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:
1Ÿ7
‡
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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