connecting rod (5) are read as shown in the figure. Figure 305 70200 Fit half bearings (1) on connecting rod and cap. IMPORTANT -- efit the main bearings that have not been replaced, in the same position found at removal. o not try to adapt the half bearings. Fitting connecting rod--piston assem l into c linder arrels 72705 Fit pin (1) split rings (2). Figure 308 Fitting split rings Figure 306 70201 Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. 32613 Use pliers 99360183 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120q. Use band (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number. EW--3--126 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 309 Figure 311 § 70202 DIAGRAM FOR CONNECTING ROD--PISTON ASSEMBLY FITTING INTO BARREL - split ring openings shall be displaced with each other by 120q; - connecting rod--piston assemblies shall have the same weight; - the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position. 70204 - lubricate the screws (1) with engine oil and then tighten them to the specified torque using the dynamometric wrench (2). Figure 312 § Finding cran pin clearance Figure 310 70205 - apply tool (1) to the socket wrench and tighten screws (2) of 60q. Figure 313 70203 To measure the clearance proceed as follows: - clean the parts accurately and remove any trace of oil; - set a piece of calibrated wire (2) on the output shaft pins (1); - fit the connecting rod caps (3) with the relevant half bearings (4). 70206 - remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2). EW--3--127 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Timing gear case Figure 316 Figure 314 70207 If a different clearance value is found, replace the half bearings and repeat the check. Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque. IMPORTANT -- Before the final fitting of the connecting rod cap fastening screws, chec that their diameter measured at the centre of the thread length is not . mm than the diameter measured at approx. mm from screw end. Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.10 – 0.33 mm.. 70209 SEALANT APPLICATION AREAS Clean accurately the timing gear case (1) and the engine block. Perfect seal is only obtained by cleaning accurately the surface to seal. Smear the case with LOCTITE 5999 to obtain a bead of few mm diam eter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities. Any imperfection shall be corrected as soon as possible. Avoid to use excess material to seal the joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging. After applying the sealant, the joint shall be assembled immediately (10 – 20 minutes). Figure 317 Chec ing piston protrusion Figure 315 70210 70208 Once connecting rod--piston assemblies refitting is over, use dial gauge (1) fitted with base (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block. Protrusion shall be 0.28 – 0.52 mm. DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR CASE FASTENING SCREWS Refit the case (1) to the engine block. Screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 Screws M8 Screws M10 65 -- 89 Nm 20 -- 28 Nm 42 -- 52 Nm EW--3--128 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Timing Figure 318 Fl wheel housing Figure 321 70211 Use a felt pen to mark the driving gear (1) tooth fitted on the output shaft (2) having the mark (o) for timing on the side surface. Figure 319 70212 70214 Clean accurately the flywheel housing (1) and timing gear case coupling surfaces. Perfect seal is only obtained by cleaning accurately the surface to seal. Smear housing (1) with LOCTITE 5999 to obtain a bead of few mm diameter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities. Any imperfection shall be corrected as soon as possible. Avoid to use excess material to seal the joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging. After applying the sealant, the joint shall be assembled immediately (10 – 20 minutes). Figure 322 Direct the output shaft (4) and the camshaft (2) so that when fitting the driven gear (1) on the camshaft the marks on the gears (1 and 3) are coinciding. Figure 320 70215 SEQUENCE FOR TIGHTENING THE FLYWHEEL HOUSING FASTENING SCREWS 70213 Tighten the screws (1) fastening gear (2) to camshaft (3) to the specified torque. Refit the housing (1) to the engine block and screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 Screws M10 75 -- 95 Nm 44 -- 53 Nm EW--3--129 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 323 Figure 325 70152 70216 Apply tool (5) to the rear output shaft tang (6), secure it by screws (4) and fit the new sealing ring (3). Screw two pins (2) having suitable length into shaft holes (3) and remove the engine flywheel (1) using proper sling and hoister. Figure 326 Position part (1) on part (5), screw nut (2) until completing sealing ring (3) fitting into flywheel housing (7). ENGINE FLYWHEEL Figure 324 70218 Tighten the screws (4) fastening the engine flywheel (3) to the output shaft. Apply tool (2) to the flywheel housing (1) to stop engine flywheel (3) rotation. Figure 327 § 70217 Check clutch plate supporting surface and turn it if scored. IMPORTANT -- Engine flywheel rated thickness is 70,5 mm. Replacing engine flywheel ring gear Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1, Figure 324) using a generic beater and fit the new one, previously heated to 150 qC for 15 – 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel. 70219 Tighten engine flywheel (2) fastening screws (1) in two stages: - 1st stage, tightening to 30 – 4 Nm torque with dynamometric wrench; - 2nd stage, tightening to 60q r 5q angle. EW--3--130 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 328 Figure 331 70223 70220 Fit the oil pump (1). Tighten the fastening screws (2) to the specified torque. Remove the sealing ring (2) from the front cover (1), clean accurately the coupling surfaces and smear them with LOCTITE 5999. Figure 332 Figure 329 70224 70221 Apply a new sealing ring (2) to the water pump (1). Clean accurately the front cover (2) surface and refit it. Tighten the screws (1) to the specified torque. Figure 333 Figure 330 70225 70222 Fit the water pump (1). Tighten the screws (2) to the specified torque. Apply tool (5) to the front output shaft tang (6), secure it by screws (4) and fit the new sealing ring (3). Position part (1) on part (5), screw nut (2) until completing sealing ring (3) fitting into front cover (7). EW--3--131 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 334 Figure 336 § 86506 Fit the plate (3), the rose pipe (5) and tighten the fastening screws (1 -- 2 and 4) to the specified torque. 70363 Fit the phonic wheel (1) and the hub (2) on the output shaft. Tighten the fastening screws (3) in two stages: - 1st stage, tightening to 50 r 5 Nm torque with dynamometric wrench; - 2nd stage, tightening to 90q angle. Fit the damper flywheel (5) and the pulley (6). Tighten the fastening screws (7) to 68 r 7 Nm torque. Figure 335 Figure 337 86505 Fit the oil sump (1) and apply the plate (3) to the gasket underneath. Tighten the screws (2) to the specified torque. 70230 Fit a new sealing ring on the speed sensor (3). Fit the speed sensor (3) on the front cover (1) and tighten the screw (2) to the specified torque. EW--3--132 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 338 Figure 340 70231 Fit on the engine block: a new gasket (1), the heat exchanger (2) a new gasket (3) and the oil filter support (4). 70234 Position the alternator support (1) so that pins (3 and 4) are set against the engine block. Tighten the screws (2) to the specified torque. Tighten the screws (5) to the specified torque. Figure 341 Figure 339 86509 Re--attach the conditioner (1) 70232 Lubricate the sealing ring (2) with engine oil and set it on the oil filter (3). Refit the alternator (2). Figure 342 Screw manually to seat the oil filter (3) on the support connection (1) and then screw again the oil filter (3) by 3/4 turn. Apply a new sealing ring on the oil temperature/pressure sensor (4) and fit it on the support (1). Tighten the screws (5) to the specified torque. Fit a new sealing ring (6) in the engine block seat. 86510 Refit the automatic belt tensioner (2). Tighten the screw (3) to the specified torque using the proper wrench, turn the automatic belt tensioner (2) to fit the belt (1) on pulleys and guide rollers. EW--3--133 ENGINE F4GE0684F -- F4HE0684J OVERHAUL CYLINDER HEAD Figure 343 Removing the valves Figure 345 70145 Refit the high pressure pump (5) including the feed pump (6) and tighten the nuts (3) to the specified torque. Fit the support (4) with a new sealing ring, the timing sensor (2) with a new sealing ring and tighten the relevant fastening nut (1) to the specified torque. 70319 Intake (1) and exhaust (2) valves have heads with the same diameter. The central notch (o) of the exhaust valve (2) head distinguishes it from the intake valve. IMPORTANT -- hould cylinder head valves be not replaced, number them before removing in order to refit them in the same position. A Figure 344 inta e side exhaust side Figure 346 70320 70321 Refit the ECU (3) including the heat exchanger to the engine block and tighten the screws (2) to the specified torque. Valve removal shall be performed using tool (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Repeat this operation for all the valves. IMPORTANT -- Replace support elastic elements . Overturn the cylinder head and withdraw the valves (5). EW--3--134 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Chec ing c linder head supporting surface Figure 349 Figure 347 70322 Remove the sealing rings (1 and 2) from the relevant valve guides. IMPORTANT -- ealing rings for inta e valves are yellow. ealing rings for exhaust valves are green. 70324 Use a rule (2) and a feeler gauge (3) to check the cylinder head (1) supporting surface. Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure. Chec ing c linder head wet seal Figure 348 Figure 350 70323 This check shall be performed using the proper tools. Use a pump to fill with water heated to approx. 90qC and 2 – 3 bar pressure. Replace the cup plugs (1) if leaks are found, use the proper beater for their removal/refitting. IMPORTANT -- Before refitting, smear the plug surfaces with water--repellent sealant. Replace the cylinder head if leaks are found. 70325 The rated thickness A for the cylinder head is 105 r 0.25 mm, max. metal removal shall not exceed thickness B by 0.13 mm. IMPORTANT -- After grinding, chec valve sin ing. egrind the valve seats, if re uired, to obtain the specified value. EW--3--135 ENGINE F4GE0684F -- F4HE0684J OVERHAUL VALVES Chec ing clearance etween valve stem and valve guide and valve centering Figure 354 Figure 351 EXHAUST VALVE INTAKE VALVE 70327 70326 INTAKE AND EXHAUST VALVE MAIN DATA Removing car on deposits chec ing and grinding valves Figure 352 Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 r 0.092 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm. 18625 Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. Regrind the valve seats, if required, using tool and removing as little material as possible. VALVE GUIDE Figure 355 Figure 353 INTAKE EXHAUST 70328 18882 Check the valve stem (1) using a micrometer (2), it shall be 6.970 r 6.999. Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure. EW--3--136 ENGINE F4GE0684F -- F4HE0684J OVERHAUL VALVE SEATS Regrinding – replacing the valve seats Figure 356 70330 Check the valve seats (2). If slight scoring or burnout is found, regrind seats using tool (1) according to the angle values shown in Figure 357. Figure 357 ASPIRAZIONE INTAKE SCARICO EXHAUST 85486 VALVE SEAT MAIN DATA EW--3--137 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 358 EXHAUST INTAKE 70332 MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD Should valve seats be not reset just by regrinding, replace them with the spare ones. Use tool (Figure 356) to remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch. Heat the cylinder head to 80q -- 100qC and using the proper beater, fit the new valve seats, previously cooled, into the cylinder head. Use tool to regrind the valve seats according to the values shown in Figure 357. VALVE SPRINGS Figure 359 Figure 360 50676 MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS 70333 After regrinding, check that valve (3) sinking value is the specified one by using the base (2) and the dial gauge (1). Before refitting use suitable tool to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table. H H1 H2 Height mm 47,75 35,33 25,2 Under a load of kg Free P 339,8 r 9 N P1 741 r 39 N EW--3--138 ENGINE F4GE0684F -- F4HE0684J OVERHAUL FITTING CYLINDER HEAD Refitting the c linder head Figure 361 Figure 363 70334 Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal. Fit the sealing rings (2 and 3) on the valve guide. IMPORTANT -- ealing rings for inta e valves are yellow and sealing rings for exhaust valves are green. 70335 Check cleanness of cylinder head and engine block coupling surface. Take care not to foul the cylinder head gasket. Set the cylinder head gasket (1) with the marking “TOP” (1) facing the head. The arrow shows the point where the gasket thickness is given. IMPORTANT -- Before reusing the cylinder head fastening screws chec whether they are free from damages or distortions, otherwise replace. Figure 362 Figure 364 § 77032 Position on the cylinder head: the spring (4), the upper cap (3); use tool (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2). 70336 Refit the cylinder head (1), tighten the screws (2) in three successive stages according to the sequence and procedure shown in the following figure. EW--3--139 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 365 Figure 367 § 70476 Cylinder head fastening screw tightening sequence: - 1st stage pre--tightening, with dynamometric wrench: x Screw 12x1.75x130 ( ) 35 5 Nm x Screw 12x1.75 x 150 ( ) 55 5 Nm 70339 Fit injectors (1) on the cylinder head seats, directed so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side. s - 2nd stage, tightening to 90q r 5q angle - 3rd stage, tightening to 90q r 5q angle A = front side Figure 368 Fitting in ectors Figure 366 70338 Fit a new sealing ring (2) lubricated with vaseline and a new sealing washer (3) on injector (1). 70133 Use tool 380001099 (1) to fit the injector (2) into its seat. Screw injector fastening screws without tightening them. EW--3--140 ENGINE F4GE0684F -- F4HE0684J OVERHAUL RODS Figure 369 Figure 371 32655 70341 Fit a new sealing ring (3) lubricated with vaseline on the fuel manifold (2) and fit it into the cylinder head seat so that the positioning ball (5) is coinciding with the relevant housing (4). Rocker control rods shall not be distorted; the ball seats in touch with the rocker adjusting screw and with tappets (arrows) shall not show seizing or wear; otherwise replace them. Intake and exhaust valve control rods are identical and are therefore interchangeable. Roc er assem l Figure 372 IMPORTANT -- emoved fuel manifolds shall not be reused but replaced with new ones. Screw the fastening nuts (2, Figure 370) without locking them. IMPORTANT -- uring this operation, the in ector shall be moved so that the manifold is properly inserted into the fuel inlet hole , Figure . 70343 ROCKER ASSEMBLY COMPONENTS: 1. Screws -- 2. Bracket -- 3. Shafts -- 4. Rockers. Figure 370 Figure 373 70342 Use the dynamometric wrench to tighten gradually and alternately the injector fastening screws (1) to 8.5 r 0.8 Nm torque. Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm torque. 70344 SHAFT--ROCKER MAIN DATA Check that shaft/rocker coupling surfaces are not showing excessive wear or damages. EW--3--141 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Tappet clearance ad ustment Figure 374 Figure 376 70345 Fit the rods (2). Position jumpers (1) on valves with marks (o) facing the exhaust manifold. 70520 Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Working clearance shall be as follows: -intake valves 0.25 r 0.05 mm -- exhaust valves 0.51 r 0.05 mm IMPORTANT -- In order to more uic ly perform the operating clearance ad ustment for roc er arms valves, proceed as follows rotate the drive shaft, balance cylinder valves and ad ust the valves mar ed by the asteris as shown in the table cylinder n. intake exhaust Figure 375 1 --- 2 -* 3 * -- 4 -* 5 * -- 6 * * otate the drive shaft, balance cylinder 6 valves and adjust the valves marked by the asterisk as shown in the table: cylinder n. intake exhaust 70346 Check that tappet adjusters (1) are loosen to prevent their balking on the rods (2, Figure 374) when refitting the rocker assembly. Then refit the rocker assembly consisting of: bracket (5), rockers (3), shafts (4) and secure them to the cylinder head by tightening the fastening screws (2) to 36 Nm torque. 1 * * 2 * -- 3 -* 4 * -- 5 -* 6 --- EW--3--142 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 377 Figure 379 70349 Fit the rail (2) and tighten the screws (1) to the specified torque, connect the ground cable (3) to the intake manifold (4) and tighten the fastening nut (5) to the specified torque. 70351 IMPORTANT -- ipe connections shall be tightened to m tor ue, using the proper wrench and the dynamometric wrench . Connections shall be tightened by holding the flow limiting valve hexagon with the proper wrench. Connect the fuel pipe (3) to the rail (2) following the procedure shown in the following figure. Figure 378 Figure 380 70350 Connect new fuel pipes (1) to rail (3) and injector manifolds (2). IMPORTANT -- hen removed, pipes ways be replaced. shall al- 70126 Press the clamp (1) in arrow direction (Figure B) and connect the pipe to the rail (2, Figure 379), reset the clamp to the initial locking position “A”. IMPORTANT -- Chec proper fuel pipe connection. EW--3--143 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Harness support Figure 381 Figure 384 72501 Check the condition of the electric cables (5), if they are damaged, replace by cutting the clips that fasten them to the support (2) and removing the screws (4) that fasten the connectors (3) to this. Fit a new gasket (1) on the support (2). 72502 Fit a new gasket (2) on the tappet cover (1). Figure 385 Figure 382 72511 Fit the tappet cover (1), draw up the nuts (2) and tighten them to the prescribed torque Figure 386 70353 Fit the harness support (2), draw up the screws (1) and tighten them to the prescribed torque. Figure 383 86511 70354 Connect the electric cables (1) to the electro--injectors (3) and using torque wrench (4) tighten the lock nuts (2) to the prescribed torque. Re--attach the exhaust manifold (3) with new gaskets. Draw up the lock screws (6) and tighten them to the prescribed torque. Re--attach the turbo--blower (1) with a new gasket to the exhaust manifold (3) and tighten the lock nuts (2) to the prescribed torque. Connect the oil hose (5) to the heat exchanger support (7) and to the turbocompressor (1). Attach the oil duct (4) to the heat exchanger support. EW--3--144 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 387 Figure 389 86512 Connect the air conveyor (2) to the turbo--blower (3) and secure it to this with the clip (1). 70126 Press the clip (1) in the direction of the arrow (fig. B) and connect the pipe. Return the clip to the initial clamping position A. IMPORTANT -- Make sure the fuel hose is connected correctly. Figure 388 86513 With the fittings (13--15) and new copper washers, connect the pipe (14) to the tappet cover (10) and to the timing case (6). Connect the pipe (7) to the fitting located on the timing box (6) and secure it with a clamp (8). Fit the new snap ring on the fitting of the pipe (11) and assemble it in the tappet cover (10). Fasten the pipe (11) to the tappet cover (10) with the bracket and nut (12), connect the pipe (4) to the fitting (5) and to the air compressor (3). Connect the pipe (2) to the pressure limiting device (1) as shown in the figure below. EW--3--145 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 390 70129 70129 1. Injector connections -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor -- 4. Engine oil temperature and pressure sensor -- 5. Output shaft sensor -- 6. Injector -- 7. Air temperature/pressure sensor -- 8. Timing sensor -- 9. Fuel heater and fuel temperature sensor -- 10. Pressure regulator -- 11. Control unit Reconnect the engine cable by connecting injector wiring (6) connectors (1); (7) air pressure/temperature sensor; (3) rail pressure sensor; (11) control unit; (10) high pressure pump sensor; (8) timing sensor; (2) engine coolant temperature sensor on thermostat; (5) engine speed sensor. Apply to engine lifting hooks the lifting rig, hook the latter to the hoister and remove the engine from the revolving stand. Remove the brackets. EW--3--146 ENGINE F4GE0684F -- F4HE0684J OVERHAUL Figure 391 Figure 393 70128 Complete engine refitting as follows: Form the right side: Refit the starter (5) to the flywheel housing (4) and tighten the fastening nuts to the specified torque. Fit the oil pipe (3) with a new sealing ring into the engine block and secure it to the turbosupercharger (1) by the screws (2) tightened to the specified torque. Figure 392 70125 Screw manually the fuel filter to the support (1), screw the filter by ¾ turn, connect the pipes (2--3--4) to the relevant support connections (1) as shown in the following figure. Figure 394 70362 Refit the bracket (2) including the fuel filter support (1) to the engine block, tighten the screws (3) to the specified torque. 70126 Press the clamp (1) as shown in figure B. After disconnecting the pipe, reset the clamp (1) to the initial locking position A, to prevent deformations. When refitting is over, fill engine with the prescribed lubricating oil in the specified quantity.
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