Engines Nef Tier 3 F4CE9484, F4CE9684, F4DE9484, F4DE9684, F4DE9687, F4GE9484, F4GE9684, F4HE9484, F4HE9684

SERVICE MANUAL
ENGINES NEF
Tier 3
F4CE9484, F4CE9684,
F4DE9484, F4DE9684,
F4DE9687, F4GE9484,
F4GE9684, F4HE9484,
F4HE9684
84250518
Issued 12-2009
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS............................................................. A
ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A
POWER PRODUCTION ................................................................. B

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A
84250518 09/11/2009
INTRODUCTION
84250518 09/11/2009
1
Contents
INTRODUCTION
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4CE9484, F4GE9484, F4CE9684, F4GE9684
84250518 09/11/2009
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INTRODUCTION
Foreword
Engine Overhaul
Part of the operations illustrated within this manual can be partially executed while the engine is assembled on the
vehicle, depending on the room available for access to the engine and on the equipment application as well.
NOTE: With regard to the engine disassembly operations, please apply for information consulting the specific manual.
The following information relates to the engine overhaul operations only for what concerns the different components
customizing the engine, according to its specific duties.
In section "General Overhaul", all the operations of engine block overhaul have been contemplated. Therefore the
above mentioned section is to be considered as following the part hereby described.
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INTRODUCTION
Safety rules
Standard safety prescriptions
Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working
area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the
personnel in charge of maintenance.
Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation
available for consultation.
• Keep working areas as clean as possible, ensuring adequate aeration.
• Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided
with adequate sanitary equipment.
• Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency
must be checked on a regular basis and the personnel must be trained on interventon methods and priorities.
• Organize and identify specific exit points to evacuate the areas in case of an emergency, providing for adequate
indications of the emergency indications of the emergency exit lines.
• Smoking in working areas subject to fire danger must be strictly prohibited.
• Provide warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy com-
prehension of the instructions even in case of an emergency.
Prevention of injury
• Do not wear unsuitable clothes for work, with fluttering ends, nor jewels such as and chains when working close
to engines and equipment in motion.
• Wear safety gloves and goggles when performing the following operations:
• • filling inhibitors or anti-frost

• lubrication oil topping or replacement
• utilization of compressed air or liquids under pressure (pressure allowed < 2 bar (29 psi)).
• Wear safety helmet when working close to hanging loads or equipment working at head height level.
• Always wear safety shoes and clothes adhering to the body, better if provided with elastics at the ends.
• Use protection cream for hands.
• Change wet clothes as soon as possible.
• In presence of electrical current exceeding 48 - 60 V verify efficiency of earth and mass electrical connections.
Ensure that hands and feet are dry and execute working operations utilizing isolating foot boards. Do not carry
out working operations if not trained for.
• Do not smoke nor light up flames close to batteries and to any fuel material.
• Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.
• Do not execute any intervention if not provided with necessary instructions.
• Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided
for. Serious injury may occur.
• In case of test or calibration operations requiring engine running, ensure that the area is sufficiently ventilated or
utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning or death.
During maintenance
• Never open filler cap of cooling system when the engine is hot. Operating pressure would provoke high tempera-
ture with serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F).
• Never top up an overheated engine with cooler and utilize only appropriate liquids.
• Always operate when the engine is tuned off; when particular circumstances require maintenance intervention on
running engine, be aware of all risks involved with such operation.
• Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil.
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INTRODUCTION
• Keep the engine clean from oil spills, diesel fuel and or chemical solvents.
• Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas venti-
lated. Whenever necessary wear safety mask.
• Do not leave rags impregnated with flammable substances close to the engine.
• Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of a runaway
speed rate.
• Do not utilize fast screw tightening tools.
• Never disconnect batteries when the engine is running.
• Disconnect batteries before any intervention on the electrical system.
• Disconnect batteries from system before applying a load to them with the battery loader.
• After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from
accidental short circuit and oxidation.
• Do not disconnect and connect electrical connections in presence of electrical feed.
• Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air
under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves.
Always wear adequate safety mask or goggles. Non fulfillment of these precautions may cause serious injury and
poisoning.
• Avoid incorrect tightening or out of sequence. Danger: incorrect tightening may seriously damage engine’s com-
ponents, affecting engine’s duration.
• Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters.
• Do not modify cable wires: their lengths shall not be changed.
• Do not connect to the engine electrical equipment unless specifically approved by Iveco.
• Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unautho-
rized modification will compromise warranty assistance and furthermore may affect engine correct working and
duration.
For engines equipped with electronic controller:

• Do not execute electric arc welding without having previously removed electronic controller.
• Remove electronic controller in case of any intervention requiring heating over 80 °C (176 °F) temperature.
• Do not paint the components and the electronic connections.
• Do not vary or alter any data filed in the electronic controller driving the engine. Any manipulation or alteration
of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine
correct working and duration.
Respect of the Environment

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

Plug ¼" 10 - 14 Nm (7.4 - 10.3 lb ft)
½" 20 - 28 Nm (14.8 - 20.7 lb ft)
¾" 31 - 41 Nm (22.9 - 30.2 lb ft)
Grid Heater M6 Nut 6 - 10 Nm (4.4 - 7.4 lb ft)
Intake Manifold M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Engine Lifting Bracket
Rear M12 65 - 89 Nm (47.9 - 65.6 lb ft)
Front M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Cylinder Head M12x1.75x130 mm
First Phase 30 - 40 Nm (22.1 - 29.5 lb ft)
Second Phase 85 - 95 °
Third Phase 85 - 95 °
Cylinder Head M12x1.75x150 mm
Rocker Bracket 31 - 41 Nm (22.9 - 30.2 lb ft)
Rocker Arm Jam Nuts 20 - 28 Nm (14.8 - 20.7 lb ft)
Exhaust Manifold 48 - 58 Nm (35.4 - 42.8 lb ft)
Valve Cover M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Turbocharger
6 Cylinder M8 Screw 6 - 8 Nm (4.4 - 5.9 lb ft)
M8 Nut 37 - 49 Nm (27.3 - 36.1 lb ft)
4 Cylinder M8 Screw 6 - 8 Nm (4.4 - 5.9 lb ft)
M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Front Case
Front Cover M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Rear Case
Gear Case M12 Screw 65 - 89 Nm (47.9 - 65.6 lb ft)
M10 Screw 42 - 52 Nm (31.0 - 38.4 lb ft)
M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Flywheel Housing M10 75 - 95 Nm (55.3 - 70.1 lb ft)
M12 44 - 54 Nm (32.5 - 39.8 lb ft)
Cylinder Block and Crankshaft Components
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INTRODUCTION

Camshaft Retaining Plate M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Camshaft Gear M8 Screw 32 - 40 Nm (23.6 - 29.5 lb ft)
Crankcase Plate M10 Screw 38 - 48 Nm (28.0 - 35.4 lb ft)
Vibration Damper and Adapter M12
Second Phase 90 °
Drive Pulley M10 61 - 75 Nm (45.0 - 55.3 lb ft)
Engine Flywheel M12
Main Caps M12
Second Phase 74 - 86 Nm (54.6 - 63.4 lb ft)
Connecting Rod Caps
Lubrication System and Components
Oil Pump
First Phase M8 7 - 9 Nm (5.2 - 6.6 lb ft)
Second Phase M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Pressure Relief Valve M22 72 - 88 Nm (53.1 - 64.9 lb ft)
Oil Cooler and Oil Filter Base M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Filter Contact + ¾ Turn
Connection on Filter Base for Turbo Oil 1 ⅛" 20 - 28 Nm (14.8 - 20.7 lb ft)
Supply
Turbo Lubrication Pipe M12 Nut 8 - 12 Nm (5.9 - 8.9 lb ft)
Turbo Lubrication Pipe Adapter M12 30 - 40 Nm (22.1 - 29.5 lb ft)
Oil Pan 20 - 28 Nm (14.8 - 20.7 lb ft)
Piston Spray Nozzles M8 12 - 18 Nm (8.9 - 13.3 lb ft)
Electrical Components
Camshaft Sensor M6 Studs 6 - 10 Nm (4.4 - 7.4 lb ft)
M6 Nut 8 - 12 Nm (5.9 - 8.9 lb ft)
M6 Screw 6 - 10 Nm (4.4 - 7.4 lb ft)
Wiring Bulkhead M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
Support Bracket for Injector Wiring M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Injector Wiring 1.25 - 1.75 Nm (0.92 - 1.29 lb ft)
ECU Cooling Plate M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Outlet M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Fuel Inlet M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Crankshaft Speed Sensor M6 Screw 6 - 10 Nm (4.4 - 7.4 lb ft)
Coolant Temperature Sensor M14 Screw 17 - 23 Nm (12.5 - 17.0 lb ft)
Oil Pressure / Temperature Sensor M5 Screw 5 - 7 Nm (3.7 - 5.2 lb ft)
Fuel Pressure Sensor 30 - 40 Nm (22.1 - 29.5 lb ft)
Fuel Temperature Sensor M14 17 - 23 Nm (12.5 - 17.0 lb ft)
Air Pressure / Temperature Sensor 5 - 7 Nm (3.7 - 5.2 lb ft)
Engine Oil Level Sensor M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Alternator Support Bracket M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Alternator Tension Bracket M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Starter 37 - 49 Nm (27.3 - 36.1 lb ft)
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INTRODUCTION
Fuel System and Components

Feed Pump M8 Studs 10 - 14 Nm (7.4 - 10.3 lb ft)
High Pressure Pump Gear M18 Nut 100 - 110 Nm (73.8 - 81.1 lb ft)
Fuel Pump M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Injector
First Phase M6 Screw 8.15 - 8.85 Nm (6.0 - 6.5 lb ft)
Second Phase M6 Screw 70 - 80 °
Injector Feed Connector 45 - 55 Nm (33.2 - 40.6 lb ft)
Common Rail M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
High Pressure Fuel Line M14 Fitting 18 - 22 Nm (13.3 - 16.2 lb ft)
High Pressure Pipe Connector M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Filter Bracket M12 Screw 71 - 85 Nm (52.4 - 62.7 lb ft)
Fuel Filter Holder M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Filter Contact + ¾ Turn
Cooling System and Components
Engine Coolant Inlet M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Fitting on Coolant Inlet 90 ° Elbow 20 - 28 Nm (14.8 - 20.7 lb ft)
Compressor Cooling Pipe 20 - 24 Nm (14.8 - 17.7 lb ft)
Engine Coolant Drain Collector M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
Water Pump M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Belt Tensioner M10 37 - 49 Nm (27.3 - 36.1 lb ft)
Idler Pulleys M10 37 - 49 Nm (27.3 - 36.1 lb ft)
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INTRODUCTION
Torque
F4CE9484, F4GE9484, F4CE9684, F4GE9684

Rocker Assembly M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Cylinder Head M12x70
Phase 1 50 Nm (36.9 lb ft)
Phase 2 90 °
Phase 2 180 °
Phase 2 180 °
Valve Cover M8x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
Intake manifold M8x1.25 20 - 28 Nm (14.8 - 20.7 lb ft)
Air intake elbow M8x1.25 20 - 28 Nm (14.8 - 20.7 lb ft)
Exhaust manifold M10x1.5x65 37 - 49 Nm (27.3 - 36.1 lb ft)
Rear lifting bracket M12x1.75x30 65 - 89 Nm (47.9 - 65.6 lb ft)
Turbocharger M10 37 - 49 Nm (27.3 - 36.1 lb ft)
Front Case
Front cover assembly M8x1.25x45 20 - 28 Nm (14.8 - 20.7 lb ft)
M8x1.25x30 20 - 28 Nm (14.8 - 20.7 lb ft)
Rear Case
Gear Case M8x1.25x40 20 - 28 Nm (14.8 - 20.7 lb ft)
M8x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
M10x1.5 44 - 54 Nm (32.5 - 39.8 lb ft)
Flywheel housing M12x120 75 - 95 Nm (55.3 - 70.1 lb ft)
M12x80 75 - 95 Nm (55.3 - 70.1 lb ft)
M10x80 44 - 54 Nm (32.5 - 39.8 lb ft)
M10x40 44 - 54 Nm (32.5 - 39.8 lb ft)
Phase 1 M12x1.25 26 - 34 Nm (19.2 - 25.1 lb ft)
Phase 2 M12x1.25 55 - 65 °
Main bearing cap
Phase 1 44 - 56 Nm (32.5 - 41.3 lb ft)
Phase 2 74 - 86 Nm (54.6 - 63.4 lb ft)
Phase 3 85 - 95 °
Connecting rod M11x1.25
Phase 1 27 - 33 Nm (19.9 - 24.3 lb ft)
Phase 2 55 - 65 Nm (40.6 - 47.9 lb ft)
Phase 3 55 - 65 °
Timing Pin 4 - 6 Nm (3.0 - 4.4 lb ft)
Crankshaft pulley M12x1.75 105 - 115 Nm (77.4 - 84.8 lb ft)
Camshaft retaining plate M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Camshaft gear M8 32 - 40 Nm (23.6 - 29.5 lb ft)
Lubrication System and Components
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INTRODUCTION

Piston Cooling Nozzles M8x1.25x10 12 - 18 Nm (8.9 - 13.3 lb ft)
Oil pump M8x1.25x30 7 - 9 Nm (5.2 - 6.6 lb ft)
Stiffening Plate M10x1.25x25 38 - 48 Nm (28.0 - 35.4 lb ft)
Oil plug M10x1 5 - 7 Nm (3.7 - 5.2 lb ft)
M14x1.5 9 - 13 Nm (6.6 - 9.6 lb ft)
Oil Pick up tube M8x1.25x20 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Pan M8x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
M18x1.50 51 - 69 Nm (37.6 - 50.9 lb ft)
Oil Bypass Valve M22x1.5x10 72 - 88 Nm (53.1 - 64.9 lb ft)
Turbo Lubrication Lines
Turbo end M12x1.5 20 - 28 Nm (14.8 - 20.7 lb ft)
Filter base end 20 - 28 Nm (14.8 - 20.7 lb ft)
Drain M8x1.25x16 20 - 28 Nm (14.8 - 20.7 lb ft)
Electrical Components
Alternator
M8x1.25x30 20 - 28 Nm (14.8 - 20.7 lb ft)
M10x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
M10 44 - 54 Nm (32.5 - 39.8 lb ft)
M12x1.75x120 37 - 49 Nm (27.3 - 36.1 lb ft)
Alternator wiring M6x1.0 nut 8 - 11 Nm (5.9 - 8.1 lb ft)
Starter M10 54 - 44 Nm (39.8 - 32.5 lb ft)
Fuel System and Components
Fuel pump M8 screw 20 - 28 Nm (14.8 - 20.7 lb ft)
M6 screw 9 - 11 Nm (6.6 - 8.1 lb ft)
M6 nut 9 - 11 Nm (6.6 - 8.1 lb ft)
Fuel Pump Drive Gear
Phase 1 15 - 20 Nm (11.1 - 14.8 lb ft)
Phase 2 85 - 90 Nm (62.7 - 66.4 lb ft)
Timing Pin Cap 30 - 35 Nm (22.1 - 25.8 lb ft)
Fuel injectors 55 - 65 Nm (40.6 - 47.9 lb ft)
Fuel lift pump 20 - 28 Nm (14.8 - 20.7 lb ft)
Cooling System and Components
Water Pump M8x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
Water outlet connection M8x1.25x35 20 - 28 Nm (14.8 - 20.7 lb ft)
M8x1.25x70 20 - 28 Nm (14.8 - 20.7 lb ft)
Fan support M10x1.5x20 28 - 38 Nm (20.7 - 28.0 lb ft)
Fan pulley M6 8 - 12 Nm (5.9 - 8.9 lb ft)
M10 27 - 49 Nm (19.9 - 36.1 lb ft)
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INTRODUCTION
Special tools
Tool No. Description Image

380000301 Revolving engine stand
REVOLVING STAND 1
380000665 Crankshaft front seal puller
FRONTSEALPULLER 2
380000663 Crankshaft rear seal puller
REARSEALPULLER 3
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INTRODUCTION

380001099 Injector puller
INJECTORPULLER 4
380000666 Crankshaft front seal

installer
FRONTSEALINSTAL 5
380000664 Crankshaft rear seal

installer
CRANKREARSEALIN 6
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INTRODUCTION

380000670 Oil filter wrench
OILFILTERWRENCH 7
380000302 Valve spring compressor
VALVESPRINGCOMP 8
380000221 Pliers for removing/refitting

piston rings 65 - 110 mm
(2.559 - 4.331 in)
PISTONRINGPLIER 9
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INTRODUCTION

380000667 Beater for removing/refitting
camshaft bushes
CAMBUSHBEATER 10
380000362 Tool for lifting the crankshaft
CRANKHOIST 11
380000216 Engine lifting rig
ENGINEHOIST 12
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INTRODUCTION

380000661 Brackets for fastening the
engine to the revolving
stand
STANDBRACKETS 13
380000669 Seal remover
SEALREMOVER 14
380000668 Hand grip for

interchangeable beaters
HANDGRIP 15
380000364 Gauge base for dial indicator
GAUGEBASE 16
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INTRODUCTION

N/A Torque wrench
TORQUEWRENCH 17
380000158 Torque screwdriver
TORQUESCREWDRIV 18
380000304 Tool for angle tightening
ANGLETIGHTENING 19
380000988 Flywheel rotation tool
ROTATOR 20
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INTRODUCTION

Piston ring compressor
PISTONRINGCOMP 21
Dial indicator ( 0 - 5 mm
(0.000 - 0.197 in))
DIALINDICATOR 22
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INTRODUCTION
Special tools
F4CE9484, F4GE9484, F4CE9684, F4GE9684

380000979 Injection pump gear puller
PUMPGEARPULLER 1
380000665 Crankshaft front seal puller
FRONTSEALPULLER 2
380000663 Crankshaft rear seal puller
REARSEALPULLER 3
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INTRODUCTION

380000671 Injector puller
INJECTORPULLERG 4
380000666 Crankshaft front seal

installer
FRONTSEALINSTAL 5
380000664 Crankshaft rear seal

installer
CRANKREARSEALIN 6
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INTRODUCTION

380000670 Oil filter wrench
OILFILTERWRENCH 7
380000302 Valve spring compressor
VALVESPRINGCOMP 8
380000221 Pliers for removing/refitting

piston rings 65 - 110 mm
(2.559 - 4.331 in)
PISTONRINGPLIER 9
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INTRODUCTION

380000732 Flywheel crank handle
FLYWHEELCRANK 10
380000988 Flywheel rotation tool
ROTATOR 11
380000667 Beater for removing/refitting

camshaft bushes
CAMBUSHBEATER 12
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INTRODUCTION

380000362 Tool for lifting the crankshaft
CRANKHOIST 13
380000216 Engine lifting rig
ENGINEHOIST 14
380000994 Piston ring compressor
PISTONRINGCOMP 15
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INTRODUCTION

380002729 Engine TDC positioning
tool (non-structural engines
only)
TIMINGPIN 16
380000661 Brackets for fastening the

engine to the revolving
stand
STANDBRACKETS 17
380000669 Seal remover
SEALREMOVER 18
380000668 Hand grip for

interchangeable beaters
HANDGRIP 19
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INTRODUCTION

380000364 Gauge base for dial indicator
GAUGEBASE 20
380000229 Dial gauge holder and 0 -

5 mmDial gauge for rotary
injection pump timing.
PUMPTIMEADAPT 21
380000304 Tool for angle tightening
ANGLETIGHTENING 22
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INTRODUCTION

380001005 Dial gauge 0 - 10 mm
DIALGAUGE 23
380001006 Diesel engine compression

tester
COMPTESTER 24
380000140 Adapter for engine

compression tester
COMPADAPTER 25
380000301 Revolving engine stand
REVOLVING STAND 26
84250518 09/11/2009
25
INTRODUCTION
84250518 09/11/2009
26
DISTRIBUTION SYSTEMS - A
ELECTRICAL POWER SYSTEM - 30.A
F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 ,

F4GE9684 , F4HE9484 , F4HE9684
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Contents
FUNCTIONAL DATA
Alternator
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4CE9484, F4GE9484, F4CE9684, F4GE9684
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4GE9484, F4GE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4CE9484, F4GE9484, F4CE9684, F4GE9684
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
Alternator - Overview
F4CE9484, F4GE9484, F4CE9684, F4GE9684
ALTERNATORCG2 1
The alternator is placed on the front right hand side of the engine and is driven by a Poly V-belt.
Specifications:
• Working voltage:
• 12 V
• Current delivered:
• 90 A @ 6000 RPM
• Absorption in stand-by:
• Less than or equal to 1 mA
• Sense of rotation:
• Clockwise
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Alternator - Remove
Prior operation:
Fan and drive Belt - Remove (B.50.A)
1. Remove the cables from the back of the alternator

(1).
2. Remove the retaining bolts (2) securing the alterna-
tor (1) to the support.
3. Remove the alternator (1).
ALTERNATOR 1
Next operation:
Alternator - Install (A.30.A)
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Alternator - Install
Prior operation:
Alternator - Remove (A.30.A)
1. Install the alternator (1) and tighten the bolts (2) to

the specified torque.
2. Connect the positive and negative cables onto the
back of the alternator.
ALTERNATOR 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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Alternator - Remove
F4GE9484, F4GE9684
Prior operation:
1. Properly hold the alternator (1) separating it from its

support by loosening the screw (2).
2. Remove the screw, nut and washer.
3. Remove the alternator (1).
ALTERNATORG 1
Next operation:
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Alternator - Remove
F4CE9484, F4CE9684
Prior operation:
1. Properly hold the alternator (2) and loosen the screw

(3) to remove the alternator from its support.
2. Remove it from its bracket by loosening the screw
(1).
3. Recover the nuts and washers.
ALTERNATORC 1
Next operation:
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Alternator - Install
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Connect the alternator (1) to the support.

2. Tighten the screw (2) without locking it.
ALTERNATORG 1
3. Fit the alternator (2) bracket (1) to the engine block.

4. Tighten the screws (3) fastening the alternator to the
support.
ALTERNATORCG 2
Next operation:
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Index

Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Alternator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9484, F4GE9684
F4CE9484, F4CE9684
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POWER PRODUCTION - B
ENGINE - 10.A

F4GE9684 , F4HE9484 , F4HE9684
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Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4HE9484, F4HE9684
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4DE9484, F4DE9684, F4DE9687
Service limits Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

F4CE9484, F4CE9684
F4GE9484, F4GE9684
Service limits Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

F4CE9484, F4GE9484, F4CE9684, F4GE9684
FUNCTIONAL DATA
ENGINE
Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4CE9684
F4GE9484, F4GE9684
Valve drive
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connecting rod and piston

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wiring harness
Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F4HE9484, F4HE9684
Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
F4DE9484, F4DE9684, F4DE9687
Electronic control
Control module - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Control module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Sensing system
Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
F4HE9484, F4HE9684
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Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
F4HE9484, F4HE9684

F4DE9484, F4DE9684, F4DE9687
Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

F4DE9484, F4DE9684, F4DE9687

F4CE9484, F4CE9684
SERVICE
ENGINE
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
F4HE9484, F4HE9684
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
F4DE9484, F4DE9684, F4DE9687
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
F4GE9484, F4GE9684
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
F4CE9484, F4CE9684
Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

F4DE9484, F4DE9684, F4DE9687

F4GE9484, F4GE9684

F4CE9484, F4CE9684
Valve drive
Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rocker assembly - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Rocker assembly Shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
F4DE9484, F4DE9684, F4DE9687
Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Rocker assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

F4CE9484, F4CE9684
Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

F4GE9484, F4GE9684
Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

F4CE9484, F4CE9684
Rocker assembly - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Auxiliary drive
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
F4HE9484, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
F4HE9484, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
F4CE9484, F4CE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
F4GE9484, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
F4GE9484, F4GE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
F4CE9484, F4CE9684
Crankshaft
Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Gear - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
F4CE9484, F4CE9684
Timing gear housing

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
F4HE9484, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
F4HE9484, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
F4DE9484, F4DE9684, F4DE9687
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
F4GE9484, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
F4GE9484, F4GE9684
Connecting rod and piston

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Connecting rod Bushing - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Connecting rod Bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Connecting rod Bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
F4CE9484, F4HE9484, F4CE9684, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
F4HE9484, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
F4DE9484, F4DE9684, F4DE9687
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
F4GE9484, F4DE9484, F4GE9684, F4DE9684, F4DE9687
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
F4DE9484, F4DE9684, F4DE9687
84250518 09/11/2009
B.10.A / 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
F4CE9484, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
F4CE9484, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
F4GE9484, F4GE9684
Vibration damper
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
F4HE9484, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F4DE9484, F4DE9684, F4DE9687
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
F4DE9484, F4DE9684, F4DE9687
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
F4GE9484, F4GE9684
Cylinder block
Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
F4GE9484, F4GE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
F4CE9484, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
F4GE9484, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
F4CE9484, F4CE9684
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
F4GE9484, F4GE9684
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
F4CE9484, F4CE9684
Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
84250518 09/11/2009
B.10.A / 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
F4DE9484, F4DE9684, F4DE9687
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Front cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
F4DE9484, F4DE9684, F4DE9687
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
F4DE9484, F4DE9684, F4DE9687
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
F4DE9484, F4DE9684, F4DE9687
Rear cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
F4HE9484, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
F4HE9484, F4HE9684
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
F4GE9484, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
F4GE9484, F4GE9684
Wiring harness
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
F4DE9484, F4DE9684, F4DE9687
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
F4HE9484, F4HE9684
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Electronic control
Control module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
F4HE9484, F4HE9684
Control module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

F4HE9484, F4HE9684
Sensing system
Position sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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B.10.A / 7
Position sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Speed sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

84250518 09/11/2009
B.10.A / 8
POWER PRODUCTION - ENGINE
ENGINE - General specification

F4HE9484, F4HE9684
F4HECOMPLETE 1
The NEF F4HE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves
per cylinder.
They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the
working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.
NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions
provided by FPT.
Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for
which the engine has been designed.
84250518 09/11/2009
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General Specifications
Engine Type 4 Cylinders 6 Cylinders
Cycle Four-Stroke diesel engine
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6
Bore 104 mm (4 in)
Stroke 132 mm (5 in)
Total Displacement 4485 cm³ 6728 cm³
Timing
Start before T.D.C. 18.5 °
End after B.D.C. 29.5 °
Start before B.D.C. 67 °
End after T.D.C. 35 °
Valve Clearance
Intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Fuel Feed
Injection Type Bosch high pressure common rail
Control EDC7 ECU
Injector CRIU 2
Nozzle Type DSLA and DLLA
Injection Sequence 1-3-4-2 1-5-3-6-2-4
Injection pressure 250 - 1600 bar (3625 - 23200 psi)
Aspiration
Turbocharging Intercooled
Turbocharger Type Holset HX35
Lubrication
Oil Pressure @ Low Idle 0.7 bar (10 psi)
Oil Pressure @ Fast Idle 3.5 bar (51 psi)
Oil Pan Capacity 15 l (15.85 US qt)
Oil Filter Capacity 1 l (1.06 US qt)
Cooling
Water Pump Belt Driven
Thermostat 79 - 83 °C (174 - 181 °F)
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Clearance Data

Cylinder Barrels 104.000 - 104.024 mm (4.094 - 4.095 in)
Oversize 0.4 mm (0.016 in)
103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -
Pistons
4.086 in) (*)
Skirt Height 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Piston (oversize) 0.4 mm (0.016 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Piston Pin - Pin Housing 0.01 - 0.022 mm (0.0004 - 0.001 in)
Piston ring landings
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Intermediate 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*)
Oil Control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Intermediate 2.350 - 2.380 mm (0.093 - 0.094 in)
Oil Control 3.970 - 3.990 mm (0.156 - 0.157 in)
Piston Ring and Ring Landing Clearance
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Oil Control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston Ring End Gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Oil Control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rod
Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in)
Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in)
Small end bushing Inside
38.019 - 38.033 mm (1.497 - 1.497 in)
Diameter
Big end bearing shell
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
Piston Pin and Bushing
0.019 - 0.039 mm (0.001 - 0.002 in)
Clearance
Oversize Big end bearing
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Shells
Crankshaft
Main Journals 82.99 - 83.01 mm (3.267 - 3.268 in)
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
Main Bearing Shell Thickness 2.456 - 2.464 mm (0.097 - 0.098 in)
Big end Bearing Shell
1.955 - 1.968 mm (0.077 - 0.078 in)
Thickness
Main Bearing Bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
Bearing Shell and Journal Clearance
No. 1,5 / 1,7 0.041 - 0.119 mm (0.002 - 0.005 in)
No. 2,3,4 / 2,3,4,5,6 0.041 - 0.103 mm (0.002 - 0.004 in)
Bearing Shell and Crankpin
0.033 - 0.041 mm (0.001 - 0.002 in)
Clearance
(*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A
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Clearance Data
Thrust Journal 37.475 - 37.545 mm (1.475 - 1.478 in)

Thrust Bearing Bore 32.180 - 32.280 mm (1.267 - 1.271 in)
Thrust Bearing 37.28 - 37.38 mm (1.468 - 1.472 in)
Crankshaft End Play 0.095 - 0.265 mm (0.004 - 0.010 in)
Valve Guide Bore 7.042 - 7.062 mm (0.277 - 0.278 in)

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

Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
Rockers and Shaft Clearance 0.024 - 0.162 mm (0.001 - 0.006 in)
84250518 09/11/2009
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F4DE9484, F4DE9684, F4DE9687
F4DECOMPLETE 1
The NEF F4DE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves
per cylinder.
They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the
working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.
NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions
provided by FPT.
84250518 09/11/2009
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General Specifications
Engine Type 4 Cylinders 6 Cylinders
Cycle Four-Stroke diesel engine
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6
Bore 104 mm (4 in)
Stroke 132 mm (5 in)
Total Displacement 4485 cm³ 6728 cm³
Timing
Start before T.D.C. 18.5 °
End after B.D.C. 29.5 °
Start before B.D.C. 67 °
End after T.D.C. 35 °
Valve Clearance
Intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Fuel Feed
Injection Type Bosch high pressure common rail
Control EDC7 ECU
Injector CRIU 2
Nozzle Type DSLA and DLLA
Injection Sequence 1-3-4-2 1-5-3-6-2-4
Injection pressure 250 - 1600 bar (3625 - 23200 psi)
Aspiration
Turbocharging Intercooled
Turbocharger Type Holset HX35
Lubrication
Oil Pressure @ Low Idle 0.7 bar (10 psi)
Oil Pressure @ Fast Idle 3.5 bar (51 psi)
Oil Pan Capacity 15 l (15.85 US qt)
Oil Filter Capacity 1 l (1.06 US qt)
Cooling
Thermostat 79 - 83 °C (174 - 181 °F)
84250518 09/11/2009
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Clearance Data

103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -
Pistons
4.086 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Oil Control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Oil Control 3.970 - 3.990 mm (0.156 - 0.157 in)
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Oil Control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston Ring End Gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Oil Control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rod
38.019 - 38.033 mm (1.497 - 1.497 in)
Diameter
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
0.019 - 0.039 mm (0.001 - 0.002 in)
Clearance
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Shells
Crankshaft
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
1.955 - 1.968 mm (0.077 - 0.078 in)
Thickness
Main Bearing Bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
No. 1,5 / 1,7 0.041 - 0.119 mm (0.002 - 0.005 in)
No. 2,3,4 / 2,3,4,5,6 0.041 - 0.103 mm (0.002 - 0.004 in)
0.033 - 0.041 mm (0.001 - 0.002 in)
Clearance
(*) Valid for engines: F4DE9684A.
84250518 09/11/2009
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Clearance Data


Intake Valves
Face angle 59.75 - 60.25 °
Exhaust Valves
Face angle 44.75 - 44.25 °
0.052 - 0.092 mm (0.002 - 0.004 in)
Clearance
Valve Seat Bore
Intake 34.837 - 34.863 mm (1.372 - 1.373 in)
Exhaust 34.837 - 34.863 mm (1.372 - 1.373 in)
Intake 34.917 - 34.931 mm (1.375 - 1.375 in)
Exhaust 34.917 - 34.931 mm (1.375 - 1.375 in)
Valve Seat Angle
Intake 60 °
Exhaust 45 °
Valve Sink
Intake 0.59 - 1.11 mm (0.023 - 0.044 in)
Exhaust 0.96 - 1.48 mm (0.038 - 0.058 in)
Intake 0.054 - 0.094 mm (0.002 - 0.004 in)
Exhaust 0.054 - 0.094 mm (0.002 - 0.004 in)
Valve Spring Height
Free 47.75 mm (1.880 in)
330.8 - 348.8 N (74.4 - 78.4
35.33 mm (1.391 in)
lb)
702 - 780 N (157.8 - 175.4 lb) 25.2 mm (0.992 in)
Camshaft Bore
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft Journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Cam Lift
Intake 7.582 mm (0.299 in)
Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
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Clearance Data

Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
84250518 09/11/2009
B.10.A / 18
ENGINE - Service limits Maintenance Planning

To ensure optimized working conditions, in the following pages we are providing instructions for the overhaul control
interventions, checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be
suggested by common sense and by the specific conditions in which the engine is run.
Regular maintenance and inspection planning

Checks and periodical inspections Frequency (hours)
Visual check of engine Daily
Inspection presence of water in fuel filter or pre-filter Daily
Inspection blow-by filter elements -
Inspection of belt wear status -
Inspection and setting of tappet clearance 4000
EDC When anomaly occurs
Replacement of engine’s oil and filter 500
Replacement of pre-filter 1000
Replacement of fuel filter 500
Replacement of blow-by filter 500
Replacement of belt 1500
NOTICE: The frequency of the maintenance operations is just an indication since the use of the engine is the main
characteristic to determine and evaluate replacement and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
Daily Maintenance Checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty
to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and
to the vehicle’s drivers.
• Fluid levels and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
• Notify the maintenance if any inconvenience is detected or if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
• check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
• Verify absence of noise or unusual rattle during engine working.
• Verify, using vehicle devices, the prescribed pressure, temperature and other parameters.
• Visual check of fumes (color of exhaust emissions)
• Visual check of cooling liquid level, in the expansion tank.
84250518 09/11/2009
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F4CE9484, F4CE9684
SECTIONPICTUREC 1
NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment
in general.
They are characterized by diesel cycle 4 stroke atmospheric or turbocharged 4 and 6 cylinders each with 2 valves.
Feed is provided by rotary mechanical pump or on line according to the equipment application.
It differs from other applications because of the provision of different power, power take-off for the different collector
configuration, priming pump, oil pan and boost turbine.
NOTE: The picture shows application designed for 6 cylinder versions, 2 valves per cylinder, having fuel feed by a
mechanical pump.
NOTICE: Data, technical specifications and performances granted shall be valid only if the setter will follow and com-
ply with all installation prescriptions provided by FPT.
84250518 09/11/2009
B.10.A / 20
Engine Type 4 cylinder 6 cylinder

Compression ratio 17.5 : 1
Bore 104 mm (4.1 in)
Stroke 132 mm (5.2 in)
Displacement 4485 cm³ 6728 cm³
Turbocharger type Intercooled Holset HX25W Intercooled Holset HX35W
Lubrication
Oil Pressure (warm engine)
Idling 0.8 bar (11.6 psi)
Peak RPM 3.5 bar (50.8 psi)
Cooling
Thermostat opening temperature 79 - 83 °C (174.2 - 181.4 °F)
Capacity
Oil Pan - 16 l (16.9 US qt)
Oil Filter - 1 l (1.1 US qt)
Clearance Data

103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -
Pistons
4.086 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Oil Control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Oil Control 3.970 - 3.990 mm (0.156 - 0.157 in)
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Oil Control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston Ring End Gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Oil Control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rod
38.019 - 38.033 mm (1.497 - 1.497 in)
Diameter
84250518 09/11/2009
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Clearance Data
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
0.019 - 0.039 mm (0.001 - 0.002 in)
Clearance
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Shells
Crankshaft
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
1.955 - 1.968 mm (0.077 - 0.078 in)
Thickness
Main Bearing Bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
No. 1,5 / 1,7 0.064 - 0.095 mm (0.003 - 0.004 in)
No. 2,3,4 / 2,3,4,5,6 0.059 - 0.100 mm (0.002 - 0.004 in)
0.033 - 0.041 mm (0.001 - 0.002 in)
Clearance

Intake Valves
Face angle 59.75 - 60.25 °
Exhaust Valves
Face angle 44.75 - 44.25 °
0.039 - 0.079 mm (0.002 - 0.003 in)
Clearance
Valve Seat Bore
Intake 46.987 - 47.013 mm (1.850 - 1.851 in)
Exhaust 43.637 - 43.663 mm (1.718 - 1.719 in)
Intake 47.063 - 47.089 mm (1.853 - 1.854 in)
Exhaust 43.713 - 43.739 mm (1.721 - 1.722 in)
Valve Seat Angle
Intake 60 °
Exhaust 45 °
Valve Sink
Intake 1 - 1.52 mm (0.039 - 0.060 in)
Exhaust 1 - 1.52 mm (0.039 - 0.060 in)
Intake 0.050 - 0.102 mm (0.002 - 0.004 in)
Exhaust 0.050 - 0.102 mm (0.002 - 0.004 in)
Valve Spring Height
Free 63.50 mm (2.500 in)
330.8 - 348.8 N (74.4 - 78.4
49.02 mm (1.930 in)
lb)
84250518 09/11/2009
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Clearance Data
702 - 780 N (157.8 - 175.4 lb) 38.20 mm (1.504 in)
Camshaft Bore
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft Journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Cam Lift
Intake 11.02 mm (0.434 in)
Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Rockers 19.000 - 19.026 mm (0.748 - 0.749 in)
84250518 09/11/2009
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F4GE9484, F4GE9684
SECTIONPICTUREG 1
NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment
in general.
They are characterized by diesel cycle 4 stroke atmospheric or turbocharged 4 and 6 cylinders each with 2 valves.
Feed is provided by rotary mechanical pump or on line according to the equipment application.
It differs from other applications because of the provision of different power, power take-off for the different collector
configuration, priming pump, oil pan and boost turbine.
NOTE: The picture shows application designed for 6 cylinder versions, 2 valves per cylinder, having fuel feed by a
mechanical pump.
NOTICE: Data, technical specifications and performances granted shall be valid only if the setter will follow and com-
ply with all installation prescriptions provided by FPT.
84250518 09/11/2009
B.10.A / 24
Engine Type 4 cylinder 6 cylinder

Compression ratio 17.5 : 1
Bore 104 mm (4.1 in)
Stroke 132 mm (5.2 in)
Displacement 4485 cm³ 6728 cm³
Turbocharger type Intercooled Holset HX25W Intercooled Holset HX35W
Lubrication
Oil Pressure (warm engine)
Idling 0.7 bar (10.2 psi)
Peak RPM 3.5 bar (50.8 psi)
Cooling
Thermostat opening temperature 79 - 83 °C (174.2 - 181.4 °F)
Capacity
Oil Pan 13 l (13.7 US qt) 15 l (15.9 US qt)
Oil Filter 1 l (1.1 US qt) 1 l (1.1 US qt)
Clearance Data

103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -
Pistons
4.086 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Oil Control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Oil Control 3.970 - 3.990 mm (0.156 - 0.157 in)
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Oil Control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston Ring End Gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Oil Control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rod
38.019 - 38.033 mm (1.497 - 1.497 in)
Diameter
84250518 09/11/2009
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Clearance Data
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
0.019 - 0.039 mm (0.001 - 0.002 in)
Clearance
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Shells
Crankshaft
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
1.955 - 1.968 mm (0.077 - 0.078 in)
Thickness
Main Bearing Bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
No. 1,5 / 1,7 0.064 - 0.095 mm (0.003 - 0.004 in)
No. 2,3,4 / 2,3,4,5,6 0.059 - 0.100 mm (0.002 - 0.004 in)
0.064 - 0.090 mm (0.003 - 0.004 in)
Clearance

Intake Valves
Face angle 59.75 - 60.25 °
Exhaust Valves
Face angle 44.75 - 44.25 °
0.059 - 0.086 mm (0.002 - 0.003 in)
Clearance
Valve Seat Bore
Intake 46.987 - 47.013 mm (1.850 - 1.851 in)
Exhaust 43.637 - 43.663 mm (1.718 - 1.719 in)
Intake 47.063 - 47.089 mm (1.853 - 1.854 in)
Exhaust 43.713 - 43.739 mm (1.721 - 1.722 in)
Valve Seat Angle
Intake 60 °
Exhaust 45 °
Valve Sink
Intake 1 - 1.52 mm (0.039 - 0.060 in)
Exhaust 1 - 1.52 mm (0.039 - 0.060 in)
Intake 0.050 - 0.102 mm (0.002 - 0.004 in)
Exhaust 0.050 - 0.102 mm (0.002 - 0.004 in)
Valve Spring Height
Free 63.50 mm (2.500 in)
330.8 - 348.8 N (74.4 - 78.4
49.02 mm (1.930 in)
lb)
84250518 09/11/2009
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Clearance Data
702 - 780 N (157.8 - 175.4 lb) 38.20 mm (1.504 in)
Camshaft Bore
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft Journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Rockers 19.000 - 19.026 mm (0.748 - 0.749 in)
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ENGINE - Service limits Maintenance Planning

F4CE9484, F4GE9484, F4CE9684, F4GE9684
To ensure optimized working conditions, in the following pages we are providing instructions for the overhaul control
interventions, checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be
suggested by common sense and by the specific conditions in which the engine is run.
Regular maintenance and inspection planning

Checks and periodical inspections Frequency (hours)
Visual check of engine Daily
Inspection presence of water in fuel filter or pre-filter Daily
Inspection of belt wear status -
Inspection and setting of tappet clearance 4000
Replacement of engine’s oil and filter 500
Replacement of pre-filter 1000
Replacement of fuel filter 500
Replacement of belt 1500
NOTICE: The frequency of the maintenance operations is just an indication since the use of the engine is the main
characteristic to determine and evaluate replacement and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Checks not included in maintenance planning - daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty
to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and
to the vehicle’s drivers.
• Fluid levels and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
• Notify the maintenance if any inconvenience is detected or if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
• check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
• Verify absence of noise or unusual rattle during engine working.
• Verify, using vehicle devices, the prescribed pressure, temperature and other parameters.
• Visual check of fumes (color of exhaust emissions)
• Visual check of cooling liquid level, in the expansion tank.
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ENGINE - Component localisation

F4HE9484, F4HE9684
Location of main electrical components
CRIL04D081G01 1
(1) Coolant Temperature Sensor - (2) Electro-Injector - (3) Rail Pressure Sensor - (4) Air Temperature/Pressure
Sensor - (5) Engine Starter - (6) Timing Sensor - (7) Solenoid Valve for Pressure Regulator - (8) Fuel
Temperature Sensor - (9) EDC Electronic Control Unit - (10) Crankshaft Sensor - (11) Oil Level Sensor - (12)
Engine Oil Temperature/Pressure Sensor - (13) Heating Element for Pre-Post Heating
The NEF F4HE engines are fully driven by the electronic engine control module, which is assembled directly to the
engine by means of a heat exchanger enabling it’s cooling, utilizing rubber buffers to reduce vibration originated by
the engine.
Through the engine control module it is possible to verify the correct working of the engine.
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F4DE9484, F4DE9684, F4DE9687
Location of main electrical components
ELECCOMPD 1
(1) Coolant temperature sensor - (2) Electro-injector - (3) Starter - (4) Fuel pressure sensor - (5) Air
pressure/temperature sensor - (6) Timing sensor - (7) fuel temperature sensor - (8) EDC7 electronic control
module - (9) Crankshaft speed sensor - (10) Engine oil pressure/temperature sensor - (11) Pre-post heating
resistor.
The NEF F4DE engines are fully driven by the electronic engine control module, which is mounted remotely on the
unit utilizing rubber buffers to reduce vibration originated by the engine.
Through the engine control module it is possible to verify the correct working of the engine.
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F4CE9484, F4CE9684
ECOMPONENTSC 1
(1) Coolant temperature sensor - (2) Starter - (3) Grid heater - (4) KSB water temperature sensor - (5)
Electromagnets assembled to feed pump: (A) on hydraulic head unit (B) on KSB - (6) Oil pressure switch -
(7) (C) Fuel heater (D) Water detecting sensor - (8) Speed sensor - (9) Alternator
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F4GE9484, F4GE9684
ECOMPONENTSG 1
(1) Coolant temperature sensor - (2) Starter - (3) KSB water temperature sensor - (4) Electromagnets
assembled on feed pump: (A) on hydraulic head unit (B) on KSB - (5) Oil pressure sensor - (6) Grid
heater - (7) Alternator.
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Valve drive - Overview

Exhaust Gas Re-Circulation System (EGR)

In the Tier III version, the profile of the exhaust cam lobe has been modified in order to allow the partial opening of the
exhaust valve during the aspiration phase and introduces part of the exhaust gases into the engine cylinders. The
exhaust gases can partially be redirected into the cylinders so as to reduce the maximum combustion temperature
values responsible for the production of nitrogen oxides (NOx). The EGR system reduces the combustion temperature
by means of diminishing the concentration of oxygen in the combustion chamber. This process is an efficient control
system of the emission of NOx. The internal EGR system is not equipped with any electronically controlled elements.
The system is always active and does not require any additional components such as check valves, piping, or heat
exchangers. The exhaust cam has an additional lobe apart from the major lobe. The additional lobe, during the
aspiration phase of a cylinder, allows a brief opening of the exhaust valve generating recirculation due the intake of
the exhaust gases caused by the suction which is created in the aspiration phase inside the cylinder.
EGRSYSTEM 1
(A) Aspiration valve control - (B) Exhaust valve control
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Rocker Assembly Components
ROCKERCOMPONENT 2
(1) Screws - (2) Bracket - (3) Shafts - (4) Rockers.
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Connecting rod and piston - Overview

Components
BAPH04APH144ASA 1
(1) Stop Rings - (2) Pin - (3) Piston- (4) Split Rings - (5) Screws - (6) Half Bearings - (7) Connecting Rod
- (8) Bush
NOTE: The pistons are supplied spare with the following sizes:
- Standard
- 0.4 mm (0.016 in) oversize.
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Wiring harness - Electrical schema

F4HE9484, F4HE9684
ELECSCHEMH 1
(1) Injectors for cylinders 1 and 2 (6) Engine oil pressure/temperature (11) Pressure regulator
sensor
(2) Injectors for cylinders 3 and 4 (7) Fuel temperature sensor (12) Connector C to the EDC control
unit (sensors)
(3) Injectors for cylinders 5 and 6 (8) Coolant temperature sensor (13) Connector A to the EDC control
unit (injectors)
(4) Engine RPM sensor (9) Air pressure/temperature sensor
(5) Timing sensor (10) Fuel pressure sensor
Injectors Connector (A)
ECU PIN FUNCTION

1 Cylinder 5 injector
7 -
8 -
9 Pressure Regulator
10 Pressure Regulator
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Injectors Connector (A)
ECU PIN FUNCTION

Sensors connector (C)
ECU PIN FUNCTION

1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 Timing sensor
10 Timing sensor
11 -
12 Negative for rail temperature and pressure sensor
13 Positive for rail temperature and pressure sensor
14 Signal from rail temperature and pressure sensor
15 Coolant temperature sensor
16 -
17 -
18 signal from fuel temperature sensor
19 Engine RPM sensor
20 -
21 -
22 -
23 Engine RPM sensor
24 Negative for engine oil pressure and temperature sensor
25 Negative for air temperature and pressure sensor
26 Coolant temperature sensor
27 Signal from engine oil pressure sensor
28 Signal from engine oil temperature
29 -
30 -
31 -
32 Positive for engine oil pressure and temperature sensor
33 Positive for air temperature and pressure sensor
34 Signal from air pressure sensor
35 Negative for fuel temperature sensor
36 Signal from air temperature sensor
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Wiring harness - Electrical schema

F4DE9484, F4DE9684, F4DE9687
Connector to injectors (A)
CONNECTORA 1
ECU Pin # Cable Function

Color
4 cyl.version 6 cyl. version
1 - - -
2 - - -
3 MN - Injector Cylinder 2
4 MV Injector Cylinder 4 Injector Cylinder 3
5 VB - Injector Cylinder 4
6 HR - Injector Cylinder 2
7 - Earth Earth
8 - - -
9 MB Injector Cylinder 1 Injector Cylinder 1
10 VN Injector Cylinder 2 Injector Cylinder 6
11 VG Injector Cylinder 3 Injector Cylinder 5
12 HN Injector Cylinder 4 Injector Cylinder 3
13 HG Injector Cylinder 1 Injector Cylinder 1
14 CN - Injector Cylinder 4
15 CB Injector Cylinder 2 Injector Cylinder 6
16 CL Injector Cylinder 3 Injector Cylinder 5
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Feed connector (B) to components and to functions of the specific equipment
CONNECTORB 2
ECU Pin # Cable # Function

1 8150 Positive driven by battery
2 0087 Negative for switch of fuel filter heater/starter
3 0000 Earth
4 8885/0159 Positive for pre-post heating resistor
7 8150 Positive driven by battery
8 7777 Positive for blink-code button, low oil pressure LED, pre-heating LED, Air
conditioner switch (if available), EDC
9 0000 Earth
12/13 8150 Positive driven by battery
14/15 0000 Earth
16 0094 Negative for post-heating resistor
19 0150 Negative start/stop push buttons from eng./accelerator pressed
20 8153 Positive from change over switch to key in starting phase (+50)
27 0156 Positive from blink-code button
28 5535 Positive for EDC diagnostic LED
31 2298 K line for diagnostic connector, 30 poles (pin 2)
32 - Negative for multi-switch couple-limiter
36 8837 Positive for fuel heating switch
37 8888 Positive for starter
39 8051 Positive from key switch/ L line for diagnosis connector, 30 poles (pin 11)
44 9905 Negative from starter push button from engine
45 9906 Negative from engine stop push button from engine
46 5553 Negative for pre-heating LED in on position
49 5584 Diagnosis connector (pin 28)
50 0158 Negative from accelerator push button pressed
52 6109 CAN Line (if equipped), diagnosis connector (pin 22)
53 6108 CAN Line (if equipped), diagnosis connector (pin 22)
55 5158 Positive for sensor of foot accelerator pedal pos. / Earth multi-switch
62 0160 Negative for clutch sensor
63 5503 Negative for low engine oil pressure LED
64 0535 Negative for EDC diagnosis LED
72 0159 Positive from pressed accelerator push button / multi-switch signal
73 0159 Positive redundant from pressed accelerator push button
78 8162 Positive air conditioner device (if equipped)
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ECU Pin # Cable # Function

81 0157 Negative sensor of foot accelerator pedal pos. / Earth Multi-switch
83 5157 Signal from sensor of foot accelerator pedal pos. / Signal Multi-switch
87 - Positive for couple multi-switch limiter
Color Legend
Symbol Color Symbol Color

C Orange N Black
A Sky Blue W Light Brown
B White S Pink
L Blue R Red
G Yellow V Green
H Gray Z Purple
M Brown
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Connector to sensors (C)
CONNECTORC 3
ECU Pin Cable Color Function

#
5 C Earth for pressure regulator
7 V Pressure regulating device
9 MN Feed for engine oil temperature/pressure sensor
10 CR Feed for air pressure/temperature sensor
12 HN Feed for rail pressure sensor
17 BL Earth for fuel temperature sensor
18 CV Earth for coolant temperature sensor
19 GV Earth for engine oil temperature sensor
20 BZ Feed for rail pressure sensor
21 GN Feed for air pressure/temperature sensor
23 R Timing system sensor
24 B Driving shaft sensor
25 R Driving shaft sensor
27 RV Signal from rail pressure sensor
28 LN signal from air pressure sensor
29 BH Signal from air pressure sensor
30 B Earth for timing system sensor
33 GR Signal from engine oil temperature sensor
34 CN Signal from fuel temperature sensor
35 NS Signal from engine oil pressure sensor
36 BG Signal from coolant temperature sensor
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Electronic control Control module - Detailed view

EDC7 ECU
CRIL04D082G01 1
(A) - Connector to injectors; (B) - Connector (Provide reference of the vehicle to which the engine is
assembled);
(C) - Connector to sensors.
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Electronic control Control module - Overview

EDC 7 OPERATION
Engine preheating element control

Pre-post heating is activated when any of the following requirements are met. Water, air, or fuel temperature sensors
detect a temperature less than or equal to 5 °C (41 °F).
Phase recognition
Signals transmitted by the camshaft and crankshaft sensors determine which cylinder fuel is to be injected at the time
of starting.
Injection control
On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and
modifies the pre-injection and main injection mode. On F4 engines pre-injection is activated at all engine speeds.
Injection pressure closed loop control

On the basis of the engine load, as determined by processing of data transmitted by the various sensors, the control
unit administrates the regulator to maintain injection pressure at constantly optimal values.
Pilot and main injection advance control

On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on
the basis of internal mapping.
Idle speed control

The control unit processes signals transmitted by the various sensors and adjust the quantity of fuel injected.
It also controls the pressure regulator and modulates injection duration of the electro-injectors.
Within specific limits, the control unit also monitors battery voltage.
Overheating protection
If the water temperature reaches 110 °C (230 °F), the control unit reduces engine performance.
When the temperature returns below 100 °C (212 °F), the engine resumes normal operation, (in some applications,
the over boosting temperature is the reference temperature).
Maximum engine speed limiting

Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine
speed surpasses these limits the control unit activates power reduction strategies by controlling the electro-injectors.
In some applications the maximum limiting response consists in stopping the engine.
Cut Off
Fuel cut off in release phases is managed by the control unit with the following logical interventions:
• Deactivation of the electro-injectors.
• Reactivation of electro-injectors immediately prior to reaching idle speed.
• Control of fuel pressure regulator.
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Smoke control under acceleration

With heavy load demands, in accordance with signals received from the air inlet meter and the engine speed sensor,
the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent
the emission of smoke from the exhaust.
After Run
After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, in-
cluding the faults log so that they will be available the next time the engine is started.
Control of working speed in normal operating conditions

Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions.
If the load causes a reduction in power, the control unit increases torque by increasing the amount of fuel injected in
order to restore the engine to maximum power.
Recovery strategies
Recovery strategies are characterized by certain differences as application varies:
• Control of fuel leaks
In the case of fuel supply problems, the system controls the engine with suitable constant power values obtained
with a low number of RPMs and high torque values in order to inject the maximum quantity of fuel.
• Control of pressure in the rail
When the pressure in the rail exceeds the safety values, the engine reduces power.
• Synchronism problems
In the case of synchronism problems, faulty RPM sensors, the system controls the engine by increasing the num-
ber of RPMs in order to improve interpretation of the signals.
• Power restrictions as operating temperature increases
When the temperature of the charge air rises above 88 °C (190 °F), power reduction is started. When a temper-
ature of 120 °C (248 °F) is reached, performance is further reduced and is comparable to a naturally aspirated
engine.
• Reduction of power as reference temperature varies
In normal operating conditions, the system knows the charge air, oil and water temperatures.
If the temperature of the engine water is not available, the system takes the temperature of the oil as a reference
and when this reaches the threshold of 103 °C (217 °F), it starts to reduce the power available. Upon reaching
113 °C (235 °F), power is reduced to 50 %.
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Sensing system Crankshaft sensor - Overview

F4HE9484, F4HE9684
CRANKSENSOR 1
This is an inductive sensor located at the left hand side of the engine. The crankshaft sensor produces signals ob-
tained from a magnetic flux field closing through the openings in a tone wheel fitted on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is ~900 Ω.
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Sensing system Camshaft speed sensor - Overview

F4HE9484, F4HE9684
CAMSENSOR 1
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals
obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated
by this sensor is utilized by the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are no interchangeable because of the different external
shape.
The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance is ~900 Ω.
ECU pin
Reference Description
Crankshaft Sensor Timing Sensor
1 Signal 19C 10C

2 Signal 23C 9C
3 Shield - -
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F4DE9484, F4DE9684, F4DE9687
CRANKSENSOR 1
The crankshaft sensor is an inductive type sensor that is located on the front of the engine.
It generates some signals originated by the magnetic flow lines that close up through the openings of a tone wheel
splined to the crankshaft. The same signal is utilized to control the eventual electronic engine speed indicator placed
on the vehicle instrument board.
It is connected to the engine control module by pin 25C (signal) and 24C (signal). The third pin is for screening.
The resistance value of the sensor is about 900 Ω.
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Sensing system Camshaft speed sensor - Overview

F4DE9484, F4DE9684, F4DE9687
CAMSENSOR 1
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals
obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated
by this sensor is utilized by the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are no interchangeable because of the different external
shape.
The timing sensor is connected to the control unit on pins 23C - 30C. The sensor impedance is ~900 Ω.
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F4CE9484, F4CE9684
CRANKSENSOR 1
It is an induction type sensor and it is placed on the front part of the engine above the crankshaft. It generates signals
obtained from magnetic flow lines.
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ENGINE - Place on stand

F4HE9484, F4HE9684
NOTE: In order to apply the brackets 380000661 to the engine block, it is necessary to perform the following opera-
tions on the left hand side of the engine.
1. Using the tool unscrew the fuel filter and remove it
from the support.
2. Disconnect the electrical connection from the sup-
port.
3. Disconnect the fuel low pressure pipelines from the
support.
4. Disconnect pipeline from the support.
5. Remove the sustaining support bracket from the
block.
6. Disconnect the high pressure fuel pipeline from the
rail diffuser and from the high pressure pump and
disassemble it from the engine block removing the
fixing clamps.
7. Disconnect the pipeline feeding the mechanical
pump that is combined to the high pressure pump
through the exchanger of the engine control module. F4HE123456 1
8. Disassemble the oil fill tube (if present) by removing

the bolts. Remove the O-ring from the tube.
NOTICE: Because of the high pressure in the pipelines running from the high pressure pump to the rail and from the
rail to the electro-injectors, DO NOT, under any circumstances, disconnect or crack pipelines while engine is running
or reuse the disassembled pipelines.
9. Remove the screws holding the turbocharger (1) oil
drain pipe (2) and remove pipe from the engine block.
TURBOLUBEF4HE 2
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10. Remove the starter from the flywheel housing.

11. Apply brackets 380001298 to the engine block and
use them to secure the engine to the revolving stand
380000301.
12. Remove the drain plug from the oil sump and drain
out the oil.
13. Remove the fan from the output shaft pulley.
STARTERF4HE 3
NOTICE: Collect and dispose of engine oil according to regulations in your area.
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F4DE9484, F4DE9684, F4DE9687
NOTE: In order to apply the brackets 380000661 to the engine block, it is necessary to perform the following opera-
tions on the left hand side of the engine.
1. Using the tool 380000670, unscrew the fuel filter (6)
and remove it from the support (1).
2. Disconnect the electrical connection (2) from the
support (1).
3. Disconnect the fuel low pressure pipelines (3), (4)
and (5) from the support (1).
4. Disconnect pipeline (9) from the support (1).
5. Remove the sustaining support bracket (1) from the
block.
6. Disconnect the high pressure fuel pipeline (7) from
the rail diffuser and from the high pressure pump (8)
and disassemble it from the engine block removing
STANDMOUNTING 1
the fixing clamps.
7. Disconnect the pipeline feeding the mechanical
pump that is combined to the high pressure pump
through the exchanger of the engine control module.
8. Disassemble the oil fill tube (if present) by removing
the bolts. Remove the O-ring from the tube.
NOTICE: Because of the high pressure in the pipelines running from the high pressure pump to the rail and from the
rail to the electro-injectors, DO NOT, under any circumstances, disconnect or crack pipelines while engine is running
or reuse the disassembled pipelines.
9. Disconnect the oil drain pipe (1)for the turbocharger.
10. Unscrew the fixing screws and disconnect the start-
ing motor (2) from its seat.
PIPEANDSTARTER 2
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11. Disconnect the lubricating pipe (2) from the upper

side of the heat exchanger on the turbo blower (1).
12. Undo the fastening screws (4) and remove the sup-
port (3).
13. Disassemble the thermostat body including the seal.
TURBOLUBEF4DE 3
14. Make holes (1) and (2) on both sides of the en-
gine base, brackets 380000661 and then fix by
means of the later, the engine to the revolving stand
380000301.
15. Empty the engine oil by removing the cap off the
sump.
NOTE: Collect and dispose of the engine oil according to
enforced regulations.
STANDMOUNTHOLES 4
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F4GE9484, F4GE9684
1. In order to apply the brackets 380000661 to the en-

gine block to fix it on to the stand 380000301 for the
overhaul, it is necessary to perform the following op-
erations.
2. Disassemble the oil filter (1) from the support using
tool 380000670.
NOTICE: The oil filter contains inside approximately 1 kg
(2.2 lb) of engine oil. Provide for oil recovery and disposal
in compliance with the laws and regulations in force.
OILFILTERREMOVE 1
3. Disassemble lubrication oil exhaust pipe (1) from the

turbo-blower.
4. Underneath the turbo-blower, loosen the two screws
(2), and loosen the screw (3) fixing the pipe through-
out the stop collar (4) fixing the block.
5. Finally, loosen and remove the union (5) from the
block.
6. Plug the pipe ends and the exhaust of the turbo-
blower.
TURBODRAING 2
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7. Disassemble the starter (1) by loosening the fixing

screws (2).
8. Assemble the bracket bearing 380000661 using the
four screw threaded ports (3).
STARTERG 3
9. From the left hand side, assemble the second

bracket 380000661 throughout the threaded ports
(1).
10. Lift the engine using the hoist 380000216 and it on
the turning stand 380000301.
11. Drain the oil through the plug in the pan.
NOTICE: Avoid contact of engine oil with the skin. In case
of skin contamination, rinse in running water.
NOTE: Engine oil is highly pollutant. Provide for disposal
in compliance with the law and regulations in force.
STANDMOUNTHOLES 4
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F4CE9484, F4CE9684
1. In order to apply the brackets 380000661 to the en-

gine block to fix it on to the stand 380000301 for the
overhaul, it is necessary to perform the following op-
erations.
2. Remove the oil level rod (4).
3. Remove the oil filter (3) using the tool 380000670.
NOTICE: Provide for oil recovery and disposal in compli-
ance with the law and regulations in force.
OILFILTERREMOVC 1
4. Disassemble the starter (2) by loosening the fixing

screws (1).
5. Assemble the supporting brackets 380000661 using
the threaded ports on the block.
STARTERC 2
6. Assemble the second bracket 380000661 through-

out the threaded ports (1).
7. Lift the engine using the hoist 380000216 and put it
on the turning stand 380000301.
8. Drain the oil by removing the plug from the oil pan.
NOTICE: Avoid contact of engine oil with the skin. In the
case of skin contamination, rinse in running water.
NOTE: Engine oil is highly pollutant. Provide for disposal
in compliance with the law and regulations in force.
STANDMOUNTC 3
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ENGINE - Service instruction Maintenance Procedures

CHECKS AND INSPECTIONS
Engine oil level check

The check can be made using the dipstick (1) placed on
the right hand side of the EDC.
NOTICE: The check must be executed when the engine is
off and possibly cool.
Draw off the rod from it’s slot and check that the level is
within the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, pro-
ceed cleaning the rod using a clean cloth with no contami-
nation and put it back in it’s slot. Draw it off again and check
the level.
In case the level results being close to the tag showing min-
imum level, provide filling lubrication of the engines com-
ponents.
Add oil through the upper top or through the lateral top (2).
During filling operation, the tops must be removed as well
as the rod in order to make the oil flow easier.
OILFILLH 1
CAUTION
When handling lubricants (oil, grease etc.,) and other
chemical products, always follow instructions for their
proper use. Use proper containers to collect fluid. Dis-
pose of fluids and filters in a way that will protect the
environment and in accordance with the law. DO NOT
smoke or use an open flame during the service pro-
cedure. Use eye protection. DO NOT run the engine
or transmission when the engine or transmission oil
temperatures exceed 49 C (120 F). Failure to comply
will result in a environmental hazard and cause death
or serious injury.
M1159
Combustion system inspection

The check must be executed both when the engine off and
when it is running.
The check operation consists in examining the fuel
pipelines running from the tank to the pre-filter (if provided
in the specific equipment), to the filter, to the high pressure
pump and to the rail diffuser and from this last one to the
head.
Special attention must be paid to the connections on the
high pressure pipelines.
WARNING
Diesel fuel escaping under pressure can penetrate the
skin causing serious injury. Do not use your hand to
check for leaks. Use a piece of cardboard or paper
to search for leaks. Wear protective gloves and eye
protection.If any fluid is injected into the skin, obtain
medical attention immeadiately or gangrene may re-
sult. Failure to comply could result in serious injury
or death.
B071
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Cooling system inspection

The check must be executed both when the engine is off
and when it is running.
Check the pipelines from the engine to the radiator, from
the expansion tank and vice-versa. Find out any blow-by,
verify the status of the pipes specially close to the holding
strips.
Verify that the radiator is clean, the correct working of the
fan flywheels, the presence of any leakage from the con-
nectors, from the manifold and from the radiating unit.
DANGER
Hot coolant can spray out if radiator cap is removed.
To remove radiator cap: Wear face protection, let sys-
tem cool, turn to first notch, then wait until all pressure
is released. Scalding can result from fast removal of
radiator cap. Check and service engine cooling sys-
tem according to maintenance instructions.
SB023
The density of the cooling liquid must be checked any how

every year before winter season and be replaced in any
case every two years.
NOTE: In case of new filling, proceed bleeding the system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious inconve-
nience might be caused to the engine due to the presence
of air pockets in the engine’s head.
Lubricating system inspection

Verify the presence of any oil leakage or blow-by from the
head, from the engine pan or from the heat exchanger.
CAUTION
or serious injury.
M1159
Inspection of water presence within the fuel

filter or pre-filter
The components of the common rail system can be dam-
aged very quickly in presence of water or impurity within
the fuel.
Timely proceed operating on the pre-filter (not available on
the engine block) to carry out the drainage of the water
within the feed circuit.
84250518 09/11/2009
B.10.A / 58
Inspection / replacement of blow-by filter

The filter in subject has been developed and equipped for
the collection , filtering and condense of the lubricating oil
vapors.
Within the filter unit (1) two cartridge filters are included (2).
The check of the filtering element is carried out by removing
the cover and drawing off the cartridges (2).
86070785_RESIZE 2
Inspection of drive belt tensioning

The drive belt tensioning control is made using an au-
tomatic tensioning device therefore no intervention is
required apart from checking the wear status of the belt
itself.
Inspection and setting of tappet clearance

Adjust clearance between rockers and valves using
setscrew wrench (1), box wrench (3) and feeler gauge (2).
Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
NOTICE: On TIER 3 engines, due to the additional lobe
for the INTERNAL E.G.R., it is not possible to use the valve
clearance adjustment procedure that requires adjusting the
clearance of all the valves by positioning the crankshaft 2
times only.
Each cylinder must be checked by taking it to the T.D.C.
(top dead center) at the end of compression and adjusting
the clearance of both valves on the cylinder in question.
VALVEADJUST 3
84250518 09/11/2009
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Engine oil and filter replacement

Due to the several applications, the pan shape and the
oil quantity can change slightly. However, the following
operations are valid for all applications.
We recommend to carry out the oil drainage when the en-
gine is hot.
Place a proper container for the oil collecting under the pan
connected with drain plug.
Unscrew the plug and then take out the control dipstick and
the inserting plug to ease the downflow of the lubrication oil.
CAUTION
or serious injury.
M1159
After the complete drainage, screw the plug and carry out
the clean oil filling.
NOTICE: Use only recommended oil or oil having the re-
quested features for the correct engine functioning. In case
of topping up, don’t mix oils having different features. If you
don’t comply with these rules, the service warranty is no
more valid.
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.
Whereas you replace the lubrication oil, it is necessary to
replace the filter. According to the application the filter can
be located in different positions: the following procedure is
a valid guide for all applications.
The filter is composed of a support and a filtering cartridge.
For the cartridge replacement use the tool 380000670.
ATTENTION: The oil filter contains inside a quantity of oil
of about 1 kg.
CAUTION
or serious injury.
M1159
84250518 09/11/2009
B.10.A / 60
Replace the filtering cartridge with a new one and screw

manually until when the gasket is in contact with the sup-
port.
Tighten by means of the tool 380000670 of three fourth
turn.
Operate the engine for some minutes and check the level
through the dipstick again. If it is necessary, carry out a
topping up to compensate the quantity of oil used for the
filling of the filtering cartridge.
Fuel filter replacement

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

Due to several applications the belt run can change very
much.
WARNING
Rotating belts. Contact with rotating belts will cause
serious injury or death. Always stop the engine and
remove the key before working in this area.
M411
For applications with automatic belt tensioner, the proce-

dure is the following:
By means of square wrench of proper size, act on point
(A), indicated in the figure, of the automatic belt tensioner
(1) and release the pressure.
Remove the control belt (2) from the driven and intermedi-
ALTBELT 4
ate pulleys.
Replace the worn belt with a new one.
Place the belt on the pulleys and guide rollers.
Place the automatic tightener in order to key the belt in the
functioning position.
Check proper position in the races of the pulleys.
84250518 09/11/2009
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F4DE9484, F4DE9684, F4DE9687

the level.
ponents.
OILFILLD 1
Add oil through the upper top (1) or through the lateral top
(2). During filling operation, the tops must be removed as
well as the rod in order to make the oil flow easier.
CAUTION
or serious injury.
OILFILLD2 2
M1159
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Combustion system inspection

head.
WARNING
or death.
B071

strips.
DANGER
SB023

84250518 09/11/2009
B.10.A / 63

CAUTION
or serious injury.
M1159

the fuel.

itself.

Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
times only.
VALVEADJUST 3
84250518 09/11/2009
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gine is hot.
CAUTION
or serious injury.
M1159
more valid.
of about 1 kg.
CAUTION
or serious injury.
M1159
84250518 09/11/2009
B.10.A / 65

manually until the gasket is in contact with the support.
turn.

tions.
Screw manually the new filtering cartridge until the when
the gasket is completely on its seat.
lb ft) torque.

much.
WARNING
M411

By means of square wrench of proper of proper size, act
on point (A), indicated in the figure, of the automatic belt
tensioner (1) and release the pressure.
ate pulleys.
ALTBELT 4
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F4GE9484, F4GE9684

the level.
ponents.
OILLEVELG 1
CAUTION
or serious injury.
M1159
OILFILLG 2
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Fuel system inspection

head.
WARNING
or death.
B071

strips.
DANGER
SB023

84250518 09/11/2009
B.10.A / 68

CAUTION
or serious injury.
M1159

the fuel.

itself.

Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
times only.
VALVEADJUSTG 3
84250518 09/11/2009
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gine is hot.
CAUTION
or serious injury.
M1159
more valid.
of about 1 kg.
CAUTION
or serious injury.
M1159
84250518 09/11/2009
B.10.A / 70

port.
turn.

tions.
lb ft) torque.

much.
WARNING
M411

ALTBELT 4
ate pulleys.
84250518 09/11/2009
B.10.A / 71

F4CE9484, F4CE9684

The check can be made using the dipstick (1).
the level.
ponents.
OILLEVELC 1
CAUTION
or serious injury.
M1159
OILFILLC 2
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Fuel system inspection

head.
WARNING
or death.
B071

strips.
DANGER
SB023

84250518 09/11/2009
B.10.A / 73

CAUTION
or serious injury.
M1159

the fuel.

itself.

Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in).
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in).
times only.
VALVEADJUSTC 3
84250518 09/11/2009
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gine is hot.
CAUTION
or serious injury.
M1159
more valid.
of about 1 kg.
CAUTION
or serious injury.
M1159
84250518 09/11/2009
B.10.A / 75

port.
turn.

tions.
lb ft) torque.

much.
WARNING
M411

ate pulleys.
ALTBELT 4
84250518 09/11/2009
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Rocker assembly Housing - Remove

Prior operation:
Valve cover - Remove (B.10.A)
1. Unscrew the nuts (3) from the top of the electro-in-

jectors (4) and disconnect the electrical wires.
2. Unscrew the bolts (1) securing the rocker housing
(2).
3. Remove the rocker housing (2) and gasket from the
cylinder head.
ROCKERHOUSING 1
Next operation:
Rocker assembly Housing - Install (B.10.A)
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Rocker assembly Housing - Install

Prior operation:
Valve drive Rocker assembly - Install (B.10.A)
1. Check the condition of the electrical cables (5) and

connectors (3), replace if damaged by removing the
screw (4).
2. Install a new gasket (1) on the support (2).
VALVEBASEDH 1
3. Install the housing (2) and tighten the screws (1) to

the specified torque.
NOTE: Before any assembly operation always verify that
the hole and bolt threads have no evidence of wear or dirt.
VALVEBASEDH2 2
4. Connect the electrical cables (1) to the injectors (3)

and use the torque wrench (4) to tighten the fastening
nuts (2) to the specified torque.
VALVEBASEDH3 3
Next operation:
Valve cover - Install (B.10.A)
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Valve drive Rocker assembly - Disassemble

Prior operation:
1. Loosen tappet adjustment jam nuts (1) and unscrew

the adjusting screws.
2. Remove the rocker shaft mounting bolts (2).
3. Remove the rocker assembly (3), which consists of
the pedestal (6), rockers (4), and shaft (5).
4. Remove the valve bridges (7).
5. Remove the push rods (8).
BACD04APH020ASA 1
Next operation:
Rocker assembly Shaft - Clearance (B.10.A)
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Rocker assembly Shaft - Clearance

Prior operation:
Valve drive Rocker assembly - Disassemble (B.10.A)
1. Check that the shaft/rocker coupling surfaces are not

showing excessive wear or damage.
SHAFTMEASURE 1
Next operation:
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Valve drive Rocker assembly - Install

Prior operation:
Valve drive Camshaft - Install (B.10.A)
1. Check that the tappet adjusters (1) are loose to pre-

vent their binding on the rods when fitting the rocker
assembly
2. Install the rocker assembly consisting of:
• Bracket (2).
• rockers (4).
• shafts (3).
3. Secure them to the cylinder head by tightening the
fastening screws (2) to a torque of 36 Nm (27 lb ft).
ROCKERASSEMDH 1
Next operation:
Valve drive Rocker assembly - Adjust (B.10.A)
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Rocker assembly Rocker arm - Adjust

Prior operation:
1. Adjust the clearance between the rockers and valves

using a set screw wrench (1), box wrench (3), and
feeler gauge (2).
2. Set the clearance to the following specifications.
• Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012
in)
• Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022
in)
on the camshaft for INTERNAL E.G.R., it is not possible
to use the valve clearance adjustment procedure that re-
quires adjusting the clearance of all the valves by position- BACD04APH162ASA 1
ing the crankshaft two times only.
Each cylinder must be checked by taking it to TDC (top
dead center) at the end of the compression stroke and ad-
justing the clearance of both valve on the cylinder in ques-
tion.
Next operation:
84250518 09/11/2009
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Camshaft Gear - Remove

Prior operation:
Rear cover - Remove (B.10.A)
1. Remove the screws (1) securing the camshaft gear

(3) to the camshaft (2).
2. Withdrawal the camshaft gear (3).
CAMGEARH 1
Next operation:
Camshaft Gear - Install (B.10.A)
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F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Undo the screws (1) and remove the gear (3) from
the camshaft (2).
CAMGEARD 1
Next operation:
84250518 09/11/2009
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Camshaft Gear - Install

Prior operation:
Camshaft Gear - Remove (B.10.A)
NOTE: For ease of crankshaft rotation, install two pins in the end of the crankshaft.
1. Highlight the timing mark on the crankshaft gear (1)
with a felt tip pen so it’s easier to see.
BACD04APH064ASA 1
2. Turn the crankshaft (4) and the camshaft (2) so that

by mounting the drive gear (1) on the camshaft (2),
both timing marks (3) will align properly.
BACD04APH065ASA 2
3. Tighten the bolts (1) that secure the gear (2) to

camshaft (3) to the specified torque.
BACD04APH066ASA 3
Next operation:
Rear cover - Cleaning (B.10.A)
84250518 09/11/2009
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Valve drive Camshaft - Remove

Prior operation:
1. Remove the bolts (1)and disconnect camshaft (3)re-

taining plate (2).
NOTE: Take note of the retaining plate (2) assembly posi-
tion.
BACD04APH047ASA 1
2. Carefully extract the camshaft (1) from the cylinder

block.
BACD04APH048ASA 2
Next operation:
Valve drive Camshaft - Measure (B.10.A)
84250518 09/11/2009
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Valve drive Camshaft - Measure

Prior operation:
Valve drive Camshaft - Remove (B.10.A)
Checking cam lift and pin alignment

Set the camshaft on the tailstock using a 1/100 gauge set
on the central support, check whether the alignment error is
not exceeding 0.04 mm (0.002 in), otherwise replace the
camshaft. Check cam lift; found values shall be: 6.045
mm (0.238 in) for exhaust cams and 7.582 mm (0.299
in) for intake cams, in case of different values replace the
camshaft.
Check the camshaft (2) pin diameter using micrometer (1)
on two perpendicular axes.
BACD04APH117ASA 1
CAMSHAFT MAIN DATA (4 cyl.)
BACD04APH116FSA 2
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CAMSHAFT MAIN DATA (6 cyl.)
BAIL07APH360FSA 3
NOTE: Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring
replace the camshaft and the bush.
Next operation:
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Valve drive Camshaft - Install

Prior operation:
1. Lubricate the camshaft bush and fit the camshaft (1)

taking care not to damage the bush or the housings.
CRIL04J056A01 1
2. Set camshaft (3) retaining plate (1) with the slot fac-
ing the top of the engine block and the marking facing
the operator, then tighten the screws (2) to the spec-
ified torque.
CRIL04J064A01 2
Next operation:
Valve drive Camshaft - End play (B.10.A)
84250518 09/11/2009
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Valve drive Camshaft - End play

Prior operation:
1. Check camshaft end play (1). It shall be 0.10 - 0.36

mm (0.004 - 0.014 in).
CRIL04J065A01 1
Next operation:
Rear cover - Install (B.10.A)
84250518 09/11/2009
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Camshaft Push rod - Install

Prior operation:
1. Before installation be sure to check that there is no

signs of wear or distortion. Intake and exhaust rods
are identical and therefore interchangeable.
PUSHROD 1
2. Install the push rods (2).

3. Install the valve bridges (1) with the marks facing the
exhaust manifold
BACD04APH093ASA 2
Next operation:
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Camshaft Tappet - Remove

Prior operation:
1. Withdraw the tappets (1) from the engine block.
BACD04APH049ASA 1
Next operation:
Camshaft Tappet - Measure (B.10.A)
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Camshaft Tappet - Measure

Prior operation:
Camshaft Tappet - Remove (B.10.A)
BAIL07APH361FSA 1
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK
Next operation:
84250518 09/11/2009
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Camshaft Tappet - Measure

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Camshaft Tappet - Remove (B.10.A)
TAPPETMEASURECG 1
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK
(dimensions in mm)
Next operation:
84250518 09/11/2009
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Camshaft Tappet - Install

Prior operation:
Camshaft Tappet - Measure (B.10.A)
Lubricate the tappets (1) and fit them into the relevant hous-
ings on the engine block.
CRIL04J063A01 1
Next operation:
84250518 09/11/2009
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Camshaft Bushing - Measure

Prior operation:
Bushes
1. Camshaft bush (2) shall be pressed into its housing.
Internal surface must not show seizing or wear. Use
bore dial gauge (3)to measure camshaft bush (2) and
intermediate housing (1) diameter. Measurements
shall be performed on two perpendicular axes.
CRIL04J060A01 1
BAIL07APH367FMA 2
MAIN DATA ABOUT CAMSHAFT BUSH AND RELATED HOUSING
*Height to be obtained after driving the bush.
Next operation:
Valve drive Camshaft - Replace (B.10.A)
84250518 09/11/2009
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Camshaft Bushing - Replace

Prior operation:
Bush Replacement
To replace bush (1), remove and refit it using the beater (2)
and the hand-grip 380000145 (3).
NOTICE: When refitting the bush (1), direct it to make the
lubricating holes coincide with the holes on the block hous-
ing.
ZEIL06EN0048A0B 1
Next operation:
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Valve drive Valve assembly - Remove

Prior operation:
Cylinder head - Remove (B.10.A)
1. Intake (1) and exhaust (2) valves heads with the

same diameter. The central notch of the exhaust
valve (2) head distinguishes it from the intake valve.
NOTE: Should cylinder head valves not be replaced, num-
ber them before removing in order to refit them in the same
position.
A = intake side - S = exhaust side
BACD04APH145ASA 1
2. Valve removal shall be performed using tool

380000302 (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).
3. Repeat this operation for all the valves.
4. Overturn the cylinder head and withdraw the valves
(5).
BACD04APH146ASA 2
5. Remove the sealing rings (1) and (2) from the valve
guide.
NOTE: Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
BACD04APH147ASA 3
Next operation:
Valve drive Valve assembly - Install (B.10.A)
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Valve assembly Valve - Measure

Prior operation:
Valve drive Valve assembly - Cleaning (B.10.A)
VALVE 1
INTAKE AND EXHAUST VALVE MAIN DATA
1. Check the valve stem (1) using a micrometer (2), it
shall be 6.970 - 6.990 mm (0.274 - 0.275 in).
BAPH04APH152ASA 2
Next operation:
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Valve assembly Valve - Cleaning

Prior operation:
Valve drive Valve assembly - Remove (B.10.A)
1. Remove carbon deposits from valves using the

proper metal brush.
2. Check that the valves show no signs of seizing, scor-
ing, or cracking.
3. If necessary, rectify the valve seats, taking away the
least amount of material possible.
BAPH04APH151ASA 1
Next operation:
Valve assembly Valve - Measure (B.10.A)
84250518 09/11/2009
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Valve assembly Spring - Check

Prior operation:
Before installing the valve springs use tool to check the

springs flexibility. Compare load and elastic deformation
data with those of the new springs in the following table:
50676 1
Height Under a load of

(H) 47.75 mm (1.880 in) Free
(H1) 35.33 mm (1.391 in) (P) 320.8 - 358.8 N (72.1 - 80.7 lb)
(H2) 25.2 mm (0.992 in) (P1) 702 - 780 mm (27.6 - 30.7 in)
Next operation:
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Valve drive Valve assembly - Install

Prior operation:
1. Lubricate the valve stems (1) and fit them into the rel-
evant valve guides according to the position marked
at removal.
2. Fit the sealing rings (2) and (3) on the valve guide.
NOTE: Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
80713 1
3. Position on the cylinder head: the springs (4) the

upper cap (3) use tool 380000302 (1) to compress
the spring (4) and lock the parts to the valve (5) by
the cotters (2).
BACD04APH146ASA 2
Next operation:
Cylinder head - Install (B.10.A)
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Valve drive Rocker assembly - Remove

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Disassemble the rocker arm supports by loosening

the two fixing screws (1) and remove the entire as-
sembly as one unit.
2. Withdraw the push rods.
ROCKERASSEMBCG 1
Next operation:
84250518 09/11/2009
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F4CE9484, F4CE9684
Prior operation:
1. Remove the screws (1) and disassemble the gears

(3) and (4) from the camshaft (2).
CAMSHAFTGEARC 1
Next operation:
84250518 09/11/2009
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F4GE9484, F4GE9684
Prior operation:
1. With a felt tip pen, highlight the conducting gear (1)

tooth mounted on the engine crankshaft (2) upon the
upright surface on which a groove has been created
for the injection timing.
NOTE: Screw in two pins to facilitate operation of the en-
gine crankshaft rotation.
CAMGEARTIMING 1
2. Turn the engine crankshaft (3) and the camshaft

(4) so that by mounting the bevel gear (1) on the
camshaft (4) so the stenciled mark on the gear (1)
coincides with the groove on the gear (2).
CAMGEARTIMING2 2
84250518 09/11/2009
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3. Position a dial indicator (1) on the timing gear (2).

4. Check the clearance between gears (2) and (3) is
within 0.076 - 0.280 mm (0.003 - 0.011 in) range.
CAMGEARTIMING3 3
Next operation:
84250518 09/11/2009
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F4CE9484, F4CE9684
Prior operation:
NOTE: For ease of crankshaft rotation, install two pins in the end of the crankshaft.
1. Highlight the timing mark on the crankshaft gear (1)
with a felt tip pen so it’s easier to see.
BACD04APH064ASA 1
2. Turn the crankshaft (4) and the camshaft (2) so that

by mounting the drive gear (1) on the camshaft (2),
both timing marks (3) will align properly.
CAMGEARTIMINGC 2
3. Place the dial gauge (1) on the timing gear (2) and
check that the slack between the gears (2) and (3) is
in the range of 0.076 - 0.280 mm (0.003 - 0.011 in).
CAMGEARTIMINGC2 3
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4. Fit the screws (1) fastening the gears (2) to the

camshaft (3) and tighten them to the prescribed
torque.
CAMGEARTIMINGC3 4
Next operation:
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Valve drive Rocker assembly - Check

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Valve drive Rocker assembly - Remove (B.10.A)
ROCKERCOMPCG 1
(1) Elastic ring - (2) Spacer - (3) Rocker arms - (4) Support.
1. Carry out the assembly of the rocker arms after
checking the components.
2. Check the coupling surfaces of bearings and shaft.
No evidence of excessive wear or damages shall be
detected. Replace if necessary.
ROCKERCOMPCG2 2
84250518 09/11/2009
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3. Tighten the threaded nut (1) to 4 - 6 Nm (3.0 - 4.4 lb

ft).
ROCKERCOMPCG3 3
Next operation:
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Camshaft Push rod - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Before executing assembly, check the rocker arm

driving rods. They shall not be deformed. The spher-
ical ends in contact with the rocker arm adjustment
screw and with the tappet (arrows) shall not present
evidence of seizure or wear. In case of detection, re-
place the rods with new.
The rods driving the suction and exhaust valves are
identical and therefore interchangeable.
PUSHROD 1
Next operation:
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Valve drive Rocker assembly - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Valve drive Rocker assembly - Check (B.10.A)
1. Install the assembly (1) on the cylinder head and

tighten the screws (2) to the prescribed torque.
ROCKERASSEMCG2 1
Next operation:
Rocker assembly Rocker arm - Adjust (B.10.A)
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Rocker assembly Rocker arm - Adjust

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Adjust the clearance between the rockers and valves

using a set screw wrench (1), box wrench (3), and
feeler gauge (2).
2. Set the valve clearance to the following specifica-
tions.
• Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012
in)
• Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022
in)
on the camshaft for INTERNAL E.G.R., it is not possible
to use the valve clearance adjustment procedure that re-
quires adjusting the clearance of all the valves by position- ROCKERADJUSTCG 1
ing the crankshaft two times only.
Each cylinder must be checked by taking it to TDC (top
dead center) at the end of the compression stroke and ad-
justing the clearance of both valve on the cylinder in ques-
tion.
Next operation:
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Valve drive Valve assembly - Remove

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Intake (1) and exhaust (2) valves heads with the

same diameter.
NOTE: Should cylinder head valves not be replaced, num-
ber them before removing in order to refit them in the same
position.
A = intake side
VALVESCG 1
2. Valve removal shall be performed using tool

380000302 (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).
3. Repeat this operation for all the valves.
4. Overturn the cylinder head and withdraw the valves
(5).
VALVESCG2 2
5. Remove the sealing rings (1) and (2) from the valve
guide.
VALVESEALCG 3
Next operation:
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Valve assembly Valve - Measure

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
VALVE 1
INTAKE AND EXHAUST VALVE MAIN DATA
1. Check the valve stem (1) using a micrometer (2), it
shall be 7.960 - 7.980 mm (0.313 - 0.314 in).
VALVESCG4 2
Next operation:
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Valve assembly Spring - Check

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Before refitting use tool to check spring flexibility. Compare

load and elastic deformation data with those of the new
springs in the following table:
50676 1
Height Under a load of

H 63.50 mm (2.500 in) Free
H1 49.02 mm (1.930 in) P 320.8 - 358.8 N (72.1 - 80.7 lb)
H2 38.20 mm (1.504 in) P1 702 - 780 mm (27.6 - 30.7 in)
Next operation:
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Valve drive Valve assembly - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Lubricate the valve stems (1) and fit them into the rel-
evant valve guides according to the position marked
at removal.
2. Fit the sealing rings (2) and (3) on the valve guide.
VALVESEALCG2 1
3. Position on the cylinder head, the protection cap (5),

the spring (4), the upper cap (3).
4. Use tool 380000302 (1) to compress the spring (4)
and lock the parts to the valve (6) by the cotters (2).
VALVESCG2 2
Next operation:
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Auxiliary drive - Remove

F4HE9484, F4HE9684
1. Unscrew the cover bolts (3) and remove the cover

(1). Save the cover gasket (4).
2. Remove the power take-off adapter (2). Save the
gasket (4).
AUXDRIVEH 1
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Auxiliary drive - Install

F4HE9484, F4HE9684
1. Insert the power take-off adapter (2) with gaskets (4)

and cover (1).
2. Tighten the bolts (3) to the specified torque.
AUXDRIVEH 1
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F4CE9484, F4CE9684
1. Fit the power take-off gear (2) (where equipped) into

the specially provided housing and fasten the screws
(1).
AUXDRIVEC 1
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F4GE9484, F4GE9684
1. Loosen the two screws (3) securing the cover plate

(1).
2. Remove the cover (1), power take-off (2) and the
relative gaskets (4).
NOTE: The gasket cannot be used again. They must be
replaced upon reassembly.
AUXDRIVEG 1
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F4GE9484, F4GE9684
1. Fit the power take-off (2) in its housing with a new

gasket (4). Make sure the gears mesh properly.
2. Install the cover plate (1) also with a new gasket (4).
Tighten the screws (3) to the prescribed torque.
AUXDRIVEG 1
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F4CE9484, F4CE9684
1. Loosen the two screws (1) and remove the cover (2).
AUXDRIVEC2 1
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Crankshaft Front seal - Remove

Prior operation:
Vibration damper - Remove (B.10.A)
1. Remove the ring sealing the engine’s driving shaft

from the front cover (6). Use the tool (4) to operate
on the front bar hold of the driving shaft. Through the
steering holes of the tool, perforate the inside hold-
ing ring (1) with a straight way drill with a diameter of
3.5 mm (0.138 in) for the depth of 5 mm (0.197 in).
Fix the tool to the ring tightening the six screws (5)
provided with the equipment. Then proceed remov-
ing the ring (2) by tightening the screw (3).
MAINSEALDH 1
2. Using the specific tie rod (3) of the tool 380000669

and the ancillary lever (4), remove the external hold-
ing ring (2) from the front cover (1).
EXHOLDRINGDH 2
Next operation:
Crankshaft Front seal - Install (B.10.A)
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Crankshaft Front seal - Install

Prior operation:
Crankshaft Front seal - Remove (B.10.A)
1. Apply tool (4) to the front crankshaft tang (6) and

secure it by screws (5) and install the new sealing
ring (7). Position part (2) on part (4), tighten nut (3)
until completing installation of the sealing ring (7) into
the front cover (1).
BACD04APH074ASA 1
Next operation:
Vibration damper - Install (B.10.A)
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Crankshaft Rear seal - Remove

Prior operation:
Flywheel - Remove (B.10.A)
1. Remove the holding ring of the flywheel cover box

using the tool (3) to operate on the driving shaft’s
back bar hold (5).
2. Through the steering holes of the tool, perforate the
inside holding ring with a straight way drill bit with a
diameter of 3.5 mm (0.138 in) for the depth of 5 mm
(0.197 in).
3. Fix the tool (3) to the ring tighten the six screws (4)
provided with the equipment.
4. Then proceed removing the ring (1) by tightening the
screw (2).
REARMAINSEALDH 1
5. Using a specific tie rod (3) of the tool 380000669 and

an ancillary lever (4), remove the external holding
ring (2)from the rear cover (1).
EXHOLDRINGDH 2
Next operation:
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Crankshaft Rear seal - Install

Prior operation:
Crankshaft Rear seal - Remove (B.10.A)
1. Apply tool (6), to the rear crankshaft tang (5), secure

it by screws (4) and install the new sealing ring (3).
Position part (1) on part (5), tighten nut (2) until com-
pleting installation of the sealing ring (3) into the fly-
wheel housing (7).
BACD04APH219ASA 1
Next operation:
Flywheel - Install (B.10.A)
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Crankshaft Main bearing - Remove

Prior operation:
Oil pan - Remove (B.60.A)
1. Remove the screws (1) and the main bearing caps

(2).
BACD04APH043ASA 1
2. The second to last main bearing cap (1) and the rele-
vant support are fitted with shoulder half-bearing (2).
NOTE: Take note of the lower and upper half-bearing as-
sembling positions since in case of reuse they shall be fitted
in the same position found at removal.
BACD04APH044ASA 2
Next operation:
Crankshaft Main bearing - Install (B.10.A)
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Crankshaft Main bearing - Install

Prior operation:
Crankshaft Main bearing - Remove (B.10.A)
NOTE: Refit the main bearings that have not been replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 - 0.500
mm (0.010 - 0.020 in) undersize on the internal diameter.
Clean accurately the main half bearings (1) having the lu-
bricating and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
BACD04APH056ASA 1
NOTICE: Do not try to adapt the bearings.
Next operation:
Oil pan - Install (B.60.A)
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Crankshaft - Remove
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
1. Use tool 380000362 (1)and hoist to remove the

crankshaft (2) from the block.
BACD04APH045ASA 1
Next operation:
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Crankshaft - Remove
Prior operation:
1. Use tool 380000362 (1)and hoist to remove the

crankshaft (2) from the block.
CRANKSHAFTD 1
Next operation:
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Crankshaft - Measure
Prior operation:
Crankshaft - Remove (B.10.A)
Grind journals and crank pins if seizing, scoring or exces-

sive ovalization are found. Before grinding the pins (2)
measure them with a micrometer (1) to decide the final di-
ameter to which the pins are to be ground.
NOTE: It is recommended to insert the found values in the
table below.
NOTICE: Journals and crank pins shall always be ground
to the same undersize class.
Journals and crank pins undersize shall be marked on the
side of the crank arm No.1.
For undersized crank pins: letter M
For undersized journals: letter B
For undersized crank pins and journals: letters MB. BACD04APH108ASA 1
MEASURING JOURNALS AND CRANK PINS (4 cyl.)
BACD04APH109FSA 2
Fill this table with crankshaft journal and crank pin measured values (4 cyl.)
* Rated value
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Tolerances Tolerance Characteristic Graphic Symbol
Roundness
Shape
Cilindricity
Parallelism
Direction Verticality
Straightness
Position Concentricity or coaxiality
Circular oscillation
Oscillation
Total oscillation
Levels of Importance for Product Characteristics Graphic Symbol

Critical
Important
Secondary
MEASURING JOURNALS AND CRANK PINS (6 cyl.)
BACD04APH186FSA 3
Fill this table with crankshaft journal and crank pin measured values
* Rated value
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ZEIL06EN0183F0B 4
MAIN CRANKSHAFT TOLERANCES
* Measured on a radius greater than 45.5 mm (1.791 in)
** 0.500 mm (0.020 in) between adjacent main journals
Tolerances Tolerance Characteristic Graphic Symbol
Roundness
Shape
Cilindricity
Parallelism
Direction Verticality
Straightness
Position Concentricity or coaxiality
Circular oscillation
Oscillation
Total oscillation
Levels of Importance for Product Characteristics Graphic Symbol

Critical
Important
Secondary
Next operation:
Crankshaft Journal - Clearance (B.10.A)
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Crankshaft Gear - Replace

Check that gear toothing (1) is not damaged or worn, oth-
erwise remove it from the crankshaft (2) using the proper
puller (3).
When installing the new gear, heat it to 180 °C (356 °F) for
10 minutes in an oven and then key it to the crankshaft.
CRIL04J068A01 1
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Crankshaft Journal - Clearance

Prior operation:
Crankshaft - Measure (B.10.A)
Finding journal clearance

Refit the crankshaft (2).
Check the backlash between crankshaft main journals and
the relevant bearings as follows:
BACD04APH057ASA 1
Clean accurately the parts and remove any trace of oil;

Position a piece of calibrated wire (3) on the crankshaft pins
(4) so that it is parallel to the longitudinal axis;
Fit caps (1), including the half bearings (2) on the relevant
supports.
BACD04APH112ASA 2
NOTE: Before using the fixing screws again, measure

them twice as indicated in the picture, checking (D1) and
(D2) diameters:
if (D1)- (D2) < 0.1 mm (0.004 in) the screw can be utilized
again;
if (D1)- (D2) > 0.1 mm (0.004 in) the screw must be re-
placed.
80621 3
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Tighten the pre-lubricated screws (1) in the following three

successive stages:
STAGE 1: with torque wrench to 44 - 56 Nm (32.5 - 41.3
lb ft).
STAGE 2: with torque wrench to 74 - 86 Nm (54.6 - 63.4
lb ft).
BACD04APH058ASA 4
STAGE 3: with tool 380001001 (1) set as shown, tighten

the screws (2) with 85 - 95 ° angle.
BACD04APH113ASA 5
Remove the caps from the 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) con-
taining 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.
BACD04APH114ASA 6
Checking crankshaft shoulder clearance

This check is performed by setting a magnetic base dial
gauge (2) on the crankshaft (3) as shown in the figure, stan-
dard value is 0.068 - 0.41 mm (0.003 - 0.016 in).
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft pins and main half bearings.
BACD04APH115ASA 7
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Crankshaft Rear seal - Install

F4CE9484, F4CE9684
Prior operation:
Crankshaft Rear seal - Remove (B.10.A)
1. Apply tool 380000664 (6), to the rear crankshaft tang

(5), secure it by screws (4) and install the new sealing
ring (3). Position part (1) on part (5), tighten nut (2)
until completing installation of the sealing ring (3) into
the flywheel housing (7).
REARSEALC 1
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Timing gear housing - Remove

F4GE9484, F4HE9484, F4GE9684, F4HE9684
1. Remove the screws (2) and disconnect the timing

gear case (1) from the engine block.
NOTE: Mark locations of mounting screws (2) since they
are different sizes. This will make assembly much easier.
TIMINGGEARHOUSI 1
Next operation:
Timing gear housing - Cleaning (B.10.A)
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Timing gear housing - Cleaning

F4HE9484, F4HE9684
Prior operation:
Timing gear housing - Remove (B.10.A)
1. Clean the timing gear housing (1) and it’s mating sur-
face on the engine block.
NOTE: A perfect seal is only obtained by completely clean-
ing the surface to seal. Any imperfection should be cor-
rected as soon as possible. Avoid using excess sealant.
Excessive sealant could squeeze out the sides and cause
blockage of lubrication passages.
2. Apply a thin bead of LOCTITE 5205 (2), a few mil-
limeters thick, to the sealing surface of the housing.
NOTE: After applying the sealant, the housing should be
assembled within 10 to 20 minutes.
GEARCASESEAL 1
Next operation:
Timing gear housing - Install (B.10.A)
84250518 09/11/2009
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Timing gear housing - Install

F4HE9484, F4HE9684
Prior operation:
NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.
1. Install the housing (1) on the engine block.
2. Insert the fastening bolts in the same position found
upon disassembly and tighten them to the prescribed
torque.
GEARCASEINSTALL 1
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Timing gear housing - Remove

F4DE9484, F4DE9684, F4DE9687
1. Disconnect the high pressure pump stroke sensor

(3).
2. Remove the screws (2) and remove the timing gear
housing (1) from the engine block.
GEARHOUSING 1
Next operation:
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Timing gear housing - Cleaning

F4GE9484, F4GE9684
Prior operation:
Timing gear housing - Remove (B.10.A)
1. Clean the timing gear housing (1) and it’s mating sur-
face on the engine block.
limeters thick, to the sealing surface of the housing.
NOTE: After applying the sealant, the housing should be
assembled within 10 to 20 minutes.
TIMINGGEARCASEG 1
Next operation:
Timing gear housing - Install (B.10.A)
84250518 09/11/2009
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Timing gear housing - Install

F4GE9484, F4GE9684
Prior operation:
NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.
1. Install the housing (1) on the engine block.
2. Insert the fastening bolts in the same position found
upon disassembly and tighten them to the torque.
TIMINGGEARCASE2 1
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Connecting rod and piston - Remove

Prior operation:
1. Loosen the fixing screws (1) and remove the rod caps
(2).
2. Withdraw the piston including the connecting rod
from the top of the engine block.
3. Repeat these steps for the remaining cylinders.
NOTE: Keep the half bearings into their housing since in
case of use they shall be fitted in the same position found
at removal.
BACD04APH042ASA 1
Next operation:
Connecting rod and piston - Install (B.10.A)
84250518 09/11/2009
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Connecting rod and piston Piston - Measure

Prior operation:
Connecting rod and piston Piston - Remove (B.10.A)
1. Using a micrometer (2), measure the diameter of the

piston (1) to determine the assembly clearance.
BAPH04APH123ASA 1
2. The clearance between the piston and the cylinder

barrel can be checked also with a feeler gauge (1)
as shown in the figure.
BACD04APH124ASA 2
Next operation:
Connecting rod and piston - Assemble (B.10.A)
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Connecting rod and piston Connecting rod - Measure
BACD04APH131BSA 1
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN, AND HALF BEARINGS
* Value for the inside diameter to be obtained after driving in connecting rod small end and grinding.
NOTE: The surface of the connecting rod and rod cap are knurled to ensure a better coupling. Therefore, it is recom-
mended not to smooth the knurls.
84250518 09/11/2009
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CRIL04D023F 2
NOTE: Every connecting rod is marked as follows:
(1) - On the body and cap with a number showing their coupling and the corresponding cylinder. In case of replace-
ment, it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.
(2) - On the body with a letter showing the weight of the connecting rod assembled at production:
- V - 1820 - 1860 g (64.2 - 65.6 oz) (yellow marking)
- W - 1861 - 1900 g (65.6 - 67.0 oz) (green marking)
- X - 1901 - 1940 g (67.1 - 68.4 oz) (blue marking)
Spare connecting rods are of the - W - class with a green marking. Material removal is not allowed.
84250518 09/11/2009
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Connecting rod Bushing - Service instruction

Prior operation:
Piston Pin - Remove (B.10.A)
1. Check that the bush in the connecting rod small end

is free from scoring or seizing and that it is not loose.
Otherwise replace.
2. Removal and refitting shall be performed using the
proper beater.
3. When refitting take care to make the oil holes in the
bush coincide with the holes in the connecting rod
small end.
4. Grind the bush to obtain the specified diameter.
Next operation:
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Piston Ring - Remove

Prior operation:
Connecting rod and piston - Remove (B.10.A)
1. Remove the split rings (1) from the piston (3) using
pliers 380000324 (2).
ZEIL06EN0060A0B 1
Next operation:
Piston Ring - Measure (B.10.A)
84250518 09/11/2009
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Piston Ring - Measure

Prior operation:
1. Use a micrometer (1) to check split ring (2) thickness.
BAPH04APH127ASA 1
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).
BAPH04APH128ASA 2
3. Since the first sealing ring is trapezoidal, the clear-

ance 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 cylin-
der barrel (3). In this position, use a feeler gauge
to check the clearance (X) between ring and slot.
Found value shall be the specified one.
BAPH04APH129ASA 3
4. Use feeler gauge (1) to measure the clearance be-

tween the ends of the split rings (2) fitted into the
cylinder barrel (3).
BACD04APH130ASA 4
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Next operation:
Connecting rod and piston Piston - Install (B.10.A)
84250518 09/11/2009
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Piston Ring - Install

Prior operation:
1. Use pliers 380000221 (3) to fit the split rings (1) on

the piston (2).
NOTICE: Split rings shall be fitted with the marking "TOP"
(4) facing upwards and their openings shall be displaced
with each other by 120 °.
NOTE: Split Rings are supplied spare with the following
sizes:
- standard
- 0.4 mm (0.016 in) oversize.
MID0330A 1
Next operation:
Connecting rod and piston Piston - Install (B.10.A)
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Piston Pin - Remove

Prior operation:
1. Remove the piston pin (1) by extracting the stop rings

(2) using a scriber (3).
BACD04APH121ASA 1
Next operation:
Piston Pin - Measure (B.10.A)
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Piston Pin - Measure

Prior operation:
1. To measure the piston pin (1) diameter, use a mi-

crometer (2).
BAPH04APH125ASA 1
2. Lubricate the pin (1) and its seat on the piston hubs
with engine oil; the pin shall be fitted into the piston
with a slight finger pressure and shall not be with-
drawn by gravity.
BAPH04APH126ASA 2
Next operation:
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Connecting rod and piston - Assemble

Prior operation:
1. The piston crown is marked as follows:

1. Part number and design modification number.
2. Arrow showing piston assembling direction into
cylinder.
3. Manufacturing date.
4. Stamp indicating the ring carrier US inspection.
BACD04APH136ASA 1
2. 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 (5) marked
on the connecting rod (4) are read as shown in the
figure.
BACD04APH137ASA 2
3. Position the piston (3) on the connecting rod accord-

ing to the diagram shown in the figure and fit the pin
(1) and stop at the stop rings (2).
BACD04APH138ASA 3
Next operation:
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Connecting rod Bearing - Install

Prior operation:
1. Fit the half-bearings (1) on the connecting rod and

cap.
NOTE: Refit the bearings that have not been replaced in
the same position found at removal. Do not relocate the
half-bearings.
BAPH04APH059ASA 1
Next operation:
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Connecting rod and piston - Install

Prior operation:
Connecting rod and piston Connecting rod - Install (B.10.A)
1. Lubricate accurately the pistons, including the split

rings and the cylinder barrel inside.
2. Use band 380000325 (1) to fit the connecting rod
- piston assembly (2) into the cylinder barrels and
checking the following:
MID0332A 1
The number of each connecting rod shall correspond to the

cap coupling number.
Split ring openings shall be displaced with each other by
120 °.
Connecting rod - piston assemblies shall have the same
weight.
The arrow (1) 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.
BACD04APH061ASA 2
Next operation:
Connecting rod and piston Connecting rod - Install (B.10.A)
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Connecting rod Bearing - Clearance

Prior operation:
1. Clean the parts accurately and remove any trace of

oil.
2. Set a piece of calibrated wire (2) on the crank pins
(1).
3. Fit the connecting rod caps (3) with the relevant half
bearings (4).
NOTE: Before the final fitting of the connecting rod cap fas-
tening screws, check that their diameter measured at the
center of the thread length is not < 0.1 mm (0.004 in) than
the diameter measured at approximately 10 mm (0.394 in)
from the screw end.
BAPH04APH139ASA 1
4. Lubricate the screws (1) with engine oil and then

tighten them to the specified torque using the torque
wrench (2).
BACD04APH140ASA 2
5. Apply tool 380001001 (1) to the socket wrench and

tighten screws (2) to 60 °.
0B00200405BACD0 3
6. Remove the cap and find the existing clearance by

comparing the calibrated wire width (1) with the scale
on the wire envelope (2).
7. If a different clearance value is found, replace the half
bearings and repeat the check.
8. Once the specified clearance has been obtained, lu-
bricate the half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified
torque.
BACD04APH141ASA 4
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9. Check manually that the connecting rods (1) are slid-

ing axially on the crank pins and that their end float,
measured with a feeler gauge (2) is 0.10 - 0.33 mm
(0.004 - 0.013 in).
BACD04APH142ASA 5
Next operation:
Connecting rod and piston Piston - Check (B.10.A)
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Connecting rod and piston Piston - Check

Prior operation:
Connecting rod and piston Connecting rod - Clearance (B.10.A)
1. Once connecting rod - piston assemblies installation

is completed, use dial gauge 380000228 (1) fitted
with base 380000364 (2) to check piston (3) protru-
sion at T.D.C. with respect to the top of the engine
block.
Protrusion shall be 0.28 - 0.52 mm (0.011 - 0.020 in).
BACD04APH143ASA 1
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Flywheel - Remove
F4GE9484, F4HE9484, F4GE9684, F4HE9684
1. Insert tool 380000988 (2) into flywheel housing (1) to

keep the flywheel (3) from rotating.
FLYWHEELH 1
2. Loosen two bolts opposite each other and place two

guide pins (2)in place of the bolts.
3. Remove the remaining bolts securing the flywheel (1)
to the crankshaft.
4. Remove the flywheel locking tool from the flywheel
housing.
5. Insert two bolts of medium length into the threaded
holes (4) at the top of the flywheel to sling the fly-
wheel with a hoist.
6. Remove the flywheel (1) from it’s housing.
FLYWHEEL2H 2
Next operation:
Flywheel - Check (B.10.A)
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Flywheel - Check
F4CE9484, F4HE9484, F4CE9684, F4HE9684
Prior operation:
1. Check the supporting surface of the clutch plate (1)

and if it is scratched, it is necessary to carry out turn-
ing.
2. Check ring gear teeth (2), if breakage or excessive
wear is found, remove the ring gear from the engine
flywheel using a suitable hammer.
3. Heat the ring gear to 150 °C (302 °F)for 15 to 20
minutes.
4. Install the ring gear with the chamfering on the inside
diameter facing the flywheel.
FLYWHEELH3 1
Next operation:
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Flywheel - Install
F4HE9484, F4HE9684
Prior operation:
1. Install two guide pins (2) having suitable length into

crankshaft (3) holes.
2. Using the proper sling and hoist, install the flywheel
(1).
FLYWHEELH4 1
3. Apply tool 380000988 (2) to the flywheel housing to

stop rotation of the flywheel (3).
4. Tighten the bolts (1) securing the flywheel (3) to the
crankshaft (4).
FLYWHEELH5 2
5. Tighten the flywheel bolts (1) in two stages:

1. Torque bolts to 26 - 34 Nm (19 - 25 lb ft).
2. Finish by turning the bolts an additional 55 - 65
°.
NOTE: Torquing to an angle is performed by using the tool
380000304.
Before any assembly operation always verify that the hole
and bolt threads have no evidence of wear or dirt.
FLYWHEELH6 3
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Flywheel - Remove
F4DE9484, F4DE9684, F4DE9687
1. Remove two opposite screws (1) from the area

where the guide pins will be introduced.
2. Loosen the remaining flywheel fixing screws (3) from
the driving shaft (2).
3. Remove the flywheel locking tool (4).
FLYWHEELD 1
4. Tighten two screws of medium length into the holes

(4) to sling the flywheel with hoist.
5. Throughout the two guide pins (2) previously screw
into the driving shaft holes (3) withdraw the engine
flywheel (1) after slinging it with the hoist.
FLYWHEELD2 2
Next operation:
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Flywheel - Check
Prior operation:
1. Check the supporting surface of the clutch plate (1)

and if it is scratched, it is necessary to carry out turn-
ing.
2. Check ring gear teeth (2), if breakage or excessive
wear is found, remove the ring gear from the engine
flywheel using a suitable hammer.
3. Heat the ring gear to 150 °C (302 °F)for 15 to 20
minutes.
4. Install the ring gear with the chamfering on the inside
diameter facing the flywheel.
FLYWHEELD3 1
Next operation:
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Flywheel - Install
F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Screw two bolt of medium length into the flywheel (1)

using holes (4).
crankshaft holes (3).
(1).
FLYWHEELD4 1
4. Screw engine flywheel (3) fixing screws (4) on the

engine shaft.
5. Install the tool (1) in the proper hole (2) in order to
block engine flywheel rotation.
crankshaft.
FLYWHEELD5 2

°.
380000304.
FLYWHEELD6 3
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Flywheel - Remove
F4CE9484, F4CE9684
1. Using tool 380000988, block flywheel (2) rotation.

2. Loosen the flywheel fixing screws (3) to the engine
crankshaft.
3. Screw out the opposite screws (3) from the ports and
introduce the withdrawal pins. (See figure below).
4. Loosen the remaining flywheel fixing screws (3) to
the engine crankshaft.
5. Remove the flywheel block tool.
FLYWHEELC 1
6. Screw up to medium length screws in the ports (4) to

sling the flywheel with a hoist.
7. Throughout two guide pins (2), previously installed
into the engine crankshaft ports (3), control the en-
gine flywheel withdrawal by means of a hoist.
FLYWHEELC2 2
Next operation:
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Flywheel - Install
F4CE9484, F4CE9684
Prior operation:

crankshaft (3) holes.
(1).
FLYWHEELC2 1
3. Apply tool 380000988 (2) to the flywheel housing (1)

to stop rotation of the flywheel (2).
crankshaft.
FLYWHEELC 2

°.
380000304.
FLYWHEELC3 3
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Flywheel - Install
F4GE9484, F4GE9684
Prior operation:
1. Screw two hooks or trail rings in the flywheel (1)

threaded holes (4) for lifting.
2. Insert two guide pins (2), having the appropriate
length, in the shaft ports (3).
3. Using a hoist, handle the flywheel (1) to place it in
the housing.
FLYWHEELG 1
4. Tighten the screws (4) fixing the engine flywheel (3)

to the engine crankshaft.
5. Use tool 380000988 (2) in the flywheel housing (1)
to block engine flywheel rotation.
FLYWHEELG2 2
6. Tighten the engine flywheel (1) fixing screws (2) in

two phases.
• Phase 1 - Use a torque wrench to tighten the
bolts to 26 - 34 Nm (19.2 - 25.1 lb ft).
• Phase 2 - Use tool 380000304 to tighten an
additional 55 - 65 °.
NOTE: Before assembly, always check that the threads of
the ports and of the screws have no evidence of wear or
dirt.
FLYWHEELG3 3
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Vibration damper - Remove

Prior operation:
1. Remove the bolts (3) securing the vibration damp-

ener (2) and withdrawal the damper (2) and pulley
(1).
VIBDAMPENERH 1
Next operation:
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Vibration damper - Install

F4HE9484, F4HE9684
Prior operation:
1. Attach the vibration damper (2) and the pulley (1) to

the crankshaft, and torque the mounting bolts (3) to
61 - 75 Nm (45 - 55 lb ft).
VIBDAMPENERH 1
Next operation:
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Vibration damper - Remove

F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Remove the bolts (1) securing the vibration damp-

ener (2) and withdrawal the damper (2) and pulley
(3).
VIBDAMPERD 1
Next operation:
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Vibration damper - Install

F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Attach the vibration damper (2) and the pulley (3) to

the crankshaft, and torque the mounting bolts (1) to
61 - 75 Nm (45 - 55 lb ft).
VIBDAMPERD 1
Next operation:
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Balancer - Remove
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
1. Remove the screws (1) and withdraw the oil pickup

tube.
2. By means of pin (2) lock the dynamic balancer (3) in
the TDC (Top Dead Center) position.
3. Loosen the fixing screws (4) and remove the dynamic
balancer (3).
DYNAMICBALANCER 1
Next operation:
Balancer - Install (B.10.A)
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Balancer - Install
F4GE9484, F4GE9684
Prior operation:
Balancer - Remove (B.10.A)
1. Match the marks (A) engraved on the gears for tim-

ing.
2. Once the balancer is mounted on the engine, remove
the pin from point (B).
BALANCERG 1
Next operation:
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Cylinder block Bore - Check

Prior operation:
Once engine is disassembled, clean accurately the cylinder

block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case
of uncertain seal or if rusted.
Inspect cylinder bore surfaces; they shall be free from seiz-
ing, scores, ovalization, taper, or excessive wear.
Inspection of cylinder bore to check ovalization, taper, and
wear shall be performed using the bore dial gauge (1) fitted
with the dial gauge previously set to zero on the ring gauge
(2) of the cylinder bore diameter.
NOTE: Should a ring gauge not be available, use a mi- BACD04APH104ASA 1
crometer for zero-setting.
Measurements shall be performed on each cylinder at
three different heights in the barrel and on two planes per-
pendicular with each other: one parallel to the longitudinal
axis of the engine (A), and the other perpendicular (B).
Maximum wear is usually found on plane (B) in correspon-
dence with the first measurement.
Should ovalization, taper, or wear be found, bore and grind
the cylinder bores. Cylinder bore regrinding shall be per-
formed according to the spare piston diameter oversized by
0.4 mm (0.016 in) and to the specified assembling clear-
ance.
NOTE: In case of regrinding, all bores shall have the same
oversize 0.4 mm (0.016 in).
BAIL07APH372AMA 2
Next operation:
Cylinder block - Check (B.10.A)
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Cylinder block - Check

Prior operation:
Crankshaft - Remove (B.10.A)
Main Bearing Housings

Check main bearing housings as follows:
• fit the main bearing caps on the supports with-
out bearings
• tighten the fastening screws to the specified
torque
• use the proper internal gauge to check whether
the housing diameter is falling within the spec-
ified value.
Replace if a higher value is found.
Checking head supporting surface on cylinder unit

When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm (0.003 in)
Check cylinder unit operating plug (1) conditions, replace
them in case of uncertain seal or if rusted.
CRIL04J058A01 1
Next operation:
Crankshaft Journal - Clearance (B.10.A)
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Cylinder head - Remove

Prior operation:
Fuel injector Electro injector - Remove (B.20.A)
1. Remove the fastening screws (1) from the cylinder

head (2).
NOTE: The highlighted screws are shorter.
CYLHEADF4DF4HE 1
2. Hook brackets (1) with suitable lifting chains and re-

move the cylinder head (2) from the cylinder block
using a hoist.
CYLHEADREMOVE 2
Next operation:
Cylinder head - Check (B.10.A)
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Cylinder head - Check

Prior operation:
Checking cylinder head wet seal

This check shall be performed using the proper tools.
1. Use a pump to fill with water heated to approximately
90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of
pressure.
2. Replace the core plugs (1) if leaks are found, use the
proper punch for their removal/refitting.
NOTE: Before refitting, smear the plug surfaces with water
repellent sealant.
3. Replace the cylinder head if leaks are found.
80709 1
Checking cylinder head supporting surface

4. Distortion found along the whole cylinder head shall
not exceed 0.20 mm (0.008 in).
If higher values are found, grind the cylinder head
according to values and indications shown in the fol-
lowing figure.
5. The rated thickness (A) for the cylinder head is
104.75 - 105.25 mm (4.124 - 4.144 in). Maximum
metal removal shall not exceed thickness (B) by 1
mm (0.039 in).
NOTE: After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
70325 2
Next operation:
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Cylinder head - Install

Prior operation:
Cylinder head - Check (B.10.A)
1. Check the cleanliness of the cylinder head and en-

gine block coupling surface.
2. Taking care not to foul the cylinder head gasket, set
the gasket (1) with the marking "TOP" facing the
head.
3. The arrow shows the point where the gasket thick-
ness is given.
80714 1
4. There are two head gasket thicknesses, ( 1.25 mm

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

PROTRUSION 2
Repeat the operation for pistons 2, 3 and 4 and
calculate the average value.

Repeat the operation for pistons 2, 3, 4, 5 and
6 and calculate the average value.
• If S is > 0.40 mm (0.016 in) use seal type A.

• If S is < 0.40 mm (0.016 in) use seal type B.
84250518 09/11/2009
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5. Before using the fixing screws again, measure them

twice as indicated in the picture, checking D1 and D2
diameters:
if D1 - D2 < 0.1 mm (0.004 in) the screw can be
utilized again;
If D1 - D2 > 0.1 mm (0.004 in) the screw must be
replaced.
the hole and bolt threads have no evidence of dirt or wear.
BACD04APH224ASA 3
6. Using a suitable hoist, set the cylinder head on the

engine block.
CYLHEADREMOVE 4
7. Tighten the cylinder head bolts in the following order

using tool 380000304 for the angle tightening proce-
dure.
1. Tighten with a torque wrench.
• 12x1.75x130 are torqued to 30 - 40 Nm
(22 - 30 lb ft).
• 12x1.75x150 are torqued to 50 - 60 Nm
(37 - 44 lb ft).
2. Turn the bolt clockwise 85 - 95 °.
3. Turn the bolt clockwise an additional 85 - 95 °.
CYLINDERHEADDH 5
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6-Cylinder Engines
70476 6
Tightening sequence for the 6 cylinder engine.
A = Front of engine
4-Cylinder Engines
BACD04APH085ASA 7
Tightening sequence for the 4 cylinder engine.
A = Front of engine
Next operation:
Fuel injector Electro injector - Install (B.20.A)
84250518 09/11/2009
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Cylinder head Valve guide - Clearance

Prior operation:
1. Use a magnetic base dial gauge (1) set as shown in

the figure, the assembling clearance shall be 0.052 -
0.092 mm (0.002 - 0.004 in).
2. Turn the valve (2) and check that the centering error
is not exceeding 0.03 mm (0.001 in).
80710 1
3. 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.
0B0O200405BACD0 2
Next operation:
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Cylinder head Valve seat - Regrind

Prior operation:
Should slight scratches or burns be found, go over with

the adequate tool (1) according to the inclination values
indicated as follows:
80711 1
70331 2
VALVE SEAT MAIN DATA (4 CYL.)
Should valve seats be not reset just by regrinding, replace
them with spare ones. Using a suitable tool, remove as
much material as possible from the valve seats (take care
not to damage the cylinder head) until they can be ex-
tracted from the cylinder head using a punch.
1. Heat the cylinder head to 80 - 100 °C (176.0 - 212.0
°F) and using the proper punch, fit the new valve
seats, previously cooled, into the cylinder head.
2. Therefore, with an adequate tool, go over the valve
seats according to the values stated in the previous
figure.
84250518 09/11/2009
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70332 3
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD
3. After regrinding, check that the valve (3) sink-
ing value is the specified one by using the base
380000364 (2) and the dial gauge 380000228 (1).
80712 4
Next operation:
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F4GE9484, F4GE9684
Prior operation:
Fuel injector Mechanical injector - Remove (B.20.A)
1. Loosen the screws (1) and (2) fixing the cylinder head
(3).
2. Hook the brackets with a suitable lifting device.
3. With a hoist, withdraw the cylinder head from the
block.
4. Remove the gasket (4).
CYLHEADG 1
Next operation:
84250518 09/11/2009
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F4CE9484, F4CE9684
Prior operation:
1. Loosen the screws (1) and (2) fixing the cylinder head
(3).
2. Hook the brackets with a suitable lifting device.
3. Using a hoist, withdraw the cylinder head from the
block.
4. Remove the gasket (4).
CYLHEADC 1
Next operation:
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F4GE9484, F4GE9684
Prior operation:

head.
ness is given.
80714 1
4. There are two head gasket thicknesses, ( 1.25 mm

• For each piston, measure protrusion in two
places 180 ° apart, at a distance of 45 mm
(1.8 in)from the center of the piston S1 and S2.
Then calculate the average:

PROTRUSION 2


84250518 09/11/2009
B.10.A / 189
5. Place the head (3) over the block and insert screws
(1) and (2).
NOTE: If the valves have been removed, it is necessary to
assemble them before installing the head onto the engine
block.
CYLHEADG 3
6. Before using the screws again, measure them twice

as indicated in the picture.
- if D1 - D2 < 0.1 mm (0.004 in) the screw can be
used again.
- if D1 - D2 > 0.1 mm (0.004 in) the screw must be
replaced.
HEADBOLT 4
7. Lubricate the head bolts and install them in the head.

8. Bolts must be torqued starting with the center bolts
and moving out. Bolts shall be torqued in the follow-
ing stages.
• Make all bolts snug then turn 90 °.
• Turn bolts M12x140 and M12x180 an addi-
tional 90 °.
9. The end result should look like this.
• M12x70 = 50 Nm (36.9 lb ft) + 90 °.
• M12x140 = 40 Nm (29.5 lb ft) + 180 °.
• M12x180 = 70 Nm (51.6 lb ft) + 180 °.
TORQUEPATTERNG2 5
Next operation:
Fuel injector Mechanical injector - Install (B.20.A)
84250518 09/11/2009
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F4CE9484, F4CE9684
Prior operation:
1. Place the gasket (1) over the block. The choice of

the gasket thickness shall be made in consideration
of the cylinder protrusion measured with the respect
to the block’s upper surface.
NOTE: Verify that the engine block is clean.
Do not grease the gasket. It is recommended to keep the
gasket inside its packaging until assembly to the cylinder
head.
Gasket assembly shall be made following the direction of
wording printed on the gasket itself so that this will be read-
able as indicated in the picture.
HEADGASKETG 1
2. Place the head (3) over the block and insert screws
(1) and (2).
NOTE: If the valves have been removed, it is necessary to
assemble them before installing the head onto the engine
block.
CYLHEADC 2
3. Before using the screws again, measure them twice

as indicated in the picture.
- if D1 - D2 < 0.1 mm (0.004 in) the screw can be
used again.
- if D1 - D2 > 0.1 mm (0.004 in) the screw must be
replaced.
HEADBOLT 3
84250518 09/11/2009
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4. Lubricate the head bolts and install them in the head.

5. Bolts must be torqued starting with the center bolts
and moving out. Bolts shall be torqued in the follow-
ing stages.
• Make all bolts snug then turn 90 °.
• Turn bolts M12x140 and M12x180 an addi-
tional 90 °.
6. The end result should look like this.
• M12x70 = 50 Nm (36.9 lb ft) + 90 °.
• M12x140 = 40 Nm (29.5 lb ft) + 180 °.
• M12x180 = 70 Nm (51.6 lb ft) + 180 °.
TORQUEPATTERNG2 4
Next operation:
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F4GE9484, F4GE9684
Prior operation:

90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of
pressure.
repellent sealant.
CYLHEADWETSEAL 1

lowing figure.
104.75 - 105.25 mm (4.124 - 4.144 in). Maximum
mm (0.039 in).
CYLHEADG2 2
Next operation:
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F4CE9484, F4CE9684
Prior operation:

90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of
pressure.
repellent sealant.
CYLHEADWETSEAL 1

lowing figure.
104.75 - 105.25 mm (4.124 - 4.144 in). Maximum
mm (0.039 in).
CYLHEADC2 2
Next operation:
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Cylinder head Valve guide - Clearance

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Use a magnetic base dial gauge (1)set as shown in

the figure, the assembling clearance shall be 0.052 -
0.092 mm (0.002 - 0.004 in).
2. Turn the valve (2) and check that the centering error
is not exceeding 0.03 mm (0.001 in).
VALVEGUIDE 1
3. 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.
VALVEGUIDE2 2
Next operation:
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Cylinder head Valve seat - Regrind

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Should slight scratches or burns be found, go over with

the adequate tool (1) according to the inclination values
indicated as follows:
VALVESEAT 1
VALVESEAT2 2
VALVE SEAT MAIN DATA (dimensions in mm)
Should valve seats be not reset just by regrinding, replace
them with spare ones. Using a suitable tool, remove as
much material as possible from the valve seats (take care
not to damage the cylinder head) until they can be ex-
tracted from the cylinder head using a punch.
1. Heat the cylinder head to 80 - 100 °C (176.0 - 212.0
°F) and using the proper punch, fit the new valve
seats, previously cooled, into the cylinder head.
2. Therefore, with an adequate tool, go over the valve
seats according to the values stated in the previous
figure.
84250518 09/11/2009
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VALVESEAT3 3
VALVE SEAT HOUSING MAIN DATA (dimensions in mm)
3. After regrinding, check that the valve (3) sink-
ing value is the specified one by using the base
380000364 (2) and the dial gauge 380000228 (1).
VALVESINK 4
Next operation:
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F4CE9484, F4GE9484, F4CE9684, F4GE9684

head.
ness is given.
80714 1
4. There are two head gasket thicknesses ( 1.25 mm

• for each piston measure protrusion in two
places 180 ° apart, at a distance of 45 mm
(1.8 in)from the center of the piston S1 and
S2. Then calculate the average:

PROTRUSION 2


84250518 09/11/2009
B.10.A / 198
5. Before using the fixing screws again, measure them

twice as indicated in the picture, checking D1 and D2
diameters:
if D1 - D2 < 0.1 mm (0.004 in) the screw can be
utilized again;
If D1 - D2 > 0.1 mm (0.004 in) the screw must be
replaced.
BACD04APH224ASA 3
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Valve cover - Remove

1. Remove the nuts securing the valve cover to base.

2. Remove valve cover and gasket.
BACD04APH004ASA 1
Next operation:
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Valve cover - Install

Prior operation:
1. Install a new gasket (2) on the valve cover (1).

2. Place the valve cover (1) on its seat, and install the
mounting bolts.
VALVECOVER 1
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1. Loosen the nuts (1) on top of the valve cover (2).

2. Remove the valve cover (2) from it’s base.
VALVECOVERF4DE 1
Next operation:
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F4CE9484, F4GE9484, F4CE9684, F4GE9684
1. Remove the fastening screws (1) from the valve cov-

ers (2). Remove the covers (2) and the related gas-
kets.
VALVECOVERCG 1
2. On one of the caps there is a blow-by valve for the

lubrication oil vapors. This can be disassembled with
the relevant valve cover (2) by removing screws (1).
NOTE: All gaskets should be replaced upon reassembly.
VALVECOVERCG2 2
Next operation:
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Valve cover - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Assemble the valve covers (2) with new gaskets.

2. Install the seals on the bolts and tighten the screws
to the prescribed torque.
VALVECOVERCG 1
3. Install the cover (2) that incorporates the blow-by

valve and tighten the screws (1) to the prescribed
torque.
VALVECOVERCG2 2
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Front cover - Remove

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
1. Remove the screws (1) from the front cover. Be sure

to remove the two screws (3) underneath the cover.
NOTE: Take note of screw (1) assembling positions since
they have different lengths.
2. Remove the front cover from the cylinder block.
FRONTCOVERH 1
Next operation:
Front cover - Cleaning (B.10.A)
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Front cover - Cleaning

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
Front cover - Remove (B.10.A)
1. Remove the sealing ring (2) from the front cover (1).
FRONTCOVERH2 1
2. Clean the sealing surfaces and apply LOCTITE

5205.
FRONTCOVERG 2
Next operation:
Front cover - Install (B.10.A)
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Front cover - Install

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
1. Install the front cover (2) and tighten the mounting

bolts (1) to the specified torque.
FRONTCOVERD3 1
Next operation:
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Front cover - Remove

F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Remove the screws (1) from the front cover (2). Be

sure to remove the four screws (3) from underneath
the cover (2).
NOTE: Take note of screw assembling positions since that
have different lengths.
2. Remove the front cover (2).
FRONTCOVERD 1
Next operation:
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Front cover - Cleaning

F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Disassemble the sealing ring (2) from the front cover

(1), clean the coupling surfaces accurately.
FRONTCOVERD2 1
Next operation:
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Front cover - Install

F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Position the front cover seal (1) on the engine block.
FRONTCOVERD4 1
2. Install the front cover (1) on the block and tighten the
screws (2) to the prescribed torque.
FRONTCOVERD5 2
Next operation:
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Rear cover - Remove

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
1. Remove the retaining bolts (2) from the rear cover

(1) and withdrawal the cover.
NOTE: Take note of the bolt location due to the different
lengths. This will aid in ease of assembly.
REARCOVERH3 1
Next operation:
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Rear cover - Cleaning

F4HE9484, F4HE9684
Prior operation:
1. Clean the rear cover and it’s mating surface on the

timing gear cover.
limeters thick, to the sealing surface of the cover.
NOTE: After applying the sealant, the cover should be as-
sembled within 10 to 20 minutes.
REARCOVERH 1
Next operation:
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Rear cover - Install

F4HE9484, F4HE9684
Prior operation:
NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or
dirt.
1. Install the cover (1) onto the timing gear housing and
install the bolts in same location that they were re-
moved.
2. Tighten them to the prescribed torque.
REARCOVERH2 1
Next operation:
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Prior operation:
1. Clean the rear cover and it’s mating surface on the

timing gear cover.
REARCOVERD 1
Next operation:
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Prior operation:
NOTE: Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
1. Install the cover (1) on the engine.
2. Tighten the fixing screws (2) in the same position
from where they have been removed, to the pre-
scribed torque.
REARCOVERC2 1
Next operation:
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Rear cover - Remove

Prior operation:
1. Loosen the screws (2) and remove the rear cover (1).
NOTE: Take of the screw assembly position, since the
screws have different lengths.
REARCOVERC 1
Next operation:
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F4GE9484, F4GE9684
Prior operation:
1. Clean the rear cover (1) and it’s mating surface on

the timing gear cover.
REARCOVERG 1
Next operation:
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F4GE9484, F4GE9684
Prior operation:
NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or
dirt.
1. Install the cover (1) onto the timing gear housing and
install the bolts in same location that they were re-
moved.
2. Tighten them to the prescribed torque.
REARCOVERG2 1
Next operation:
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Wiring harness - Disconnect

F4DE9484, F4DE9684, F4DE9687
0B0O200406CRIL0 1
(1) Connections for electro-injectors - (2) Coolant temperature sensor - (3) Fuel pressure sensor - (4) Oil
pressure/temperature sensor - (5) Driving shaft sensor - (6) Electro-injector - (7) Air pressure/temperature
sensor - (8) Timing system sensor - (9) Fuel temperature sensor - (10) Pressure regulating gauge - (11)
EDC 7 electronic module.
1. Disconnect the engines cable from the connectors
(1) to electro-injector (6), air pressure/temperature
sensor (7), fuel pressure sensor (3), engine control
module (11), high pressure pump sensor (10), timing
system sensor (8), coolant temperature sensor (2),
driving shaft sensor (5).
2. Disassemble the harness from the engine block by
removing the fixing clamps.
0B0O200406CRIL0 2
Next operation:
Wiring harness - Connect (B.10.A)
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Wiring harness - Disconnect

F4HE9484, F4HE9684
HARNESS 1
(1) Fuel Pressure Sensor - (2) Coolant Temperature Sensor - (3) Engine Oil Temperature Sensor - (4)
Crankshaft Speed Sensor - (5) Electro-Injector - (6) Air Pressure/Temperature Sensor - (7) Timing Sensor
- (8) Fuel Temperater Sensor - (9) Fuel Pressure Regulator - (10) EDC 7 Electronic Control Unit - (11)
Connectors for Electro-Injectors
1. Disconnect the engine’s cable from the connectors
wiring harness to Electro-Injectors (11); Air Pres-
sure/Temperature Sensor; (6) Fuel Pressure Sensor
(1); Engine Control Module (10); Timing Sensor (7);
Coolant Temperature Sensor (2); Crankshaft Speed
Sensor (4).
HARNESS 2
Next operation:
Wiring harness - Connect (B.10.A)
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Wiring harness - Connect

Prior operation:
Wiring harness - Disconnect (B.10.A)
1. Reconnect the engine wiring harness to all the sen-

sors, the engine control module and the common rail.
Refer to Wiring harness - Disconnect (B.10.A) for
the harness routing and connections.
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Electronic control Control module - Remove

F4HE9484, F4HE9684
Prior operation:
Fuel line Low pressure - Disconnect (B.20.A)
1. Disconnect the main wiring harness from the elec-

tronic control module (2).
2. Disconnect the low pressure fuel lines that are at-
tached to the control module cooling plate.
3. Remove the three mounting bolts (1) that secure the
control module and the cooling plate to the engine
block.
4. Remove the control module and cooling plate as one
unit.
EDC7H 1
Next operation:
Electronic control Control module - Install (B.10.A)
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Electronic control Control module - Install

F4HE9484, F4HE9684
Prior operation:
Electronic control Control module - Remove (B.10.A)
1. Install the electronic control module (2) and cooling

plate on the side of the engine block.
2. Install the mounting bolts (1) and rubber isolators and
tighten to the specified torque.
NOTE: If the rubber isolators are cracked or excessively
deformed, replace them before installation.
EDC7H 1
Next operation:
Fuel line Low pressure - Connect (B.20.A)
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Sensing system Position sensor - Remove

1. Remove the mounting nut and slide the timing sensor

out of the timing gear housing.
Next operation:
Sensing system Position sensor - Install (B.10.A)
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Sensing system Position sensor - Install

Prior operation:
Sensing system Position sensor - Remove (B.10.A)
1. Install a new O-ring on the timing sensor.

2. Slide the sensor over the mounting stud and install
the nut. Tighten to the specified torque.
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Sensing system Speed sensor - Install

1. Install a new O-ring on the speed sensor (3).

2. Install the speed sensor (3) on the front cover (1).
3. Tighten the screw (2) to the specified torque.
SPEEDSENSORH 1
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Index
ENGINE - 10.A
Auxiliary drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
F4HE9484, F4HE9684
F4CE9484, F4CE9684
F4GE9484, F4GE9684
Auxiliary drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
F4HE9484, F4HE9684
F4GE9484, F4GE9684
F4CE9484, F4CE9684
Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
F4GE9484, F4GE9684
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
F4GE9484, F4GE9684
Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
F4CE9484, F4CE9684
Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
F4DE9484, F4DE9684, F4DE9687
Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
F4CE9484, F4CE9684
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Connecting rod and piston - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Connecting rod and piston Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Connecting rod and piston Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Connecting rod Bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Connecting rod Bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Connecting rod Bushing - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Crankshaft Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Crankshaft Gear - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Crankshaft Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Crankshaft Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
F4CE9484, F4CE9684
Crankshaft Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Cylinder block - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
F4GE9484, F4GE9684
F4CE9484, F4CE9684
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
F4GE9484, F4GE9684
F4CE9484, F4CE9684
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
F4GE9484, F4GE9684
F4CE9484, F4CE9684
Cylinder head Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Cylinder head Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Cylinder head Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Cylinder head Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Electronic control Control module - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electronic control Control module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
F4HE9484, F4HE9684
Electronic control Control module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electronic control Control module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
F4HE9484, F4HE9684
ENGINE - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4CE9684
F4GE9484, F4GE9684
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4HE9484, F4HE9684
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4CE9684
F4GE9484, F4GE9684
ENGINE - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
F4HE9484, F4HE9684
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F4GE9484, F4GE9684
F4CE9484, F4CE9684
ENGINE - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
F4DE9484, F4DE9684, F4DE9687
F4GE9484, F4GE9684
F4CE9484, F4CE9684
ENGINE - Service limits Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE - Service limits Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
F4CE9484, F4HE9484, F4CE9684, F4HE9684
Flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4CE9684
F4GE9484, F4GE9684
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
F4DE9484, F4DE9684, F4DE9687
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
F4CE9484, F4CE9684
Front cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Front cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
F4DE9484, F4DE9684, F4DE9687
Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
F4DE9484, F4DE9684, F4DE9687
Front cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Front cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
F4DE9484, F4DE9684, F4DE9687
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Rear cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
F4HE9484, F4HE9684
F4GE9484, F4GE9684
Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
F4HE9484, F4HE9684
F4GE9484, F4GE9684
Rear cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Rear cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Rocker assembly Shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Sensing system Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
F4HE9484, F4HE9684
Sensing system Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
F4DE9484, F4DE9684, F4DE9687
Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4CE9684
Sensing system Position sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Sensing system Position sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Sensing system Speed sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
F4HE9484, F4HE9684
Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
F4GE9484, F4GE9684
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
F4HE9484, F4HE9684
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
F4GE9484, F4GE9684
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
F4DE9484, F4DE9684, F4DE9687
Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve drive - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Valve drive Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Valve drive Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Valve drive Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Valve drive Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valve drive Rocker assembly - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve drive Rocker assembly - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Valve drive Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Valve drive Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve drive Rocker assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve drive Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Valve drive Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Valve drive Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Valve drive Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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Vibration damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
F4HE9484, F4HE9684
Vibration damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
F4DE9484, F4DE9684, F4DE9687
Vibration damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Vibration damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F4DE9484, F4DE9684, F4DE9687
Wiring harness - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Wiring harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
F4DE9484, F4DE9684, F4DE9687
Wiring harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
F4HE9484, F4HE9684
Wiring harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F4HE9484, F4HE9684
Wiring harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
F4DE9484, F4DE9684, F4DE9687
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FUEL AND INJECTION SYSTEM - 20.A

F4GE9684 , F4HE9484 , F4HE9684
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B.20.A / 1
Contents
FUNCTIONAL DATA
FUEL AND INJECTION SYSTEM
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4HE9484, F4HE9684
Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Regulator valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Relief valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel injection pump

Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9484, F4GE9684
Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F4CE9484, F4CE9684
Rotary injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel filter system

Water separator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel injector
Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4HE9484, F4HE9684
Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

F4DE9484, F4DE9684, F4DE9687
High pressure common rail

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F4HE9484, F4HE9684
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F4DE9484, F4DE9684, F4DE9687
Pump head and housing - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Fuel heater
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel transfer pump
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Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Priming pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Sensing system
Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F4HE9484, F4HE9684
Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

F4HE9484, F4HE9684
Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

F4HE9484, F4HE9684
Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

F4DE9484, F4DE9684, F4DE9687
Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

F4DE9484, F4DE9684, F4DE9687
Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

F4DE9484, F4DE9684, F4DE9687
Water sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

F4CE9484, F4CE9684
SERVICE
Fuel injection pump
Rotary injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Rotary injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

F4GE9484, F4GE9684
Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

F4GE9484, F4GE9684
Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

F4GE9484, F4GE9684
Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

F4CE9484, F4CE9684
Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

F4CE9484, F4CE9684
Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

F4CE9484, F4CE9684
Fuel filter system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel injector
Fuel Manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuel Manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Electro injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Electro injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Mechanical injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Mechanical injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

F4CE9484, F4GE9484, F4CE9684, F4GE9684
High pressure common rail

Pump head and housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Pump head and housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Priming pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel line
High pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

F4HE9484, F4HE9684
High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

F4DE9484, F4DE9684, F4DE9687

F4HE9484, F4HE9684
Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74


F4GE9484, F4GE9684

F4CE9484, F4CE9684

F4CE9484, F4GE9484, F4CE9684, F4GE9684
High pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

F4CE9484, F4CE9684
Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

F4GE9484, F4GE9684
Low pressure - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel connector
Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Sensing system
Air temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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POWER PRODUCTION - FUEL AND INJECTION SYSTEM
FUEL AND INJECTION SYSTEM - Dynamic description

F4HE9484, F4HE9684
4C0O200406CRILH 1
(1) Electro-Injector - (2) Common Rail - (3) Pressure limiting device for fuel return - (4) Common rail pressure
relief valve - (5) Pre-filter mounted on the frame - (6) High-pressure pump - (7) Mechanical vane pump - (8)
Fuel filter.
The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke
and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
The hydraulic system is implemented by a low pressure circuit and a high pressure circuit
The high pressure circuit is composed of the following pipings:

• piping connecting high pressure pump outlet to rail
• pipings supplying injectors from rail
The low pressure circuit is composed of the following pipings:

• fuel suction piping from tank to pre-filter
• pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and
pre-filter
• pipings supplying the high pressure pump through the fuel filter
The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.
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FUEL AND INJECTION SYSTEM - Plumbing schema

The fuel system is a Common Rail injection system with a CP3 high pressure pump.
The pressure regulator, placed upstream of the high pressure pump, adjusts the fuel flow that is necessary on the low
pressure system. Afterwards, the high pressure pump takes care of supplying the rail properly. This arrangement, by
pressurizing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.
Function of the pressure relief valve (2), assembled on the high pressure pump, is keeping the pressure, at the pres-
sure regulator inlet, constant at 5 bar (73 psi). Based on the efficiency the fuel filter.
The pressure relief valve (2) increases fuel flow in the high pressure pump cooling circuit, through inlet and drain
piping (16) from piping (8).
The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from
injectors at a pressure of 1.3 - 2 bar (19 - 29 psi).
Two bypass valves are placed in parallel with the mechanical supply pump.
The bypass valve (18) allows fuel to flow from the mechanical pump outlet to it’s inlet, when the fuel filter inlet pressure
exceeds the allowed threshold value.
The bypass valve (17) allows filling the supply system through the manual priming pump (10).
FUELSYSTEMSCHEM 1
(1) High-Pressure pump - (2) pressure relief valve on high pressure pump, 5 bar (72.5 psi) - (3) Pressure
relief valve assembled on fuel return from injectors, 1.3 - 2 bar (18.9 - 29.0 psi) - (4) Rail overpressure valve -
(5) Common rail - (6) Pressure sensor - (7) Injector - (8) Return spring - (9) Control unit heat exchanger - (10)
Mechanical priming pump - (11) Pre-Filter - (12) Fuel tank - (13) Mechanical supply pump - (14) Fuel filter -
(15) Pressure regulator - (16) High pressure pump cooling pipe - (17) By-pass valve - (18) By-pass valve.
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F4DE9484, F4DE9684, F4DE9687
4C0O200406CRIL0 1
(1) Injector - (2) Common Rail - (3) Pressure limiter for fuel return - (4) Rail overpressure valve - (5) Prefilter
mounted on the block - (6) High pressure pump - (7) Mechanical rotor pump - (8) Fuel filter.
The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke
and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
The hydraulic system is implemented by a low pressure circuit and a high pressure circuit
The high pressure circuit is composed of the following pipings:

• piping connecting high pressure pump outlet to rail
• pipings supplying injectors from rail
The low pressure circuit is composed of the following pipings:

• fuel suction piping from tank to pre-filter
• pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and
pre-filter
• pipings supplying the high pressure pump through the fuel filter
The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.
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F4CE9484, F4GE9484, F4CE9684, F4GE9684
FUELSYSTEMCG 1
(1) Fuel filter - (2) Feed pipeline from filter to fuel pump - (3) Feed pipeline from priming pump to filter -
(4) Priming pump.
Description of working principles

Fuel is sucked from the tank by the priming pump. This last one is placed on the engine block and is driven by the
camshaft.
Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For application to
be equipped in cold climate areas, the fuel filter is provided with a heater).
The transfer pump is placed inside the feed pump, and is bladed type. Its duty is to increase fuel pressure in corre-
spondence with the increase of the number of revolutions.
The fuel arrives therefore to the valve gauging the pressure inside the feed pump.
The distribution plunger further increases this pressure and delivers fuel throughout the delivery pipe fitting to the
injectors.
The fuel drawing from the injectors is recovered and delivered to the tank again.
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Regulator valve - Overview

Pressure Regulator
The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure
system; the pressure regulator is managed by the EDC7 control unit.
Delivery pressure to the rail is modulated between 250 - 1450 bar (3625 - 21025 psi) by the electronic control unit by
controlling the pressure regulator solenoid valve.
This component is a N.O. solenoid valve.
The solenoid valve impedance is approximately 3.2 Ω.
Pressure Limiter for Fuel Return

It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at pressures of
1.3 - 2 bar (19 - 29 psi). By guaranteeing this pressure to the return fuel, the fuel vapor formation inside the injectors
is avoided, optimizing fuel spraying and combustion.
BACD04APH176ASA 1
(A) - To Tank
(B) - From Injectors
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Relief valve - Overview

Mounted on the end of the rail, it has the function of protecting the system’s components in case the failure of the
rail pressure sensor or the pressure regulator of the CP3 pump causes an excessive pressure increase in the high
pressure plant.
When the rail pressure reaches 1800 bar (26100 psi), the valve initially opens in order to allow the fuel to flow and
subsequently reduce the pressure within the safety limits and then it mechanically regulates the rail pressure to ap-
proximately 800 bar (11600 psi).
This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of
the fuel preserving the return pipes to tank.
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Fuel injection pump Rotary injection pump - Overview

F4GE9484, F4GE9684
Fuel feed system is composed by:

• Fuel tank (placed on the machine)
• Fuel delivery and back-flow to tank
• Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)
• Priming pump, assembled to the engine and driven by the camshaft
• Fuel filter (assembled to the engine in different positions according to equipment application and duty)
• Fuel feed rotary pump
• Injector feed pipeline (from fuel feed pump to injectors)
• Injectors
INJECTIONPUMPG 1
(1) Injector feed pipes - (2) Fuel return pipes from injectors - (3) Fuel feed rotary pump - (4) Connector for
LDA pressure gauge pipe with suction collector - (5) KSB thermal bulb - Electro-valve - (7) Injector.
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Fuel injection pump Rotary injection pump - Overview

F4CE9484, F4CE9684
Fuel feed system is composed by:

• Fuel tank (placed on the machine)
• Fuel delivery and back-flow to tank
• Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)
• Priming pump, assembled to the engine and driven by the camshaft
• Fuel filter (assembled to the engine in different positions according to equipment application and duty)
• Fuel feed rotary pump
• Injector feed pipeline (from fuel feed pump to injectors)
• Injectors
INJECTIONPUMPC 1
(1) Injector feed pipes - (2) Injector - (3) Electro-valve - (4) KSB thermal bulb - (5) Fuel feed rotary pump
- (6) Fuel return pipes from injectors.
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Fuel injection pump Rotary injection pump - Sectional view

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Decoding the identification tag

V = Distribution rotary plunger
E = Pump dimensions
4 = Four cylinder engines (3 = Three cylinder engines and 6 = Six cylinder engines)
12 = Distribution plunger in mm
1150 = Number of pump revolutions per minute
LV = Left direction of rotation
PUMPSECTIONCG 1
(1) Diaphragm - (2) Locking nut - (3) Pivot - (4) Drive lever - (5) Speed gauge - (6) Transfer pump - (7) Drive
shaft - (8) Cam disk - (9) Advance converter - (10) Distribution plunger - (11) Delivery pipe fitting - (12)
Hydraulic head - (13) Drive plate - (14) Gauge pin - (15) Counteracting spring.
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Fuel filter system Water separator - Overview

F4CE9484, F4GE9484, F4CE9684, F4GE9684
The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities
and separation of water from fuel.
On the filter cartridge, there is a water dump screw throughout which it is possible to provide regular drainage. For
those equipment applications requiring it, a heater can be installed along with a temperature sensor. On some ver-
sions, a water presence sensor is mounted to the filtering cartridge.
FUELWATERFILTER 1
(1) Fuel filter base - (2) Filter cartridge - (3) Water dump screw.
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Fuel injector Electro injector - Overview

F4HE9484, F4HE9684
On NEF TIER III engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power
developed by the engine.
Jet Power Pressure

DLLA Up to 152 kW (207 Hp) 250 - 1600 bar (3625 - 23200 psi)
DSLA 152 kW (207 Hp) and above. 250 - 1450 bar (3625 - 21025 psi)
The injector is similar as construction to the traditional ones, apart from the absence of the plunger return springs.
The injector is composed of two parts:
• actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.
• control solenoid valve composed of a coil, and pilot valve.
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position
93095366 1
(1) Pressure Rod (6) Ball Shutter (11) Supply Duct

(2) Plunger (7) Control Area (12) Control Fuel Outlet
(3) Nozzle (8) Pressure Chamber (13) Electrical Connection
(4) Coil (9) Control Volume (14) Spring
(5) Pilot Valve (10) Control Duct (15) High Pressure Fuel Inlet
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Injection Start
93095367 2
When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct
(12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8)
makes plunger (2) lift, following fuel injection into the cylinder.
Injection End
When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance
as to make plunger (2) go back to its closing position and end the injection process.
NOTE: The injector cannot be overhauled and therefore it must not be disassembled.
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Electro-Injector Solenoid Valves

The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The Impedance of the coil of each injector is 0.56 - 0.57 Ω.
COVERBASE 3
Reference Description ECU Pin

Connector (1)
Pin #1 Cylinder 2 injector 11A
Connector (2)
Connector (3)
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Fuel injector Electro injector - Overview

F4DE9484, F4DE9684, F4DE9687
On NEF TIER III engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power
developed by the engine.
Jet Power Pressure

DLLA Up to 152 kW (207 Hp) 250 - 1600 bar (3625 - 23200 psi)
DSLA 152 kW (207 Hp) and above 250 - 1450 bar (3625 - 21025 psi)
The injector is similar as construction to the traditional ones, apart from the absence of the plunger return springs.
The injector is composed of two parts:
• actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.
• control solenoid valve composed of a coil, and pilot valve.
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position
93095366 1
(1) Pressure Rod (6) Ball Shutter (11) Supply Duct

(2) Plunger (7) Control Area (12) Control Fuel Outlet
(3) Nozzle (8) Pressure Chamber (13) Electrical Connection
(4) Coil (9) Control Volume (14) Spring
(5) Pilot Valve (10) Control Duct (15) High Pressure Fuel Inlet
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Injection Start
93095367 2
When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct
(12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8)
makes plunger (2) lift, following fuel injection into the cylinder.
Injection End
When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance
as to make plunger (2) go back to its closing position and end the injection process.
NOTE: The injector cannot be overhauled and therefore it must not be disassembled.
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Electro-Injector Solenoid Valves

The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The Impedance of the coil of each injector is 0.56 - 0.57 Ω.
COVERBASE 3
Reference Description ECU Pin

Connector (1)
Connector (2)
Connector (3)
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High pressure common rail - Overview

FUEL SYSTEM OPERATION

The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves
set on the pumping elements at about 2 bar (29 psi).
The amount of fuel supplying the high pressure pump is metered by the pressure regulator placed on the low pressure
system. The pressure regulator is controlled by the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, unable to be
released, is compressed above the supply pressure value existing in the rail.
The generated pressure makes the exhaust valve open and the compressed fuel reaches the high pressure circuit.
The pumping element compresses the fuel till top dead center of the delivery stroke, is reached. Afterwards, the
pressure decreases till the exhaust valve is closed.
The pumping element piston goes back towards bottom dead center and the remaining fuel is decompressed.
When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again
opened and the cycle is repeated.
The delivery valves must always be free in their movements, free from impurities and oxidation.
The rail delivery pressure is modulated between 250 - 1600 bar (3625 - 23200 psi) by the electronic control unit,
through the pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection - reconnection time on the engine is greatly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high pressure pump is to be removed or installed, be sure that hands and compo-
nents are absolutely clean.
RAIL
COMMONRAILOVERV 1
(1) Rail - (2) Fuel inlet from high-pressure pump - (3) Overpressure valve - (4) Pressure sensor.
The rail volume is comparatively small to allow quick pressurization at start-up, at idle and in case of high flow rates.
It has enough volume to minimize system spikes and the use of plenum chambers caused by the opening and closing
of the injectors and by the high pressure pump operation. This function is further enabled by a calibrated hole being
set downstream of the high pressure pump.
A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is feedback
information, where the rail pressure value is checked and if necessary, corrected.
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High pressure common rail - External view

F4HE9484, F4HE9684
Introduction
Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system
makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision
obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and
fuel consumption.
For engines more powerful than 152 kW (207 Hp), the CRIN2 injectors have DLLA nozzles that work up to a pressure
of 1600 bar (23200 psi), for engines less powerful than 152 kW (207 Hp), DSLA nozzles are fitted which work at
pressures up to 1450 bar (21025 psi).
Description of system
The injection system is composed of an electrical part and a hydraulic part.
Electrical system
The electronic control unit monitors engine control parameters by means of the various sensors on the engine.
HARNESS 1
(1) Fuel pressure sensor - (2) Coolant temperature sensor - (3) Oil temperature/pressure sensor - (4) Driving
shaft sensor - (5) Connection to electro-injectors - (6) Air temperature/pressure sensor - (7) Camshaft
sensor - (8) Fuel heater cable and fuel temperature sensor - (9) Pressure gauge cabling - (10) EDC 7
gearbox - (11) Electro-injector
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High pressure common rail - External view

F4DE9484, F4DE9684, F4DE9687
Introduction
Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system
makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision
obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and
fuel consumption.
For engines more powerful than 152 kW (207 Hp), the CRIN2 injectors have DLLA nozzles that work up to a pressure
of 1600 bar (23200 psi), for engines less powerful than 152 kW (207 Hp), DSLA nozzles are fitted which work at
pressures up to 1450 bar (21025 psi).
Description of system
The injection system is composed of an electrical part and a hydraulic part.
Electrical system
The electronic control unit monitors engine control parameters by means of the various sensors on the engine.
Air pressure/temperature system

It is a component integrating a temperature sensor and a pressure sensor. Fitted on the intake manifold, it measures
the maximum inlet air capacity to calculate precisely the fuel quantity to inject at every cycle. The outlet voltage is
proportional to the pressure or temperature obtained by the sensor.
Engine oil temperature and pressure sensor

Same as the air pressure/temperature sensor, it is fitted on the engine oil filter base, in a horizontal position. It mea-
sures engine oil temperature and pressure.
Fuel pressure sensor

Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The
injection pressure value is used to control the pressure and to determine the electric injection control length.
Coolant temperature sensor

It is a variable resistance sensor suitable to measure the coolant temperature to provide the control unit with an index
of the engine thermal state.
Output shaft sensor

It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that
are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used
by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it
has a different outside shape.
System functionality
The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data.
FPT Code recognition

The EDC 7 control unit communicates with the Immobilizer control unit (if fitted) to obtain the startup consent.
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0B0O200406CRIL0 1
(1) Connection to electro-injectors - (2) Coolant temperature sensor - (3) Fuel pressure sensor - (4) Oil
temperature/pressure sensor - (5) Crankshaft sensor - (6) Electro-injector - (7) Air temperature/pressure
sensor - (8) Camshaft sensor - (9) Fuel heater cable and fuel temperature sensor - (10) Pressure gauge
cabling - (11) EDC 7 gearbox.
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High pressure common rail Pump head and housing - Sectional

view
CP3 HIGH PRESSURE PUMP

Pump provided with 3 radial pumping elements driven by the timing system gear, no need for timing. The mechanical
feeding pump driven by the high pressure pump’s shaft is assembled to the rear side of the high pressure pump.
NOTE: The high pressure pump unit - feeding pump is not subject to overhaul. Do not disassemble or tamper with
the retaining bolts.
The only serviceable components are the control gear and pressure regulator.
80719 1
(1) Fuel exhaust collector to rail - (2) High pressure pump - (3) Pressure regulating gauge - (4) Driving gear -
(5) Connector to fuel entry flowing from filter - (6) Connector to fuel exhaust to filter support - (7) Connector
to fuel entry flowing from engine control module heat exchanger - (8) Connector to fuel exhaust flowing
from mechanical pump to filter - (9) Mechanical feeding pump
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HIGH PRESSURE PUMP
Inside Structure
80720 2
(1) Cylinder - (2) Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft -
(7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts.
Every pumping unit is composed of:

• A piston actuated by a three-lobe element floating on the pump shaft. The element, which is floating on an offset
part of the shaft, uses the highest part of the element to actuate the three pistons alternately.
• Cap intake valve.
• Ball delivery valve.
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Working Principle
80721 3
(1) Cylinder - (2)Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft -
(7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts
The pumping element is oriented towards the pump’s camshaft. During the intake phase, the pumping element is fed
through the feeding line. The quantity of fuel to flow to the pumping element is determined by the pressure regulating
gauge. The pressure regulating gauge, according to the PWM command received by the engine control module,
stops the fuel flow to the pumping element. During the compression phase of the pumping element, the fuel achieves
the level of pressure determining the opening of the by-pass valve to the common rail, feeding it through the exhaust
unit.
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80722 4
(1) Cylinder - (2)Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft -
(7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts
The figure shows the fuel runs at low pressure inside the pump. The following elements are clearly visible: the main
feeding line to the pumping elements, the feeding lines to the pumping elements, the duct lines run for the pump
lubrication, the pressure gauge, the flow limiting valve to 5 bar (73 psi) and the fuel exhaust flue
The pump shaft is lubricated by the fuel from the feeding and recovery lines.
The pressure gauge determines the quantity of fuel to feed the pumping elements. The excess fuel flows through the
exhaust gallery.
The 5 bar (73 psi) limiting valve, in addition to recovering exhaust fuel as a collector, also functions to keep the
pressure at a constant 5 bar (73 psi) limit at gauge entry.
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80723 5
(1) Fuel exhaust flue - (2) Fuel exhaust gallery -
(3) Fuel exhaust flowing from pump with connector to high pressure pipe for common rail
This figure shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.
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Fuel heater - Overview

The ECU drives the filter heater at fuel temperature less than our equal to 5 °C (41 °F).
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Fuel transfer pump - Sectional view

MECHANICAL FEEDING PUMP

Gear pump, placed on the rear part of the high pressure pump, whose function is to feed the high pressure pump. It
is driven by the high pressure pump’s shaft.
Ordinary working condition
BACD04APH163ASA 1
(A) Fuel entry flowing from the tank - (B) Fuel exhaust to filter - (1) and (2) By-pass valves in the closed
postion
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Overpressure condition in Exhaust unit
BACD04APH164ASA 2
The by-pass valve (1) is activated in case of overpressure on (B) Exhaust unit. The actual pressure, overcoming the
resistance of the valve’s spring (1), connects the exhaust with the entry through the gallery (2).
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Jettison condition
BACD04APH165ASA 3
The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system
through the priming pump. In this condition the by-pass (1) keeps closed while the dump by-pass valve (2) opens up
due to the pressure effect on the entry unit so the fuel flows to the exhaust unit (B).
NOTE: The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the
high pressure pump.
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Priming pump - Overview

F4CE9484, F4GE9484, F4CE9684, F4GE9684
This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is
assembled to the engine block and driven by the camshaft.
PRIMINGPUMPCG 1
(1) Fuel output to the filter - (2) Drive lever - (3) Fuel inlet from the tank
PRIMINGPUMPCG2 2
(1) Priming pump - (2) Drive lever - (3) Camshaft
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Sensing system Air temperature-pressure sensor - Overview

F4HE9484, F4HE9684
AIRPRESSTEMP 1
This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make
an accurate calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 25C - 36C for temperature and 33C - 34C for pressure.
The power supply is 5 volts.
Voltage at the sensor output is proportional to the detected pressure or temperature.
Reference Description ECU pin

1 Ground 25C
2 NTC signal (temperature) 36C
3 +5 V power input 33C
4 Signal (pressure) 34C
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Sensing system Pressure sensor - Overview

F4HE9484, F4HE9684
FUELPRESS 1
Mounted on the end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the
value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the
duration of the electrical injection command.
The sensor is connected to the control unit on pins 12C - 14C - 13C.
The power supply is 5 Volt.

1 Ground 12C
2 Signal 14C
3 Power supply 13C
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Sensing system Temperature sensor - Overview

F4HE9484, F4HE9684
FUELTEMPH 1
(1) Fuel Temperature Sensor - (2) Filter heating resistamce
Fuel Temperature Sensor

This sensor is identical to the coolant temp sensor.
This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of
the fuel.
The fuel temperature sensor is connected to the control unit on pins 35C - 18C.
The sensor impedance at 20 °C (68 °F) is approximately 2.50 Ω.

1 Ground 35C
2 Temperature signal 18C
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Sensing system Air temperature-pressure sensor - Overview

F4DE9484, F4DE9684, F4DE9687
AIRPRESSTEMP 1
This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make
an accurate calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 21C - 29C for temperature and 10C - 28C for pressure.
The power supply is 5 volts.
Voltage at the sensor output is proportional to the detected pressure or temperature.

1 Ground 21C
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Sensing system Pressure sensor - Overview

F4DE9484, F4DE9684, F4DE9687
FUELPRESS 1
Mounted on tone end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the
value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the
duration of the electrical injection command.
The sensor is connected to the control unit on pins 20C - 27C - 12C.
The power supply is 5 Volt.

1 Ground 20C
2 Signal 27C
3 Power supply 12C
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F4DE9484, F4DE9684, F4DE9687
Fuel Temperature Sensor
FUELTEMPD 1
(1) Fuel Temperature Sensor
This sensor has a variable resistor able to detect the fuel temperature to provide the engine control module an index
of the fuel thermal status.
It is connected to the control module by pin 17C (Earth) and 34C (temperature signal).
The resistor to 20 °C (68 °F) = 2.5 k Ω.
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Sensing system Water sensor - Overview

F4CE9484, F4CE9684
FUELHEATERC 1
(1) Heater - (2) Water detecting sensor.
On the bottom of the fuel filter cartridge, there is a sensor (2) that detects the presence of water in the system. For
the applications in cold climate conditions, a heater (1) may be interposed between the filter base and the filtering
cartridge.
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Fuel injection pump Rotary injection pump - Remove

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Fuel line High pressure - Disconnect (B.20.A)
1. Remove the gear (1) transmitting motion to the injec-

tion pump.
2. Remove the adjustable gear that lies behind the pri-
mary drive gear.
TIMINGGEARCG 1
Next operation:
Fuel injection pump Rotary injection pump - Install (B.20.A)
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Fuel injection pump Rotary injection pump - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Fuel injection pump Rotary injection pump - Remove (B.20.A)
1. Install the adjustable gear that lies behind the primary

drive gear.
2. Install the gear (1) transmitting motion to the injection
pump.
TIMINGGEARCG 1
Next operation:
Fuel line High pressure - Connect (B.20.A)
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Fuel injection pump Rotary injection pump - Disassemble

F4GE9484, F4GE9684
Prior operation:
NOTE: This procedure assumes that all the fuel pipes have been removed, the electrical connections have been
disconnected, and the accelerator cable shall also be disconnected.
1. Remove the starter from the flywheel housing (1) and
use tools 380000988 (2) and 380000732 (3) to rotate
the flywheel.
FLYWHEELROTATEG 1
NOTE: In the case of pump replacement, the spare part shall be supplied preset. If the pump is to be disassembled
and reassembled later on without being repaired, it will be necessary to preset the pump while it is still assembled to
the engine and disassembled afterwards.
Finding TDC with the false injector

2. Remove the rocker cover of the first cylinder.
3. Remove the injector and place the tool (1) to set the
number one cylinder to the TDC (top dead center)
position at the end of the compression phase. Pre-
load the gauge.
4. This condition is obtained by rotating the engine shaft
properly until you find the maximum value on the
gauge and then checking that the intake and exhaust
valves are both closed.
5. Once TDC is obtained, lock the flywheel by means
of tool 380000988.
TDCTOOLING 2
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Finding TDC with the timing gear blocking pin

6. Install the pin (1) in the housing on the rear cover.
7. Turn the flywheel while pushing on the pin (1) until it
blocks the gear (2) obtaining TDC of the number one
cylinder.
8. Check that the piston is in the compression phase by
making sure the intake and exhaust valves are both
closed.
TDCTOOLING2 3
9. Loosen the side screw (1) that is used to lock the

pump shaft and remove the spacer (2). The spacer
must be kept. It is recommended to fix it to the pump
with a wire or a clip.
10. Tighten the screw (1) blocking rotation of the pump
shaft.
LOCKINGSCREW 4
11. Remove the screws (1) that secure the plate (2) cov-
ering the pump drive gear.
12. Loosen the nut (3) securing the gear to the pump
shaft and remove the relating washer.
PUMPGEAR 5
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13. From the pump side, loosen the nuts (1) without re-
moving them in order to move the pump backwards
using the injection pump gear extractor.
14. Assemble the extractor throughout the two threaded
ports (2) and withdraw the gear from the pump shaft.
15. Properly hold the pump and remove the nuts com-
pletely.
16. Withdraw the pump from its mounting studs, together
with the gasket.
NOTE: Hold the pump drive gear to avoid interference or
crawling during timing gear rotation.
FEEDPUMP 6
ATTENTION: When the pump is to be installed, the engine must be at TDC of the compression phase on cylinder
number one.
Next operation:
Fuel injection pump Rotary injection pump - Assemble (B.20.A)
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Fuel injection pump Rotary injection pump - Assemble

F4GE9484, F4GE9684
Prior operation:
Fuel injection pump Rotary injection pump - Disassemble (B.20.A)
1. Assemble the pump in its housing on the engine,

while fitting the gear onto the pump shaft.
2. Tighten the nuts (1) securing the pump to the engine.
NOTE: The gasket removed during disassembly shall not
be utilized again. Always use original spare parts.
FEEDPUMP2 1
3. On the timing side, fit the washer and the fixing nut
(3) on the pump shaft.
4. Torque the nut to 90 - 95 Nm (66.4 - 70.1 lb ft).
5. Install the plate (2) with new gasket and tighten
screws (1).
PUMPGEAR 2
6. Loosen the screw (1) that prevents pump shaft rota-

tion and insert spacer (2). By doing this the pump
shaft will be able to rotate freely.
7. Disassemble the flywheel rotation/locking tool
380000988 and install the starter motor.
8. Connect all pipelines in the fuel system.
9. Connect the electrical connections to electro-mag-
nets on the hydraulic head and on the KSB.
NOTE: If the engine is installed in the application, connect
the accelerator cable.
LOCKINGSCREW 3
Next operation:
Fuel injection pump Rotary injection pump - Timing adjust (B.20.A)
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Fuel injection pump Rotary injection pump - Timing adjust

F4GE9484, F4GE9684
Prior operation:
1. With the injection pump mounted on the engine

and the mounting nuts loose, install the dial gauge
adapter for pump timing 380001601 (1) and the dial
gauge 380000228 (2). Preload the rod by 2.5 mm
(0.098 in).
2. Rotate the engine crankshaft to obtain cylinder num-
ber one TDC at the end of the compression phase.
Reset the dial gauges and rotate the engine crank-
shaft in the opposite direction until obtaining cylin-
der number one TDC at the end of the compression
phase again.
3. From this position it is necessary to compare the
value to the pumping element pre-lift specifications
below.
• 4 Cylinder Engines = 0.73 - 0.77 mm (0.029 -
0.030 in). PUMPTIMING 1

0.030 in).
Next operation:
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Fuel injection pump Rotary injection pump - Disassemble

F4CE9484, F4CE9684
Prior operation:
NOTE: This procedure assumes that all the fuel pipes have been removed, the electrical connections have been
disconnected, and the accelerator cable shall also be disconnected.
1. Loosen the screws (1) and remove the starter (2).
STARTERC 1
2. Fit the bracket of the tool 380000988 (1) holding the

flywheel provided with the rotation coil (2).
3. Carefully rotate the flywheel in the direction of normal
rotation to remove the slack in the gear.
4. Rotate the flywheel until the pin (4) provide with the
tool 380000988 engages in the notch of the flywheel
(3).
FLYWHEELROTATEC 2
Finding TDC with the false injector

5. Remove the rocker cover of the first cylinder.
6. Remove the injector and place the tool (1) to set the
number one cylinder to the TDC (top dead center)
position at the end of the compression phase. Pre-
load the gauge.
7. This condition is obtained by rotating the engine shaft
properly until you find the maximum value on the
gauge and then checking that the intake and exhaust
valves are both closed.
8. Once TDC is obtained, lock the flywheel by means
of tool 380000988.
TDCTOOLING 3
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9. Disconnect the fuel pipes from the priming pump (1).

10. Loosen the fastening screws (2) and remove the
pump (1).
PRIMINGPUMPCG3 4
11. Check through priming pump hole in the block, that

camshaft (1) is in TDC at the compression phase
by the visible notches (2) on the camshaft. If the
notches are not visible, unlock the flywheel and ro-
tate the engine 360 ° until the notches are visible.
Lock the flywheel.
CAMNOTCH 5
12. Loosen the screw (2), remove the "L" spacer (1) and
tighten the screw (2) to keep the pump timed with
the engine flywheel. The spacer must be kept. It is
recommended to fix it to the pump with a wire or a
clip.
PUMPLOCK 6
13. Remove the screws (1) that secure the plate (2) cov-
ering the pump drive gear.
14. Loosen the nut (3) securing the gear to the pump
shaft and remove the relating washer.
PUMPGEAR 7
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15. Remove the three nuts (2), (3), and (5) fastening the
pump (1) to the housing (4) and withdraw it from the
housing.
FEEDPUMP3 8
Next operation:
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Fuel injection pump Rotary injection pump - Assemble

F4CE9484, F4CE9684
Prior operation:
Fuel injection pump Rotary injection pump - Disassemble (B.20.A)
1. At the time of assembling the feed pump to the en-

gine it is necessary to ensure that the number one
cylinder is at TDC of the compression phase.
2. Install the pump unit (1), preset, into the gearbox
housing (2).
3. Install the mounting nuts (3) without tightening them.
NOTE: The gasket removed during disassembly shall not
be utilized again. Always use original spare parts.
FEEDPUMP4 1
4. On the timing side, fit the washer and the fixing nut
(3) on the pump shaft.
5. Torque the nut to 90 - 95 Nm (66.4 - 70.1 lb ft).
6. Install the plate (2) with new gasket and tighten
screws (1).
PUMPGEAR 2
7. Loosen the screw (1) that prevents pump shaft rota-

tion and insert spacer (2).
8. Tighten the screw (1) so that it locks the spacer (2)
in place. By doing this, the pump shaft will be able to
rotate freely.
9. Remove the flywheel rotation locking tool 380000988
and install the starter.
LOCKINGSCREW2 3
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10. Assemble the priming pump (1) to the engine block

and tighten the fastening screws (2) to the specified
torque.
11. Connect all pipelines in the fuel system.
12. Connect the electrical connections to electro-mag-
nets on the hydraulic head and on the KSB.
NOTE: If the engine is installed in the application, connect
the accelerator cable.
PRIMINGPUMPCG3 4
Next operation:
Fuel injection pump Rotary injection pump - Timing adjust (B.20.A)
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Fuel injection pump Rotary injection pump - Timing adjust

F4CE9484, F4CE9684
Prior operation:
1. With the injection pump mounted on the engine

and the mounting nuts loose, install the dial gauge
adapter for pump timing 380001601 (1) and the dial
gauge 380000228 (2). Preload the rod by 2.5 mm
(0.098 in).
2. Rotate the engine crankshaft to obtain cylinder num-
ber one TDC at the end of the compression phase.
Reset the dial gauges and rotate the engine crank-
shaft in the opposite direction until obtaining cylin-
der number one TDC at the end of the compression
phase again.
3. From this position it is necessary to compare the
value to the pumping element pre-lift specifications
below.
0.030 in). PUMPTIMING 1

0.030 in).
Next operation:
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Fuel filter system - Remove

Prior operation:
1. Using the tool disassemble the fuel filter (1) and re-
move it from the support (5).
2. Disconnect the electrical connections (2) from the
support (5) including the one for the fuel heater.
3. Disconnect the fuel low pressure pipelines (3) from
the support (5).
4. Disconnect pipeline (4) from the support (5).
5. Remove the sustaining support bracket (5) from the
block.
4442596398GHDC 1
Next operation:
Fuel filter system - Install (B.20.A)
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Fuel filter system Fuel filter - Install

1. Install the bracket and the base of the fuel filter.
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Fuel filter system - Install

Prior operation:
Fuel filter system - Remove (B.20.A)
1. Assemble the bracket and support (1) of the fuel filter

(6).
2. Proceed connecting in sequence the pipelines (9) (3)
(4) (5) of the support (1) to the high pressure pump
(8).
3. Connect the pipeline (7) from the high pressure pump
to the common rail.
NOTE: Refer to Fuel connector - Connect (B.20.A) for
the proper operation of the clamps on the low pressure fuel
lines.
FUELSYSTEMD 1
Next operation:
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Fuel injector Fuel Manifold - Remove

Prior operation:
NOTICE: Make sure the area around the fuel manifold is clean. Once they are removed, there is a greater risk of
contaminating the internal components.
1. Remove the nuts and remove the fuel manifolds.
NOTE: Disassembled fuel manifolds must not be used
again. Replace them with new ones during reassembly.
FUELMANIFOLD 1
Next operation:
Fuel injector Fuel Manifold - Install (B.20.A)
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Fuel injector Fuel Manifold - Install

Prior operation:
Fuel injector Fuel Manifold - Remove (B.20.A)
1. Fit a sealing ring (3) lubricated with petroleum jelly

on the fuel manifold (2).
2. Install the fuel manifold (2) into the cylinder head so
that the positioning ball (5) is coinciding with the rel-
evant housing (4).
NOTE: After removing fuel manifolds they cannot be used
again. Replace them with new ones.
3. Screw the fastening nuts on without tightening them.
NOTE: During this operation, the injector (1) can be moved
so that the manifold (2)can be properly inserted into the
inlet hole.
FUELMANIFOLDDH 1
4. After everything is in place, tighten the fuel manifold

nuts (2) to 50 Nm (37 lb ft).
NOTICE: Be sure to tighten the screws (1) securing the in-
jector to the specified torque. Refer to Fuel injector Elec-
tro injector - Install (B.20.A) for the proper procedure.
INJMANIFOLDDH 2
Next operation:
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Fuel injector Electro injector - Remove

Prior operation:
Fuel injector Fuel Manifold - Remove (B.20.A)
1. Remove the bolts securing the injector to the cylinder

head.
2. Use tool 380001099 (1) to remove the injectors (2)
from the cylinder head.
INJECTORREMOVE 1
Next operation:
Fuel injector Electro injector - Install (B.20.A)
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Fuel injector Electro injector - Install

Prior operation:
Fuel injector Electro injector - Remove (B.20.A)
1. Put a new O-ring (2) and sealing washer (3) on the

injector (1).
2. Lubricate the O-ring (2) with petroleum jelly.
ELECTROINJECTOR 1
3. Install the injectors (1) into the cylinder head directed

so the fuel inlet hole (2) is facing the fuel manifold
seat (3).
EINJECTORDH2 2
4. Use tool 380001099 (3) to seat the injector (1) in

place.
EINJECTORDH3 3
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5. Insert the bolts (2) securing the injector (1) without

tightening them.
NOTICE: You must install the fuel manifold before tighten-
ing the bolts securing the electro-injector. Refer to Fuel
injector Fuel Manifold - Install (B.20.A).
EINJECTORDH4 4
6. Use a torque wrench to tighten the injector screws

(1) gradually and alternately to a torque of 7.7 - 9.3
Nm (68 - 82 lb in).
NOTICE: Be sure to torque the nut (2) securing the fuel
manifold (3) after torquing the injector. Refer to Fuel in-
jector Fuel Manifold - Install (B.20.A) for the proper pro-
cedure.
INJMANIFOLDDH 5
Next operation:
Fuel injector Fuel Manifold - Install (B.20.A)
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Fuel injector Mechanical injector - Remove

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Loosen the retaining nut (2) on the mechanical injec-

tor.
2. Remove the injector and seal (1) from its seat in the
cylinder head.
INJECTOR3 1
Next operation:
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Fuel injector Mechanical injector - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Install the injectors after having replaced the sealing

gasket (1).
2. Verify that the positioning ball is correctly aligned in
the head housing.
MECHINJECTORCG 1
Next operation:
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High pressure common rail Pump head and housing - Remove

Prior operation:
Prior operation:
1. Disconnect all fuel lines (4) on the high pressure

pump (2).
2. Remove the mounting nuts (1) and remove the high
pressure pump (2) and feed pump (3) together as
one unit.
HPPUMPDH 1
Next operation:
High pressure common rail Pump head and housing - Install (B.20.A)
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High pressure common rail Pump head and housing - Install

Prior operation:
High pressure common rail Pump head and housing - Remove (B.20.A)
Prior operation:
1. Slide the high pressure pump (4) including the feed

pump (3) into place on the rear cover.
2. Install the nuts (1) securing the pump to the rear
cover and tighten to the specified torque.
3. Hook up all fuel lines (4).
HPPUMPDH 1
Next operation:
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High pressure common rail Common rail - Install

Prior operation:
1. Install the high pressure fuel rail (2) on the cylinder

head.
2. Tighten the mounting screws (1) to the specified
torque.
3. Connect new fuel pipes (6) to the rail (2) and to the
manifold for electro-injectors (5).
4. Tighten the pipe joints (3) to 20 Nm (14.8 lb ft).
5. Install the low pressure fuel line (4) to the rail (2).
Refer to Fuel connector - Connect (B.20.A) for the
proper procedure.
RAIL 1
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Priming pump - Remove

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Loosen the two fixing screws (2) and disassemble

the priming pump (1).
PRIMINGPUMPCG3 1
Next operation:
Priming pump - Install (B.20.A)
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Priming pump - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Priming pump - Remove (B.20.A)
1. Assemble the priming pump (1) with a new gasket

and tighten the screws (2) to the prescribed torque.
PRIMINGPUMPCG3 1
Next operation:
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Fuel line High pressure - Connect

1. Connect new fuel pipes (1) between high pressure

rail (3) and fuel manifolds (2).
HPFUELCONNECT 1
2. Pipe connection (1) should be torqued to 20 Nm (15

lb ft) using the proper wrench (4) and torque wrench
(3).
Connections should be tighten by holding the flow
limiting valve hexagon with the proper wrench.
HPFUELTORQUE 2
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Fuel line Low pressure - Connect

F4HE9484, F4HE9684
1. Connect the pipeline to the pressure limiter.

2. Connect all the fuel lines between the fuel filter base
and the high pressure pump.
3. Connect the pipeline from the high pressure pump to
the engine control module cooling plate.
4. Connect the pipeline from the high pressure pump to
high pressure common rail.
LPFUELCONNECT 1
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Fuel line High pressure - Disconnect

F4DE9484, F4DE9684, F4DE9687
1. Disconnect from the rail (1) the fuel pipe (3). Re-
fer to Fuel connector - Disconnect Low Pressure
(B.20.A). Disconnect the fuel pipes (5) from the rail
(1) and injector manifolds (4).
2. Remove the screws (2) and disconnect the rail (1).
COMMONRAILF4DE 1
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F4HE9484, F4HE9684
1. Disconnect the fuel pipe (4) from the cylinder head

Fuel connector - Disconnect Low Pressure
(B.20.A). Disconnect the fuel pipes (5) from the rail
(2) and injector manifolds (6).
NOTICE: When releasing pipe (5) connections (6) to rail
(2), use the proper wrench to avoid rotation of flow limiters
(3).
2. Remove the screws (1) and disconnect the rail (2).
COMMONRAILF4HE 1
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Fuel line Low pressure - Disconnect

1. Disconnect the fuel return pressure limiter (1). Refer

to Fuel connector - Disconnect (B.20.A).
RETURNLINEF4DEF 1
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F4GE9484, F4GE9684
1. Place a container under the fuel filter and screw out

the condense drain faucet (5) underneath the filter.
Carry out complete drainage of the fuel contained in
the filter.
2. Remove the drain faucet (5) completely and by using
the tool 380000670, remove the filter cartridge (2).
3. Disconnect the fuel pipelines (4) and (3) respectively
from priming pump to filter bearing and from the filter
bearing to the feed pump. Refer to Fuel connec-
tor - Disconnect (B.20.A) for proper removal proce-
dures.
4. Remove the fuel filter base (1) from the engine cylin-
der head.
LPFUELLINEG 1
5. Disconnect the LDA pipe (1) from the engine cylinder

head and from the feed pump.
6. Plug the ends of the pipelines as well as the feed
pump and the cylinder head.
LPFUELLINEG2 2
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F4CE9484, F4CE9684
1. Place a container under the fuel filter (1) and screw

out the condense faucet underneath the filter (1).
Carry out complete drainage of the filter.
2. Screw out completely the faucet and use tool
380000670 to remove the filter cartridge (1).
3. Disconnect fuel pipelines (2) and (3) respectively
from the priming pump to the fuel filter base and
from the fuel filter base to the feed pump. Refer to
Fuel connector - Disconnect (B.20.A) for proper
removal procedures.
4. Remove the filter base (4) from the engine cylinder
head.
LPFUELLINEC 1
5. Disconnect the LDA pipe (1) from the head and from
the feed pump.
6. Plug the ends of the pipelines as well as the feed
pump and the engine cylinder head.
LPFUELLINEC2 2
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F4CE9484, F4GE9484, F4CE9684, F4GE9684
1. Disconnect the pipelines that provide feed (1) and

fuel recovery (2) between pump and injectors.
2. Screw out the nuts fixing the pipes to the pumping
elements.
3. Loosen the fuel recovery pipe (2) collar on the injec-
tion pump (3).
4. Operate on the nuts assembled to the injectors and
loosen the screws fixing the fuel recovery pipeline.
5. Loosen the screws holding the mounting brackets
pipelines (1), (6) and (7).
6. After removal, plug the ends of the lines to reduce
the risk of dirt contamination.
HPFUELLINEG 1
HPFUELOVERVIEW 2
(1) Rear bracket fixing screw (on suction selector plate) - (2) Fuel recovery pipeline to pump - (3) Rotary
feed pump - (4) Connection nut to pumping elements - (5) Injector - (6) Bracket fixing screw to injection
pump side - (7) Front bracket fixing screw (on suction collector plate).
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Fuel line High pressure - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
1. Assemble the fastening brackets of the fuel pipes.

2. Assemble the pipes (1) and (2) providing fuel feed
and recovery between the pump and the injectors.
3. Tighten the locknuts and tighten the screws fixing the
fuel recovery manifold.
4. Assemble the pipes to the injectors and to the brack-
ets securing them.
HPFUELLINEG 1
HPFUELOVERVIEW 2
(1) Rear bracket fixing screw (on suction selector plate) - (2) Fuel recovery pipeline to pump - (3) Rotary
feed pump - (4) Connection nut to pumping elements - (5) Injector - (6) Bracket fixing screw to injection
pump side - (7) Front bracket fixing screw (on suction collector plate).
84250518 09/11/2009
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Fuel line Low pressure - Install

F4CE9484, F4CE9684
1. Assemble the fuel filter support (4) to the engine

cylinder head.
2. Connect the fuel pipelines (2) and (3) respectively
from priming pump to filter support, and from the sup-
port to the feed pump.
3. Install the fuel filter (1) using tool 380000670.
NOTE: The filter should be filled with fuel prior to assembly.
This will help facilitate fuel system bleeding.
4. Connect the electrical connections for the water
presence sensor and the fuel heater (If applicable).
LPFUELLINEC 1
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Fuel line Low pressure - Install

F4GE9484, F4GE9684
1. Assemble the fuel filter support (1) to the engine

cylinder head.
2. Connect the fuel pipelines (4) and (3) respectively
from the priming pump to the filter support and from
the support to the fuel feed pump.
3. Install the fuel filter (2) using tool 380000670.
LPFUELLINEG3 1
84250518 09/11/2009
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Fuel line Low pressure - Bleed

F4CE9484, F4GE9484, F4CE9684, F4GE9684
1. Disconnect the fuel pipe (1) of the filter and repeat

working on the drain lever (2) of the priming pump.
2. Continue the operation until fuel flows out.
3. Connect the (1) to the filter.
FUELBLEED 1
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Fuel connector - Disconnect Low Pressure

1. Hold down the clasp (1) and release the quick fitting
joint.
80628 1
Next operation:
Fuel connector - Connect (B.20.A)
84250518 09/11/2009
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Fuel connector - Connect Low Pressure

Prior operation:
Fuel connector - Disconnect (B.20.A)
1. Connect low pressure lines to the fuel rail by insert-

ing the rapid fitting joint into the connection joint and
press until the clip (1) fastens securely.
2. Check proper fuel connection.
80628 1
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Sensing system Air temperature-pressure sensor - Remove

1. Disconnect the wiring harness from the sensor.

2. Remove the retaining bolt.
3. Remove the sensor and O-ring.
84250518 09/11/2009
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Index

FUEL AND INJECTION SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4GE9484, F4CE9684, F4GE9684
FUEL AND INJECTION SYSTEM - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel connector - Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fuel connector - Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel filter system Fuel filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuel filter system Water separator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel injection pump Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
F4GE9484, F4GE9684
Fuel injection pump Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
F4CE9484, F4CE9684
Fuel injection pump Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
F4GE9484, F4GE9684
Fuel injection pump Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
F4CE9484, F4CE9684
Fuel injection pump Rotary injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel injection pump Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9484, F4GE9684
Fuel injection pump Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4CE9484, F4CE9684
Fuel injection pump Rotary injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel injection pump Rotary injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel injection pump Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
F4GE9484, F4GE9684
Fuel injection pump Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
F4CE9484, F4CE9684
Fuel injector Electro injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fuel injector Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4HE9484, F4HE9684
Fuel injector Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4DE9484, F4DE9684, F4DE9687
Fuel injector Electro injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel injector Fuel Manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fuel injector Fuel Manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuel injector Mechanical injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel injector Mechanical injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel line High pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fuel line High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
F4DE9484, F4DE9684, F4DE9687
84250518 09/11/2009
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F4HE9484, F4HE9684
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel line High pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel line Low pressure - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fuel line Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
F4HE9484, F4HE9684
Fuel line Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
F4GE9484, F4GE9684
F4CE9484, F4CE9684
Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
F4CE9484, F4CE9684
Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
F4GE9484, F4GE9684
Fuel transfer pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
High pressure common rail - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F4HE9484, F4HE9684
High pressure common rail - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F4DE9484, F4DE9684, F4DE9687
High pressure common rail - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
High pressure common rail Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
High pressure common rail Pump head and housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
High pressure common rail Pump head and housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
High pressure common rail Pump head and housing - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Priming pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Regulator valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F4HE9484, F4HE9684
Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
F4DE9484, F4DE9684, F4DE9687
Sensing system Air temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Sensing system Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F4HE9484, F4HE9684
Sensing system Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
F4DE9484, F4DE9684, F4DE9687
Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F4HE9484, F4HE9684
Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
F4DE9484, F4DE9684, F4DE9687
Sensing system Water sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
F4CE9484, F4CE9684
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AIR INTAKE SYSTEM - 30.A

F4GE9684 , F4HE9484 , F4HE9684
84250518 09/11/2009
B.30.A / 1
Contents
FUNCTIONAL DATA
AIR INTAKE SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Turbocharger
Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4HE9484, F4HE9684
Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4DE9484, F4DE9684, F4DE9687
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Air intake manifold

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4HE9484, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4HE9484, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4DE9484, F4DE9684, F4DE9687
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4DE9484, F4DE9684, F4DE9687
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4CE9484, F4GE9484, F4CE9684, F4GE9684
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POWER PRODUCTION - AIR INTAKE SYSTEM
AIR INTAKE SYSTEM - Overview

The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost
feeding pressure, one main body and one compressor.
During engine working process, the exhaust emissions flow through the body of the turbine, causing the turbine disk
wheel’s rotation.
The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air is then cooled by the radiator and flown through the piston collector.
The turbocharger is equipped with a transforming valve to regulate the pressure. It is located on the exhaust collector
before the turbine and connected by piping to the induction collector. It’s function is to restrict the exhaust of the
emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor,
reaches the prescribed pressure.
The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
BOOSTDIAGRAM 1
6 cylinder version
BOOSTDIAGRAM2 2
4 cylinder version
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Turbocharger Turbine - Remove

F4HE9484, F4HE9684
1. Remove the turbo oil supply line (3) from the oil filter
base and from the pipe fitting (4) to the turbine.
2. Remove the nuts securing the turbocharger (1) to the
exhaust manifold (2)and remove it from its seat.
TURBOF4HE 1
Next operation:
Turbocharger Turbine - Install (B.30.A)
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Turbocharger Turbine - Install

Prior operation:
Turbocharger Turbine - Remove (B.30.A)
1. With a suitable sling, place the turbocharger (1) on

the exhaust manifold (2) with a new gasket.
torque.
TURBOF4DE 1
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Turbocharger - Remove
F4DE9484, F4DE9684, F4DE9687
1. Unscrew the fixing nuts (3) of the turbocharger (1) on

the exhaust manifold (2).
TURBOF4DE 1
Next operation:
Turbocharger - Install (B.30.A)
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Turbocharger - Remove
F4CE9484, F4GE9484, F4CE9684, F4GE9684
1. Loosen the fixing nut (1) and remove the oil supply
line from the turbocharger.
2. Loosen the fixing nut on the other end of the supply
line to remove it from the the upper part of the heat
exchanger.
3. Remove the four mounting bolts (2) securing the
turbo to the exhaust manifold.
4. Lift the turbo from it’s seat and remove the mounting
gasket.
TURBOCG 1
Next operation:
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Turbocharger - Install
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Turbocharger - Remove (B.30.A)
1. Install a new gasket for the turbocharger.

2. Hold the turbocharger and place it on the exhaust
manifold.
3. Install the nuts and bolts (2) securing the turbo to the
manifold and tighten them to the prescribed torque.
4. Install the oil supply line (1) the to turbo. Tighten the
opposite end of the line on the upper part of the oil
filter support.
TURBOCG 1
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Air intake manifold - Remove

F4HE9484, F4HE9684
1. Loosen the retaining bolts (2) of the intake manifold

(1) and disassemble the intake air heater (3) for the
cold start aid.
INTAKEF4HE 1
Next operation:
Air intake manifold - Install (B.30.A)
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Air intake manifold - Install

F4HE9484, F4HE9684
Prior operation:
Air intake manifold - Remove (B.30.A)
1. Apply LOCTITE 5999to the mounting surface of the

air intake heater (3) on the intake manifold (1).
2. Install the heater (3) and tighten bolts.
3. Assemble the manifold and fasten it to the cylinder
head using screws (2).
INTAKEF4HE 1
84250518 09/11/2009
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F4DE9484, F4DE9684, F4DE9687
1. Loosen the fixing screws (2) of the intake manifold

(1) and disassemble the joint to the air heater for the
cold start.
INTAKEF4DE 1
Next operation:
84250518 09/11/2009
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F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Apply to the coupling surface of the intake manifold

(1) equipped with heater a sufficient coat of LOCTITE
5999.
2. Tighten the screws (2) to the prescribed torque.
INTAKEF4DE 1
84250518 09/11/2009
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F4CE9484, F4GE9484, F4CE9684, F4GE9684
1. Loosen the screws (1) fixing the suction manifold

plate (2) to the cylinder head.
2. Remove the plate (2) and the relative gasket from the
cylinder head.
AIRINTAKECG 1
Next operation:
84250518 09/11/2009
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F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Apply a new gasket to the assembly surface of the

intake manifold (2) plate and tighten the screws (1)
to the prescribed torque.
2. If the duct from the intake manifold has been disas-
sembled, reassemble it after fitting the gaskets and
heater (if applicable).
AIRINTAKECG 1
84250518 09/11/2009
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Index

Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4HE9484, F4HE9684
Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4DE9484, F4DE9684, F4DE9687
Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4CE9484, F4GE9484, F4CE9684, F4GE9684
AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4DE9484, F4DE9684, F4DE9687
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Turbocharger Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Turbocharger Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4HE9484, F4HE9684
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EXHAUST SYSTEM - 40.A

F4GE9684 , F4HE9484 , F4HE9684
84250518 09/11/2009
B.40.A / 1
Contents
FUNCTIONAL DATA
EXHAUST SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4GE9484, F4CE9684, F4GE9684
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POWER PRODUCTION - EXHAUST SYSTEM
EXHAUST SYSTEM - Overview

Exhaust Gas Re-Circulation System (EGR)
In the Tier 3 version, the profile of the exhaust cam has been modified in order to allow partial opening of the relative
valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of
the exhaust gas into the engine cylinders.
The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion tempera-
ture values responsible for the production of nitrogen oxides (NOx).
The exhaust gas recirculation system (EGR), reducing the combustion temperature by means of the diminishing of the
concentration of oxygen in the combustion chamber, represents therefore an efficient control system of the emission
of NOx.
The internal EGR system is not equipped with any electronically controlled elements: the system is always active. It’
configuration does not need additional elements. (i.e. checking valves, piping or heat exchangers.)
The exhaust cam (B) has another lobe apart from the major lobe (A-A) with respects to the configuration without EGR.
The additional lobe, during the aspiration phase in the cylinder in question, allows a brief opening of the exhaust
valve generating re-circulation due to the intake of the exhaust gases caused by depression which is created in the
aspiration phase inside the cylinder.
BAIL07APH368GMA 1
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Exhaust manifold - Remove

Prior operation:
Turbocharger Turbine - Remove (B.30.A)
1. Loosen the bolts (1) and remove the exhaust mani-

fold (2) from the cylinder head.
BAIL06CCM055ASA 1
Next operation:
Exhaust manifold - Install (B.40.A)
84250518 09/11/2009
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Exhaust manifold - Install

Prior operation:
Exhaust manifold - Remove (B.40.A)
1. Connect the exhaust manifold (2) with new gasket.

Tighten the mounting bolts (1) to the specified torque.
EXHAUSTMANIFOLD 1
Next operation:
Turbocharger Turbine - Install (B.30.A)
84250518 09/11/2009
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Exhaust manifold - Remove

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Turbocharger - Remove (B.30.A)
1. Loosen the fixing screws (2) from the exhaust man-

ifold (1).
2. Remove the exhaust manifold (1) and the relative
gaskets from the cylinder head.
EXHAUSTCG 1
Next operation:
Exhaust manifold - Install (B.40.A)
84250518 09/11/2009
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Exhaust manifold - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Exhaust manifold - Remove (B.40.A)
1. Assemble the exhaust manifold (1) with new gaskets

(2) to the cylinder head.
NOTE: The illustration of the exhaust manifold may not
match your model. However, the described procedure is
applicable.
EXHAUSTCG2 1
Next operation:
84250518 09/11/2009
B.40.A / 7
Index

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4CE9484, F4GE9484, F4CE9684, F4GE9684
EXHAUST SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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ENGINE COOLANT SYSTEM - 50.A

F4GE9684 , F4HE9484 , F4HE9684
84250518 09/11/2009
B.50.A / 1
Contents
FUNCTIONAL DATA
ENGINE COOLANT SYSTEM
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4GE9484, F4GE9684
F4CE9484, F4CE9684
Sensing system
Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4HE9484, F4HE9684
Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

F4DE9484, F4DE9684, F4DE9687
Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

F4CE9484, F4GE9484, F4CE9684, F4GE9684
SERVICE
Thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9484, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4CE9484, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4CE9484, F4CE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Water manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F4DE9484, F4DE9684, F4DE9687
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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fan and drive

Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F4CE9484, F4DE9484, F4HE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684
Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Remove -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Install -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F4GE9484, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F4CE9484, F4CE9684
Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F4CE9484, F4GE9484, F4CE9684, F4GE9684
84250518 09/11/2009
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POWER PRODUCTION - ENGINE COOLANT SYSTEM
ENGINE COOLANT SYSTEM - Dynamic description

F4HE9484, F4HE9684
The engine cooling system, closed circuit forced circulation type, generally incorporates the following components:
• Expansion Tank - Placement, shape and dimension are subject to change according to the engine’s equipment.
• Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid
which is then ran through the radiator. Application determines placement and dimensions.
• Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator.
Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.
• Heat Exchanger - Cools the lubrication oil. Also application specific.
• Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.
• Thermostat - regulates the circulation of the cooling liquid.
• If applicable, the circuit may be extended to the compressor.
ZEIL06EN0105G0B 1
6 cylinder version
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F4DE9484, F4DE9684, F4DE9687
BAIL07CCM266AMA 1
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F4GE9484, F4GE9684
COOLINGSYSTEMG 1
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F4CE9484, F4CE9684
COOLINGSYSTEMC 1
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Sensing system Coolant temperature - Overview

F4HE9484, F4HE9684
COOLANTTEMP 1
This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an
indication of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
The sensor is connected to the control unit on pins 15C - 26C.
The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

1 Ground 15C
84250518 09/11/2009
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F4DE9484, F4DE9684, F4DE9687
COOLANTTEMP 1
This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an
indication of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
The sensor is connected to the control unit on pins 18C - 36C.
The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

1 Ground 18C
84250518 09/11/2009
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F4CE9484, F4GE9484, F4CE9684, F4GE9684
COOLANTTEMPCG 1
The coolant temp sensor is assembled to the engine head close to the thermostat unit and its duty is to detect engine
coolant temperature.
Specifications:
• Range of working temperatures
• Connection side: -40 - +150 °C ( -40 - +302 °F) for less than 10 minutes.
• Bulb side on engine: -40 - +140 °C ( -40 - +284 °F).
• Working tensions: 6 - 28 V.
• Settings:
• 80 °C (176 °F) - 304 - 342 Ω.
• 20 °C (68 °F) - 2262 - 2760 Ω.
• -10 °C (14 °F) - 8244 - 10661 Ω.
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Thermostat - Remove
F4GE9484, F4GE9684
1. Loosen the three screws (1) and disassemble the

thermostat housing (2) together with the bracket (3)
and the thick rubber seal (4).
2. Remove the gasket (6) and the thermostat (5).
3. Assemble the bracket (3) in the original position, fix-
ing it with the screws (1) of the thermostat housing.
86082982 1
Next operation:
Thermostat - Install (B.50.A)
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Thermostat - Install
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
Thermostat - Remove (B.50.A)
1. Assemble the thermostat housing (2) including the

thermostat (5) and gasket (6).
2. Install the thick rubber seal (4) inside the bracket (3)
and the thermostat housing (2).
3. Tighten the screws (1) to the prescribed torque.
NOTE: The bracket (3) may not be available on some ap-
plications. Always replace the gasket with new upon re-
assembly.
86082982 1
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Thermostat - Remove
F4CE9484, F4CE9684
1. Loosen the three screws securing the thermostat

housing (2) to the cylinder head.
2. Remove the housing (2), the thick rubber seal (3), the
thermostat (4) and relevant seal (1) from the cylinder
head.
86082980 1
Next operation:
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F4CE9484, F4CE9684
Prior operation:
1. Install the thermostat (2) with the appropriate seal

(1).
2. Install the housing (2) and the thick rubber seal (3)
using the screws to secure it to the cylinder head.
86082980 1
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Thermostat - Remove
1. Remove the three screws securing the thermostat

housing (1) to the top of the cylinder head.
2. Remove the thermostat (2) and the seal (3) from the
housing (1).
86082981 1
Next operation:
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Prior operation:
1. Install the seal (3) around the flange of the thermostat

(2).
2. Install the thermostat (2) into the housing (1) and
secure the assembly to the cylinder head using the
three mounting screws.
86082981 1
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Water pump - Remove

Prior operation:
1. Remove the retaining bolts and withdrawal the water

pump.
BVE0294A 1
Next operation:
Water pump - Install (B.50.A)
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Water pump - Install

Prior operation:
Water pump - Remove (B.50.A)
1. Apply a new sealing ring (2) on the water pump (1).
BACD04APH220ASA 1
2. Install the water pump (1) into the engine block (2)
using the two mounting bolts (3).
ZEIL06CS0245A0B 2
3. Tighten the water pump (1) mounting bolts (2) to the

specified torque.
BACD04APH070ASA 3
Next operation:
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Water manifold - Remove

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
1. Remove the screws (2) and disconnect the water

manifold (1).
WATERMANIFOLDH 1
Next operation:
Water manifold - Install (B.50.A)
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Water manifold - Install

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
Water manifold - Remove (B.50.A)
1. Position the water manifold/alternator support (1) so

that the pins (3) and (4) are set against the engine
block.
2. Tighten the mounting bolts (2) to the specified torque.
the hole and bolt threads have no evidence of wear or dirt.
WATERMANIFOLDH2 1
Next operation:
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Water manifold - Remove

F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Remove the screws securing the water manifold.

2. Disconnect the water manifold from the block.
WATERMANIFOLDD2 1
Next operation:
Water manifold - Install (B.50.A)
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Water manifold - Install

Prior operation:
Water manifold - Remove (B.50.A)
1. Install the water manifold (1) onto the block.

torque.
WATERMANIFOLDD2 1
Next operation:
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Fan and drive Belt - Remove

1. Release tension on the belt (1) by pulling back on the

belt tensioner (2).
2. Extract the belt (1) from all the pulleys.
BELT 1
Next operation:
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Fan and drive Belt - Install

Prior operation:
1. Turn the belt tensioner and fit the belt on the pulleys.
66070776 1
Belt Configuration
(1) - Crankshaft (3) - Fan (5) - Alternator

(2) - Fixed Idler Pulley (4) - Water Pump (6) - Tensioner
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Fan and drive Belt tensioner - Remove

Prior operation:
1. Remove the bolt from the center of the belt tensioner

and remove the tensioner.
Next operation:
Fan and drive Belt tensioner - Install (B.50.A)
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Fan and drive Belt tensioner - Install

Prior operation:
Fan and drive Belt tensioner - Remove (B.50.A)
1. Install the belt tensioner. Tighten the mounting bolt

to the specified torque.
Next operation:
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Fan and drive Idler pulley - Remove

Prior operation:
1. Remove the retaining bolt from the center of the idler

pulley.
2. Remove the idler pulley.
Next operation:
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Fan and drive Idler pulley - Install

Prior operation:
Fan and drive Idler pulley - Remove (B.50.A)
1. Install the idler pulley and tighten the retaining bolt in

the center to the specified torque.
Next operation:
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Fan and drive - Remove Support - Remove

Prior operation:
1. Loosen the fastening screws (3) and remove the pul-

ley controlling the fan (2).
2. Proceed detaching the support (1).
FANDRIVEC 1
Next operation:
Fan and drive - Install (B.50.A)
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Fan and drive - Install Support - Install

Prior operation:
Fan and drive - Remove (B.50.A)
1. Re-attach the support, tightening the screws to the

prescribed torque.
Next operation:
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Fan and drive Belt - Remove

F4CE9484, F4GE9484, F4CE9684, F4GE9684
1. Loosen the screw (1) and the relevant nut on the

alternator bracket (3).
2. Loosen the screw on the bottom side of the alternator
in order to slide out the POLY-V belt (2).
ALTBELTG 1
Next operation:
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Fan and drive - Remove -Drive Pulley

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Loosen the screws (1) and disassemble the pulley

(2) from the crankshaft.
DRIVEPULLEYCG 1
Next operation:
Fan and drive - Install (B.50.A)
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Fan and drive - Install -Drive Pulley

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Fit the pulley (2) on the crankshaft and tighten the

DRIVEPULLEYCG 1
Next operation:
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Fan and drive - Install

F4GE9484, F4GE9684
Prior operation:
1. Assemble the fan pulley support and tighten the

screws to the prescribed couple.
2. Assemble the alternator tensioning bracket.
3. Mount the fan pulley (3) and secure it to the support
using screws (2).
4. Assemble the idler pulley (1).
5. Fit the new belt onto the pulleys and guide rollers.
NOTE: If the old belt is to be reused, examine it carefully in
order to see if there may be any incisions or evident signs
of yielding.
PULLEYSG 1
Next operation:
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Fan and drive - Install

F4CE9484, F4CE9684
Prior operation:
1. Assemble the support (1) of the fan pulley using

screws (2).
2. Tighten the screws (2) to the prescribe torque.
FANSUPPORTC 1
3. Assemble the fan pulley (2) to the support (1)

throughout the screws (3) tightening them to the
prescribed torque.
4. Assemble the idler pulley (4).
FANSUPPORTC2 2
5. Assemble the support (3) of the automatic tensioner

by fastening the relevant screws.
6. Tighten the fastening screw (1) and assemble the
automatic tensioner (2).
BELTTENSIONERC 3
Next operation:
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Fan and drive Belt - Install

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Prior operation:
1. Assemble the Poli-V belt (4) on the drive pulley, water

pump (5), alternator (1), fan pulley (2) and on the idler
pulley (3).
2. Insert a square drive ratchet into the relative hole on
the belt tensioner.
3. Pull on the tensioner (6) and slide the belt (4) into
place.
NOTE: In case the old belt is to be reused, examine it
carefully first in order to detect any incision or evidence of
stress.
BELTCG 1
84250518 09/11/2009
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Index

ENGINE COOLANT SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4GE9484, F4GE9684
F4CE9484, F4CE9684
Fan and drive - Install -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F4GE9484, F4GE9684
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F4CE9484, F4CE9684
Fan and drive - Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fan and drive - Remove -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fan and drive - Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Fan and drive Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fan and drive Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fan and drive Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4HE9484, F4HE9684
Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4DE9484, F4DE9684, F4DE9687
Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4CE9484, F4GE9484, F4CE9684, F4GE9684
F4CE9484, F4CE9684
Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9484, F4GE9684
F4CE9484, F4CE9684
Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F4DE9484, F4DE9684, F4DE9687
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Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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LUBRICATION SYSTEM - 60.A

F4GE9684 , F4HE9484 , F4HE9684
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Contents
FUNCTIONAL DATA
LUBRICATION SYSTEM
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4HE9484, F4HE9684
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4DE9484, F4DE9684, F4DE9687
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4GE9484, F4GE9684
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4CE9684
Blowby re-circulation system

F4HE9484, F4HE9684
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Sensing system
Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4HE9484, F4HE9684
Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F4DE9484, F4DE9684, F4DE9687
Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F4CE9484, F4GE9484, F4CE9684, F4GE9684
SERVICE
Oil pump
Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4DE9484, F4DE9684, F4DE9687
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil pan
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F4HE9484, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4HE9484, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4DE9484, F4DE9684, F4DE9687
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F4GE9484, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F4GE9484, F4GE9684
Oil filter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F4DE9484, F4DE9684, F4DE9687
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Blowby re-circulation system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F4HE9484, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F4HE9484, F4HE9684
Piston lubrication
Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil cooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil line
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F4HE9484, F4HE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
F4GE9484, F4GE9684
Sensing system
Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
F4HE9484, F4HE9684
Oil temperature-pressure sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

F4DE9484, F4DE9684, F4DE9687
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POWER PRODUCTION - LUBRICATION SYSTEM
LUBRICATION SYSTEM - Exploded view

F4HE9484, F4HE9684
Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the
block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the
crankshaft, camshaft and to the valve drive.
4C0O200406CRIL0 1
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F4DE9484, F4DE9684, F4DE9687
Lubrication by forced circulation is achieved through oil pump, placed in the front part of the basement. From the
pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive. Lubrication involves the heat
exchanger as well, the turbo blower and the eventual compressor for any eventual compressed air system. All these
components may often vary according to the specific duty and will therefore be examined in the specific section.
80733 1
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F4GE9484, F4GE9684
Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the
block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the
crankshaft, camshaft and to the valve drive.
LUBEVIEWG 1
LUBRICATION SYSTEM LAYOUT (4 cylinder engine)
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F4CE9484, F4CE9684
Lubrication by forced circulation is achieved through oil pump, placed in the front part of the basement. From the
pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive. Lubrication involves the heat
exchanger as well, the turbo blower and the eventual compressor for any eventual compressed air system. All these
components may often vary according to the specific duty and will therefore be examined in the specific section.
LUBEVIEWC 1
LUBRICATION SYSTEM LAYOUT (6 cylinder engines)
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Blowby re-circulation system - Dynamic description

F4HE9484, F4HE9684
Version with blow-by filter

The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet
speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual
vapors are removed by piping and filtered by the blow-by filter. In the blow-by filter, part of the vapors condense and
return to the oil sump. The remaining vapors are put back into circulation.
Version without blow-by filter

The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet
speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual
vapors are conveyed, collected and discharged into the open air through a bleeder.
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Blowby re-circulation system - Dynamic description

F4CE9484, F4GE9484, F4CE9684, F4GE9684
On the valve cover (3) there is a valve (1) whose duty is to condense oil vapor inducing the oil to fall back down to
the valve cover because of gravity.
The remaining non-condensed vapors shall be properly conveyed through the breather pipe (2).
BLOWBYSYSTEMCG 1
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Sensing system Oil temperature-pressure sensor - Overview

F4HE9484, F4HE9684
OILPRESSTEMP 1
This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.
The sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 24C - 28C for temperature and 32C- 27C for pressure.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls
the relative device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

1 Ground 24C
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Sensing system Oil temperature-pressure sensor - Overview

F4DE9484, F4DE9684, F4DE9687
OILPRESSTEMP 1
This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.
The sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 19C - 33C for temperature and 9C- 35C for pressure.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls
the relative device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

1 Ground 19C
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Sensing system Oil pressure - Overview

F4CE9484, F4GE9484, F4CE9684, F4GE9684
OILPRESSCG 1
The sensor is located on the engine block on the left hand side.
Specifications:
• Working tensions:
• 12 - 24 V.
• Contact closure upon lower pressure:
• 0.2 bar (2.9 psi).
• Contact opening upon higher pressure:
• 0.9 bar (13.1 psi).
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Oil pump Gear driven - Remove

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
1. Remove the retaining bolts (1) and disconnect the oil

pump (2) from the engine block.
OILPUMPH 1
Next operation:
Oil pump Gear driven - Install (B.60.A)
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Oil pump Gear driven - Install

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
Oil pump Gear driven - Remove (B.60.A)
1. Install the oil pump (1) into the engine block.

2. Tighten the bolts (2) to the specified torque.
OILPUMPH2 1
Next operation:
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Oil pump - Remove

F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Please refer to Front cover - Remove (B.10.A) for

oil pump removal instructions.
Next operation:
Oil pump - Install (B.60.A)
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Oil pump - Install

Prior operation:
Oil pump - Remove (B.60.A)
1. Position the front cover seal (1) on the engine block.
FRONTCOVERD4 1
2. Install the front cover (1) on the block and tighten the
FRONTCOVERD5 2
Next operation:
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Oil pan - Remove

F4HE9484, F4HE9684
1. Remove the bolts (2) surrounding the oil sump (1).

2. Remove the plate (2).
3. Disconnect the oil sump (1) from the engine block.
NOTE: The shape and dimensions of the oil pan and of
the suction tube may vary according to the application of
the engine. However, the procedures described are still
applicable.
OILPANH 1
4. Remove the screws (4) and (1) and disassemble the

oil suction tube (5). Remove the screws (2) and dis-
assemble the stiffening plate (3).
OILPICKUPTUBEH 2
Next operation:
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Oil pan - Install

F4HE9484, F4HE9684
Prior operation:
1. Fit the plate (3), the oil pick up tube (5) and tighten
the fastening screws (1), (2) and (4) to the specified
torque.
OILPICKUPTUBEH 1
2. Set the gasket on the oil sump.

NOTE: The pictures of the instructions relating to the oil
pan and to the suction pipe may not reflect the actual shape
and dimensions of your engine equipment. However, the
procedures described are still applicable.
OILPANH2 2
3. Fit the oil sump (1) on the engine block and apply
the mounting plate (3). Tighten the bolts (2) to the
specified torque.
OILPANH 3
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Oil pan - Remove

1. Remove the screws (2) and disconnect the oil sump

(1).
OILPAND 1
Next operation:
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Oil pan - Install

F4DE9484, F4DE9684, F4DE9687
Prior operation:
1. Install the oil pan (1) on the engine block.

2. Fit the screws (2) and tighten them to the prescribed
torque.
the hole and screw threads have no evidence of wear or
dirt.
OILPAND 1
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Oil pan - Remove

F4GE9484, F4GE9684
1. Turn the engine upside down.

2. Loosen the screws (2) disassemble the plate (3) re-
move the oil pan.
NOTE: The shape and dimensions of the pan and of the
rose pipe may vary according to the engine application.
The relating illustrations provide general guidelines of the
operation to be performed.
OILPANG 1
Version with suction rose type A

3. Loosen the screws (1) and disassemble the oil suc-
tion rose pipe (3).
4. Loosen the screws (2) and remove the stiffening
plate (4).
OILPICKUPTUBEG 2
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Version with suction rose type B

5. Remove the screws (1) and (4) and disassemble the
suction rose (5).
6. Remove the screws (2) and disassemble the stiffen-
ing plate (3).
OILPICKUPTUBEG2 3
Version with additional masses

7. Remove the screws (1) and withdraw the oil pickup
tube.
8. By means of pin (2) lock the dynamic balancer (3) in
the TDC (Top Dead Center) position.
9. Loosen the fixing screws (4) and remove the dynamic
balancer (3).
DYNAMICBALANCER 4
Next operation:
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Oil pan - Install

F4GE9484, F4GE9684
Prior operation:
Version with suction rose A

1. Assemble the plate (1), and the rose pipe (2).
2. Tighten the fixing screws (3) and tighten them to the
prescribed torque.
OILPICKUPTUBEG3 1
Version with suction rose B

3. Assemble the fixing plate (3), the suction rose (5)
and tighten the fixing screws (1), (2), and (4) to the
prescribed torque.
OILPICKUPTUBEG4 2
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Version with additional masses

4. Fit the additional masses (2) and tighten the screws
(3) on the engine block.
5. Remove the lock pin (1) of the additional masses.
6. Refer to Balancer - Install (B.10.A) for proper timing
procedures.
DYNAMICBALANCEG 3
7. Set the gasket (1) on the oil sump (2).

NOTE: The pictures of the instructions relating to the oil
pan and to the suction pipe may not reflect the actual shape
and dimensions of your engine equipment. However, the
procedures described are still applicable.
OILPANH2 4
8. Fit the oil sump (1) on the engine block and apply
the mounting plate (3). Tighten the bolts (2) to the
specified torque.
OILPANG 5
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Oil filter - Remove

1. Use the tool 380000670 to remove the oil filter.
OILFILTERF4HE 1
Next operation:
Oil filter - Install (B.60.A)
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Oil filter - Install

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
Oil filter - Remove (B.60.A)
1. Lubricate the oil filter O-ring (2) with clean engine oil.
2. Screw the filter (3) onto the base (1) until contact is
made with sealing surface.
3. Tighten the oil filter an additional 3/4 of a turn.
4. Apply a new sealing ring on the oil temperature/pres-
sure sensor (4).
5. Install the sensor (4) onto the filter base (1) and
tighten the screws (5) to the specified torque.
OILFILTERH2 1
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Oil filter - Remove

F4DE9484, F4DE9684, F4DE9687
1. Use tool 380000670 to remove the oil filter (1).

NOTE: The oil filter is equipped with an internal check valve
to minimize the amount oil loss when removing the filter.
OILFILTERF4DE 1
Next operation:
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Oil filter - Install

Prior operation:
1. Lubricate the oil filter O-ring (2) with clean engine oil.
2. Screw the filter (1) onto the base (3) until contact is
made with sealing surface.
3. Tighten the oil filter an additional 3/4 of a turn.
OILFILTERD2 1
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Blowby re-circulation system - Remove

F4HE9484, F4HE9684
1. Loosen the clamp (1)holding the blow-by tube and

remove the pipe.
2. Remove the screws (2)and remove the blow-by filter,
if applicable.
86070784_RESIZE 1
Next operation:
Blowby re-circulation system - Install (B.60.A)
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Blowby re-circulation system - Install

F4HE9484, F4HE9684
Prior operation:
Blowby re-circulation system - Remove (B.60.A)
1. Insert the blow-by filter (1) and tighten the bolts (2).
86070785_RESIZE 1
2. Install the cover (1) on the blow-by filter housing (2)

and tighten the mounting screws (3).
86070784_RESIZE 2
3. Connect the pipelines (1) and fix the oil vapor pipes
with the clamps (2).
86070784_RESIZE 3
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Piston lubrication Spray nozzle - Remove

1. Remove the main half bearing (1) to avoid damaging
them.
2. Remove the screws (2) and remove the oil nozzles
(3).
BACD04APH046ASA 1
Next operation:
Piston lubrication Spray nozzle - Install (B.60.A)
84250518 09/11/2009
B.60.A / 31
Piston lubrication Spray nozzle - Install

Prior operation:
Piston lubrication Spray nozzle - Remove (B.60.A)
1. Fit nozzles (2) and tighten the fastening screws (1)

to the specified torque.
CRIL04J066A01 1
84250518 09/11/2009
B.60.A / 32
Oil cooler - Remove

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
1. Unscrew the mounting bolts (1).

2. Remove the oil filter base (2)oil cooler (3), and all
gaskets.
OILCOOLERH 1
Next operation:
Oil cooler - Install (B.60.A)
84250518 09/11/2009
B.60.A / 33
Oil cooler - Install

F4GE9484, F4HE9484, F4GE9684, F4HE9684
Prior operation:
Oil cooler - Remove (B.60.A)
1. Place a new gasket (1) on the engine block.

2. Install the oil cooler (2).
3. Place a new gasket (3) on the oil cooler.
4. Install the oil filter base (4).
the hole and bolt threads have no evidence of wear or dirt
OILCOOLERH2 1
Next operation:
84250518 09/11/2009
B.60.A / 34
Oil cooler - Remove

Prior operation:
1. Unscrew the screws (5) that secure the oil filter base
(4) to the block.
2. Remove the base (4) and the oil cooler (2).
NOTE: Be sure to remove all the relevant gaskets and
seals (1) and (3).
OILCOOLERD2 1
Next operation:
Oil cooler - Install (B.60.A)
84250518 09/11/2009
B.60.A / 35
Oil cooler - Install

Prior operation:
Oil cooler - Remove (B.60.A)
1. Place a new gasket (1) on the engine block.

2. Install the oil cooler (2).
3. Place a new gasket (3) on the oil cooler.
4. Install the oil filter base (4).
the hole and bolt threads have no evidence of wear or dirt
OILCOOLERD2 1
Next operation:
84250518 09/11/2009
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Oil line - Install

F4HE9484, F4HE9684
Oil Fill Tube

1. Install a new O-ring on the oil fill tube (1).
2. Attach the oil fill tube (1) to the engine block using
the three M12x25 bolts.
OILFILLH2 1
84250518 09/11/2009
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Oil line - Install

Turbo oil lines

1. Connect the oil supply line (2) between the turbine
(1) and the oil filter base.
OILLINEDH 1
2. Install the oil drain pipe (1) onto the turbo and tighten
the fixing screws.
3. Connect the pipe to the block (2) also.
OILLINEDH2 2
84250518 09/11/2009
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Oil line - Install

F4GE9484, F4GE9684
1. Install the oil drain pipe (1) on the turbo by inserting

the one end into the block joint (2).
2. Install and tighten the two screws (3) underneath the
turbo securing the drain pipe.
3. Install the retaining brackets (4) and (5) which hold
the piping to the block.
OILLINEG 1
84250518 09/11/2009
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Sensing system Oil temperature-pressure sensor - Remove

F4HE9484, F4HE9684
1. Disconnect the wiring harness from the sensor.
OILPRESSTEMPH 1
2. Remove the mounting screws and remove the sen-

sor and O-ring from the oil filter base.
84250518 09/11/2009
B.60.A / 40
Sensing system Oil temperature-pressure sensor - Install

1. Install a new O-ring on the oil temperature/pressure

sensor.
2. Install the sensor on the oil filter base and tighten the
mounting bolts to the specified torque.
84250518 09/11/2009
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Sensing system Oil temperature-pressure sensor - Remove

F4DE9484, F4DE9684, F4DE9687
1. Disconnect the electrical connector (1) from the oil

temperature pressure sensor (3).
2. Unscrew the screws (2) securing the sensor to the oil
filter base (4) and remove it from its seat.
OILPRESSTEMPD 1
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Index

Blowby re-circulation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4HE9484, F4HE9684
Blowby re-circulation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Blowby re-circulation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F4HE9484, F4HE9684
Blowby re-circulation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F4HE9484, F4HE9684
LUBRICATION SYSTEM - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4HE9484, F4HE9684
F4DE9484, F4DE9684, F4DE9687
F4GE9484, F4GE9684
F4CE9484, F4CE9684
Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F4DE9484, F4DE9684, F4DE9687
Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F4HE9484, F4HE9684
Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
F4GE9484, F4GE9684
Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4HE9484, F4HE9684
Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4DE9484, F4DE9684, F4DE9687
Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F4GE9484, F4GE9684
Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F4HE9484, F4HE9684
Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F4GE9484, F4GE9684
Oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4DE9484, F4DE9684, F4DE9687
Oil pump Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4GE9484, F4HE9484, F4GE9684, F4HE9684
Piston lubrication Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4CE9484, F4GE9484, F4CE9684, F4GE9684
84250518 09/11/2009
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Sensing system Oil temperature-pressure sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Sensing system Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4HE9484, F4HE9684
Sensing system Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4DE9484, F4DE9684, F4DE9687
Sensing system Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
F4HE9484, F4HE9684
Sensing system Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
F4DE9484, F4DE9684, F4DE9687
84250518 09/11/2009
B.60.A / 44
STARTING SYSTEM - 80.A

F4GE9684 , F4HE9484 , F4HE9684
84250518 09/11/2009
B.80.A / 1
Contents
FUNCTIONAL DATA
Cold start aid
Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Sensing system
Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4CE9484, F4GE9484, F4CE9684, F4GE9684
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
84250518 09/11/2009
B.80.A / 2
POWER PRODUCTION - STARTING SYSTEM
Cold start aid Grid heater - Overview

GRIDHEATER 1
The pre-post heating resistance is located on the intake manifold.

The resistance serves to heat the air in pre / post heating operations. The resistance is powered by a contactor.
The resistance impedance is approximately 0.5 Ω.
The control contactor is connected to the control unit (B) connector.

The contactor is tripped with water and/or fuel temperature below 5 °C (41 °F).
The contactor impedance is approximately 15 Ω.
WARNING
This engine is equipped with an intake air (grid) heater. DO NOT use starting fluid on this engine. Use of
starting fluid can cause explosion, personal injury or property damage. Failure to comply could result in
death or serious injury.
M836
84250518 09/11/2009
B.80.A / 3
Cold start aid Grid heater - Overview

F4CE9484, F4GE9484, F4CE9684, F4GE9684
HEATRESISTORCG 1
It is a resistor assembled to the intake manifold and is utilized to heat the air during pre-post heating operations. It is
fed by a tele-switch usually placed very close to the engine.
Specifications:
• Working voltage:
• 12 V.
• Maximum possible air flow:
• 0.034 cm³/sec at a pressure of 138 kPa (20 psi).
84250518 09/11/2009
B.80.A / 4

F4CE9484, F4GE9484, F4CE9684, F4GE9684
Electrical Cold-start Accelerator (KKSB)
ELECTROMAGNETCG 1
(1) Hydraulic head electro-magnet - (2) KKSB electro-magnet.
The KKSB is located on the fuel injection pump. During engine start-up, the KKSB advances the injection pump timing
to reduce white smoke and emissions until the cylinders warm to normal operating temperature. By shifting the start
of injection in the advanced direction, the KKSB improves the cold-start characteristics of the emissionized engine.
Operation is triggered automatically by means of a temperature sensitive thermostatic switch, which is located in the
cylinder head on the engine’s left hand side.
KKSBSENSORCG 2
Specifications:
• Working tensions:
• 12 - 24 V.
• Electrical Power load:
• 2.5 A (induction)
84250518 09/11/2009
B.80.A / 5
• 5.0 A (resistance)
• Settings:
• 60 - 66 °C (140 - 151 °F) Contact opening upon increasing temperature.
• 50 - 56 °C (122 - 133 °F) Contact closure upon decreasing temperature.
84250518 09/11/2009
B.80.A / 6
Engine starter - Remove

1. Disconnect the starter cables from the solenoid and
the starter body (2).
2. Remove the three mounting bolts (3) securing the
starter (2) to the flywheel housing (1). Withdraw the
starter (2).
STARTERDH 1
Next operation:
Engine starter - Install (B.80.A)
84250518 09/11/2009
B.80.A / 7
Engine starter - Install

Prior operation:
Engine starter - Remove (B.80.A)
1. Install the starter (2) on the flywheel housing (1) using

the three mounting bolts (3).
NOTE: Before any assembly operation verify that the hole
STARTERDH 1
84250518 09/11/2009
B.80.A / 8
Index

Cold start aid Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cold start aid Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4CE9484, F4GE9484, F4CE9684, F4GE9684
Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4CE9484, F4GE9484, F4CE9684, F4GE9684
84250518 09/11/2009
B.80.A / 9
CNH AMERICA LLC
Racine, WI 53404 U.S.A. Printed in U.S.A.

Engines Nef Tier 3 F4CE9484, F4CE9684, F4DE9484, F4DE9684, F4DE9687, F4GE9484, F4GE9684, F4HE9484, F4HE9684

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Engines Nef Tier 3 F4CE9484, F4CE9684, F4DE9484, F4DE9684, F4DE9687, F4GE9484, F4GE9684, F4HE9484, F4HE9684

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SERVICE MANUAL

POWER PRODUCTION ................................................................. B

• • filling inhibitors or anti-frost

For engines equipped with electronic controller:

Respect of the Environment

Component Size Specification

Cylinder Head and Components

Component Size Specification

Component Size Specification

Fuel System and Components

Component Size Specification

Cylinder Head and Components

Component Size Specification

Tool No. Description Image

380000665 Crankshaft front seal puller

380000663 Crankshaft rear seal puller

Tool No. Description Image

380000666 Crankshaft front seal

380000664 Crankshaft rear seal

Tool No. Description Image

380000302 Valve spring compressor

380000221 Pliers for removing/refitting

Tool No. Description Image

380000362 Tool for lifting the crankshaft

380000216 Engine lifting rig

Tool No. Description Image

380000669 Seal remover

380000668 Hand grip for

380000364 Gauge base for dial indicator

Tool No. Description Image

380000158 Torque screwdriver

380000304 Tool for angle tightening

380000988 Flywheel rotation tool

Tool No. Description Image

Tool No. Description Image

380000665 Crankshaft front seal puller

380000663 Crankshaft rear seal puller

Tool No. Description Image

380000666 Crankshaft front seal

380000664 Crankshaft rear seal

Tool No. Description Image

380000302 Valve spring compressor

380000221 Pliers for removing/refitting

Tool No. Description Image

380000988 Flywheel rotation tool

380000667 Beater for removing/refitting

Tool No. Description Image

380000216 Engine lifting rig

380000994 Piston ring compressor

Tool No. Description Image

380000661 Brackets for fastening the

380000669 Seal remover

380000668 Hand grip for

Tool No. Description Image

380000229 Dial gauge holder and 0 -

380000304 Tool for angle tightening

Tool No. Description Image

380001006 Diesel engine compression

380000140 Adapter for engine

380000301 Revolving engine stand

ELECTRICAL POWER SYSTEM - 30.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 ,