Hyundai F4GE9454J*J604 Technical And Repair Manual Download Page 19

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SECTION 1 - GENERAL SPECIFICATIONS

F4GE N SERIES

Print P2D32N010 E

Base - February 2009

SECTION 1

General Specifications

Page

LUBRICATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL VAPOUR RECIRCULATING SYSTEM

. . . . . . .

COOLING SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION BOOST DIAGRAM

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Boosting version engines

. . . . . . . . . . . . . . . . .

Description

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Inter-cooled engine version

. . . . . . . . . . . . . . .

Description

. . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST GAS RE-CIRCULATION SYSTEM (EGR)

Summary of Contents for F4GE9454J*J604

Page 1: ...N SERIES F4G TIER 3 Agricultural applications Hyundai F4GE9484F J608 F4GE9454J J604 Technical and Repair manual...

Page 2: ...and safety of operators All repair interventions are aimed at restoring the conditions of operation efficiency and safety contemplated by FPT All on group interventions aimed at implementing changes a...

Page 3: ...F4GE N Series Part 1 F4GE N SERIES 1 F4GE N SERIES Print P2D32N010 E Base Febraury 2009...

Page 4: ...2 F4GE N SERIES Base Febraury 2009 Print P2D32N010 E...

Page 5: ...IDELINE MANUAL 3 SYMBOLS 5 Warnings 3 Service operations 3 GENERAL WARNINGS 5 GENERAL WARNINGS ON THE ELECTRIC SYSTEM 7 Bonding and screening 8 CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE...

Page 6: ...2 INTRODUCTION F4GE N SERIES Base Febraury 2009 Print P2D32N010 E...

Page 7: ...nd direct instructions to identify the cause of the major inconveniences Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such...

Page 8: ...ess or caulk Rotation Regulation Adjustment Angle Angular value Visual inspection Fitting position check Preload Measurement Value to find Check Number of revolutions Equipment Temperature Surface for...

Page 9: ...e safety indications found on the assembly Do not leave the running assembly unattended when making repairs When carrying out work on the assembly lifted off the ground verify that the assembly is fir...

Page 10: ...p with suitable fire resistant protections to protect hoses or other components where fluids or other materials flow which may catch fire easily on welding Should the vehicle be subjected to temperatu...

Page 11: ...ase always disconnect as a first one the chassis bonding cable from batteries negative terminal Before connecting the batteries to the system make sure that the system is well isolated Disconnect the...

Page 12: ...al or chain connections and to battery negative terminal Analog bonding sensors although not connected to battery negative system terminal bonding must have optimal isolation Consequently particularly...

Page 13: ...46 kW 1 HP 1 014 metric HP Torque 1 Nm 0 1019 kgm 1 kgm 9 81 Nm Revolutions per time unit 1 rad s 1 rpm x 0 1046 1 rpm 1 rad s x 9 5602 Pressure 1 bar 1 02 kg cm2 1 kg cm2 0 981 bar 1 bar 105 Pa Where...

Page 14: ...2D32N010 E KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of vehicle Section title Page number Printout number Language Publication Basic edition referred to month year editorial phase closing When...

Page 15: ...neral specifications 1 Fuel 2 Agricultural applications 3 Overhaul and technical specifications 4 Tools 5 Safety prescriptions Appendix Part 1 F4GE N SERIES 1 F4GE N SERIES Print P2D32N010 E Base Febr...

Page 16: ...2 F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 17: ...3 F4GE N SERIES Print P2D32N010 E Base February 2009 UPDATING Section Description Page Date of revision...

Page 18: ...4 F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 19: ...February 2009 SECTION 1 General Specifications Page LUBRICATION 3 OIL VAPOUR RECIRCULATING SYSTEM 4 COOLING SYSTEM 5 AIR INDUCTION BOOST DIAGRAM 6 Boosting version engines 6 Description 6 Inter cooled...

Page 20: ...2 SECTION 1 GENERAL SPECIFICATIONS F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 21: ...e camshaft and to the valve drive Lubrication involves the heat exchanger and the turboblower All these components may often vary according to the specific duty LUBRICATION SYSTEM LAYOUT 1 Lubrication...

Page 22: ...our inducing these to fall down because of gravity to the Tappet cap underneath The remaining non condensed vapours shall be properly conveyed through the breather pipe 2 by suction as an example con...

Page 23: ...ent and the dimensions Visc pusher fan having the duty to increase the heat dissipating power of the radiator This component as well will be specifically equipped based on the engine s development Hea...

Page 24: ...compressing the sucked air through the air filter The air coming out of the compressor is sent via the intake manifold directly to the pistons The turbocharger is equipped with a transforming valve to...

Page 25: ...and flown through the piston induction collector The turbocharger is equipped with a transforming valve to regulate the pressure that is located on the exhaust collector before the turbine and connec...

Page 26: ...stion chamber represents therefore an efficient control system of the emission of NOx Figure 6 A Aspiration valve control B Exhaust valve control 114789 The internal EGR system is not equipped with an...

Page 27: ...32N010 E Base February 2009 SECTION 2 Fuel Page 4 CYLINDER ENGINES WITH BOSCH VE 4 12 F ROTARY MECHANICAL PUMP 3 General information 3 Description of working principles 4 FEED PUMP 5 Example of identi...

Page 28: ...2 SECTION 2 FUEL F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 29: ...d 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...

Page 30: ...equipped in cold climate areas the fuel filter is provided with heater Transfer pump is placed inside the feed pump and is bladed type its duty is to increase fuel pressure in correspondence with the...

Page 31: ...plate 14 Gauge pin 15 Counteracting spring 30454 Figure 3 FEED PUMP The rotary type pump is driven by a gear mating the camshaft s one Example of identification V Distribution rotary plunger E Pump d...

Page 32: ...he fuel available in the tank and convey it to the feed pump inlet It is assembled to the engine basement and driven by the camshaft Figure 4 88209 1 Priming pump 2 Drive lever 3 Camshaft 6 SECTION 2...

Page 33: ...water from fuel On the filter cartridge base there is a water dump screw throughout which it is possible to provide regular drainage on the bearing for those equipment applications requiring it cold...

Page 34: ...8 SECTION 2 FUEL F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 35: ...Installation of rear components 19 Flywheel installation 22 Installation of front components 23 Completion of engine 33 Rotary feed pump disassembly and assembly pro cedure 35 Power take off disassem...

Page 36: ...checks 58 MAINTENANCE PROCEDURES 58 Checks and controls 58 Engine oil level check 58 Check of fuel system 59 Cooling system check 59 Lubricating system check 59 Check of water presence within fuel fi...

Page 37: ...nts of the engine including cylinder heads gearbox of the timing system and of the front part cover electrical directory describing the connections of the different components of the pre post heating...

Page 38: ...Loadless engine idling rpm 950 Loadless engine peak rpm rpm 2430 Bore x stroke mm Displacement cm3 104 X 132 4485 SUPERCHARGING Turbocharger type without intercooler Direct injection HOLSET HX25 bar L...

Page 39: ...50 Loadless engine idling rpm 800 Loadless engine peak rpm rpm 2430 Bore x stroke mm Displacement cm3 104 X 132 4485 SUPERCHARGING With intercooler Turbocharger type HOLSET HX25 bar LUBRICATION Oil pr...

Page 40: ...6 SECTION 3 AGRICULTURAL APPLICATION F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 41: ...PART ONE MECHANICAL COMPONENTS SECTION 3 AGRICULTURAL APPLICATION 7 F4GE N SERIES Print P2D32N010 E Base February 2009...

Page 42: ...8 SECTION 3 AGRICULTURAL APPLICATION F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 43: ...d Engine setting operations for the assembly on turning stand For specific application exigencies some units can be assembled to the engine in different positions For some versions the oil filter 3 is...

Page 44: ...tact of engine oil with the skin in case of skin contamination rinse in running water Engine oil is highly pollutant provide for disposal in compliance with the law and regulations in force The plug a...

Page 45: ...ines 2 and 3 respectively from priming pump to filter bearing and from this last one to the feed pump Remove the fuel filter bearing 4 from the bracket fixed to the engine head 123024 To disconnect fu...

Page 46: ...the injectors and loosen the screws fixing the fuel recovery pipeline loosen the screws holding the fixing brackets of such pipelines 1 6 and 7 Figure 12 pipe the pipeline ends Disassemble the inject...

Page 47: ...8 screws 1 fixing the suction manifold plate to the cylinder head two of them have already been screwed out since fixing the pipe brackets to the injectors from the exhaust manifold side loosen the 2...

Page 48: ...and the size of the thermostat casing vary according to the usage of the engine The illustrations therefore provide a general guideline for the operation to be carried out The procedures described ar...

Page 49: ...sen the screws 5 and disassemble the oil filter heat 2 exchanger bearing 4 interlayer plate 3 and relating gaskets 1 Disassemble injection pump see specific procedure and the power take off underneath...

Page 50: ...rod 3 for the tool 99363204 and the lever 4 withdraw the external holding ring 2 from the front cover 1 Loosen the screws 1 and 3 and remove the front cover 2 Take note of the screw 1 and 3 assembly...

Page 51: ...tightening the 6 screws specially provided 4 Proceed with drawing the ring 1 tightening the screw 2 Using the specially provided tie rod 3 for the tool 99363204 and the lever 4 withdraw the external h...

Page 52: ...ing plate 4 Figure 35 Figure 36 99222 Figure 37 87424 Remove the screws 1 and disassemble the gears 3 and 4 from the camshaft 2 87655 Remove the gear 1 transmitting motion to the ignition pump and the...

Page 53: ...the same position as found out during disassembly and fix the screws to the locking couples listed here below following the order as shown in the picture Screws M8 20 28 Nm Screws M10 44 54 Nm 70210...

Page 54: ...e between 0 076 0 280 mm 87654 Fit the screws 1 fastening the gears 2 to the camshaft 3 and tighten them to the prescribed pair 87655 Spline the gear 1 transferring motion to the ignition pump Figure...

Page 55: ...ings must be assembled within 10 minutes after completing the sealing operation Re assemble the box 1 to the engine basement Tighten the fastening screws 2 to the same position detected before disasse...

Page 56: ...igure 49 Tighten the engine flywheel 1 fixing screws 2 in two phases 1st phase tightening by means of dynamometric wrench to couple 30 4 Nm 2nd phase 60 5 angle dwell with tool 99395216 Before assembl...

Page 57: ...prescribed couple Figure 54 76112 Installation of front components Figure 55 Remove the fixing ring 2 from the front cover 1 accurately clean the plug surface 106549 Figure 56 Accurately clean the co...

Page 58: ...ng them to the prescribed couple Figure 57 Figure 58 Figure 59 99222 Assemble the plate 4 the rose pipe 3 tighten the fixing screws 1 2 and 4 and fix them to the prescribed couple 106550 24 SECTION 3...

Page 59: ...ring 3 Tighten the fixing screws 2 and lock them to the 110 5 Nm couple Figure 61 Set the gasket 1 on the oil sump 2 The shape and the size of the sump vary according to the usage of the engine Assemb...

Page 60: ...il assembly to the cylinder head Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be readable as indicated in the picture 122589 1 2 8775...

Page 61: ...rew threaded nut 1 to the i 4 6 Nm couple Lubricate cylinder head bolts and install to head Bolts must be torqued using stitching pattern starting with the centre bolts and moving out Bolts to be torq...

Page 62: ...cylinder must be checked by taking it to the T D C top dead centre at the end of compression and adjusting the clearance of both valves on the cylinder in question Remove the rocker covers of the cyl...

Page 63: ...sembly of injectors verify that theinjector sphere is correctly positioned on the head housing Always replace the gaskets using new ones Check the threads of the fixing screws there shall be no eviden...

Page 64: ...emble belt Poli V 4 on the pulley 5 of the engine shaft on the jockey pulley on the water pump 6 and on the alternator 3 tighten syn tension the belt by means of the automatic belt tensioner 2 NOTE Ap...

Page 65: ...underneath Figure 83 Pump mounting requires specific procedure contained in this section 75700 1 2 Figure 84 NOTE Figure 85 1 Rear bracket fixing screw on suction collector plate 2 Fuel recovery pipel...

Page 66: ...engine head Connect the fuel pipelines 2 and 3 respectively from priming pump to filter bearing and from this last one to feed pump Using 99360076 equipment assemble fuel filter 1 To connect fuel pip...

Page 67: ...s 99361037 from the engine after having properly put it on a wooden bearing 75675 1 Completion of engine 2 3 4 1 5 116386 Figure 91 On the right hand side reassemble the pipes 1 from the union 2 to th...

Page 68: ...tighten the screws 3 assembling the bracket 4 including filter bearing 5 Using tool 99360076 screw up oil filter The plug and the oil filler pipe for versions with the engine oil filter fitted directl...

Page 69: ...to pr set it while it is still assembled to the engine and disassemble it only afterwards The following procedure analyses this second hypothesis since it is the more complex 88140 1 Figure 96 88141 F...

Page 70: ...fixing nuts Withdraw the pump from the studs together with the gasket When the supply pump is to be assembled on the engine the P M S conditions at compression end stage cylinder No 1 must be carried...

Page 71: ...bly shall not be utilised again Always use original spare parts If the pump has been removed with the engine mounted connect the accelerator cable if present in the application 1 1 2 3 4 1 2 75721 Fig...

Page 72: ...ing new gasket and checking the sprocket gear meshing Assemble cover and gasket and tighten the screws to the prescribed couple Figure 105 Figure 106 Feed system bleed procedure Demonstration In case...

Page 73: ...nder head oil pan and bearing oil filter and heat exchanger as well as relating housings There is no fuel leakage from fuel pipelines There is no blow by from pneumatic pipes if provided Verify correc...

Page 74: ...40 SECTION 3 AGRICULTURAL APPLICATION F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 75: ...PART TWO ELECTRICAL EQUIPMENT SECTION 3 AGRICULTURAL APPLICATION 41 F4GE N SERIES Print P2D32N010 E Base February 2009...

Page 76: ...42 SECTION 3 AGRICULTURAL APPLICATION F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 77: ...ure sensor 2 Alternator 3 Starter 4 A Engine STOP solenoid B KSB electromagnet 5 Oil pressure sensor 6 Fuel heater where provided for 7 KSB Water temperature sensor 8 Resistance for cold start up ELEC...

Page 78: ...It is assembled to the engine head close to the thermostat unit and its duty is to detect engine cooling liquid temperature Specifications Range of working temperatures Connection side 40 130 C 150 C...

Page 79: ...the engine and is driven by tooth belt Specifications Working tension 12 V Current delivered 90A at 6000 rpm Absorption in stand by 1mA Sense of rotation clockwices 75725 Figure 113 Pre post heating...

Page 80: ...46 SECTION 3 AGRICULTURAL APPLICATION F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 81: ...PART THREE TROUBLESHOOTING SECTION 3 AGRICULTURAL APPLICATION 47 F4GE N SERIES Print P2D32N010 E Base February 2009...

Page 82: ...48 SECTION 3 AGRICULTURAL APPLICATION F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 83: ...on pump Check and correctly time the injection pump See your FPT dealer Deposits or water in the fuel tank Disconnect the hoses and clean them using a jet of compressed air Dismantle and clean the inj...

Page 84: ...See your FPT dealer Impurities or water in the fuel lines Disconnect the hoses and clean them using a jet of compressed air Dismantle and clean the injection pump Remove water from fuel tank and refue...

Page 85: ...oolant Incorrect engine timing Check timing and tune correctly Incorrect calibration of injection pump Correct the delivery rate of the pump on a bench so that the injection is at the specified rate S...

Page 86: ...cleaner Faulty operation of L D A device Check that the diaphragm is not perfor ated that the counter spring is suitable and that it has the correct loading check on test bench Check that there is ad...

Page 87: ...ournals due to excess ive play of piston hubs and in the rod bushing Loose bushings in the rod seatings Replace the piston journal and or the pis ton and rod bushing Replace with new bushings Noisy ti...

Page 88: ...lative parts Unsuitable injectors different types of in jectors or incorrectly calibrated Replace or calibrate the injectors Injection hoses with an unsuitable internal diameter end of hoses pinched d...

Page 89: ...PART FOUR MAINTENANCE PLANNING SECTION 3 AGRICULTURAL APPLICATION 55 F4GE N SERIES Print P2D32N010 E Base February 2009...

Page 90: ...56 SECTION 3 AGRICULTURAL APPLICATION F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 91: ...the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run Maintenance operations Visual check of engine Check presence of water in...

Page 92: ...The check can be made using the specially provided flexible rod 1 Figure 115 Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum level Whether it...

Page 93: ...ngine pan of from the heat exchanger The engine oil is highly polluting and harmful In case of contact with the skin rinse well with water and detergent Adequately protect the skin and the eyes operat...

Page 94: ...der remove theinjector and place the tool 99395097 see Figure 98 to set the cylinder top dead centre position end of compression phase Pre load the gauge The searched condition is obtained by rotating...

Page 95: ...sition and the quan tity can change However the following operations are valid for all applications Drain the fuel inside the filter by operating the water re lease screw Collect the fuel in a contain...

Page 96: ...A indicated on the figure of the automatic belt tightener 1 and release the pressure Remove the control belt 2 from the driven and inter mediate pulleys Replace the worn belt with a new one Place the...

Page 97: ...VAL AT THE BENCH 11 REPAIR OPERATIONS 12 CYLINDER UNIT 12 Checks and measurements 12 Checking head supporting surface on cylinder unit 13 TIMING SYSTEM 14 Camshaft 14 Checking cam lift and pin alignme...

Page 98: ...iston assembly into cylinder barrels 25 Finding crankpin clearance 25 Checking piston protrusion 26 Page CYLINDER HEAD 27 Removing the valves 27 Checking cylinder head wet seal 28 Checking cylinder he...

Page 99: ...r See properties described in Section 3 Injection Direct Number of cylinders 4 Bore mm 104 Stroke mm 132 Total displacement cm3 4485 TIMING start before T D C A end after B D C B 18 5 29 5 start befor...

Page 100: ...AND CRANKSHAFT COMPONENTS mm 1 X Cylinder barrels 1 104 000 to 104 024 0 4 1 X 2 Spare pistons type Size X Outside diameter 1 Pin housing 2 55 9 103 714 to 103 732 38 010 to 38 016 Piston cylinder bar...

Page 101: ...S 2 S 3 2 560 to 2 605 2 350 to 2 380 3 970 to 3 990 1 Split rings slots 2 3 0 100 to 0 175 0 060 to 0 110 0 040 to 0 080 Split rings 0 4 X 1 3 2 X X Split ring end opening in cylinder barrel X 1 X 2...

Page 102: ...end half bearings S 2 2 456 to 2 464 1 955 to 1 968 3 Main bearings No 1 5 3 No 2 3 4 3 87 982 to 88 008 87 977 to 88 013 Half bearings Journals No 1 5 No 2 3 4 0 440 to 0 106 0 039 to 0 111 Half bear...

Page 103: ...019 to 8 039 4 Valves 4 4 7 960 to 7 980 60 7 960 to 7 980 45 Valve stem and guide 0 039 to 0 079 1 Housing on head for valve seat 1 1 46 987 to 47 013 43 637 to 43 663 2 Valve seat outside diameter v...

Page 104: ...height free spring H under a load equal to 329 N H1 641 N H2 63 50 65 69 49 02 38 20 X Injector protrusion X 1 2 3 4 5 Camshaft bush housings No 1 5 Camshaft housings No 2 3 4 5 59 222 to 59 248 54 08...

Page 105: ...4 CYLINDERS CYLINDER HEAD TIMING SYSTEM mm 1 Tappet cap housing on block 1 16 000 to 16 030 2 3 2 Tappet cap outside diameter 2 3 15 929 to 15 959 15 965 to 15 980 Between tappets and housings Tappet...

Page 106: ...ta to calibrate the pump at the bench is identified by the code shown on injection pump body and is available at BOSCH technical assistance network Otherwise refer to FPT Technical Assistance Service...

Page 107: ...engine block Remove the screws 1 and the main bearing caps 2 The second last main bearing cap 1 and the relevant support are fitted with shoulder half bearing 2 Use tool 99360500 1 and hoist to remov...

Page 108: ...fitted with the dial gauge previously set to zero on the ring gauge 2 of the cylinder barrel diameter Measurements shall be performed on each cylinder at three different heights in the barrel and on...

Page 109: ...rsize 0 5 mm Checking head supporting surface on cylinder unit Check main bearing housings as follows fit the main bearings caps on the supports without bearings tighten the fastening screws to the sp...

Page 110: ...pin alignment Set the camshaft on the tailstock and using a 1 100 gauge set on the central support check whether the alignment error is not exceeding 0 04 mm otherwise replace the camshaft 70172 Figu...

Page 111: ...re 15 CAMSHAFT BUSH AND HOUSING MAIN DATA Value to be obtained after driving the bushes 107399 Sec A A SECTION 4 OVERHAUL AND TECHNICAL SPECIFICATIONS 15 F4GE N SERIES Print P2D32N010 E Base February...

Page 112: ...ng careful to ensure that the bearing or the shaft support seats are not damaged during the operation Set camshaft 3 retaining plate 1 with the slot facing the top of the engine block and the marking...

Page 113: ...sert the found values in the proper table See Figure 24 Undersize classes are 0 250 0 500 mm Journals and crankpins shall always be ground to the same undersize class Journals and crankpins undersize...

Page 114: ...lity Straightness POSITION Concentricity or coaxiality OSCILLATION Circular oscillation OSCILLATION Total oscillation LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL CRITICAL IMPORTANT...

Page 115: ...with shoulder half rings Check that gear toothing 1 is not damaged or worn otherwise remove it using the proper puller 3 When fitting the new gear heat it to 180 C for 10 minutes in an oven and then...

Page 116: ...re tighten the screws 2 with 90 5 angle CONNECTING ROD PISTON ASSEMBLY COMPONENTS 1 Stop rings 2 Pin 3 Piston 4 Split rings 5 Screws 6 Half bearings 7 Connecting rod 8 Bush Checking output shaft shoul...

Page 117: ...from piston using pliers 99360183 1 The circlips 2 retaining the gudgeon pin are removed using round nose pliers 1 MAIN DATA CONCERNING KS PISTON PINS AND SPLIT RINGS SECTION 4 OVERHAUL AND TECHNICAL...

Page 118: ...nd and 3rd slot and the relevant housings on the piston 2 using a feeler gauge 1 DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ri...

Page 119: ...cap with a number showing their coupling and the corresponding cylinder In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one On bod...

Page 120: ...oring or seizing and that it is not loosen Otherwise replace Removal and refitting shall be performed using the proper beater When refitting take care to make coincide the oil holes set on the bush wi...

Page 121: ...TTING INTO BARREL Split ring openings shall be displaced with each other by 120 connecting rod piston assemblies shall have the same weight the arrow marked on the piston crown shall be facing the fro...

Page 122: ...m by tightening the connecting rod cap fastening screws to the specified torque Check manually that the connecting rods 1 are sliding axially on the output shaft pins and that their end float measured...

Page 123: ...ves Valve removal shall be performed using tool 99360268 1 and pressing the cap 3 so that when compressing the springs 4 the cotters 2 can be removed Then remove the cap 3 and the springs 4 Repeat thi...

Page 124: ...r head according to values and indications shown in the following figure Checking cylinder head wet seal Before refitting smear the plug surfaces with water repellent sealant Checking cylinder head su...

Page 125: ...valve stem 1 using a micrometer 2 it shall be 7 943 to 7 963 Use a magnetic base dial gauge 1 set as shown in the figure the assembling clearance shall be 0 056 0 096 mm Turn the valve 2 and check tha...

Page 126: ...gure 68 Should valve seats be not reset just by regrinding replace them with the spare ones Use adequate tool to remove as much material as possible from the valve seats take care not to damage the cy...

Page 127: ...the following table FITTING CYLINDER HEAD Lubricate the valve stems 1 and fit them into the relevant valve guides according to the position marked at removal Fit the sealing rings 2 and 3 on the valv...

Page 128: ...on Figure 74 at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average For 4 cylinder versions Repeat the opera...

Page 129: ...bly M8x1 25x25 M18x1 50 24 4 60 9 2 4 0 4 6 0 0 9 Set timing pin 5 1 0 5 0 1 Fuel pump assembly M8 screw M6 screw M6 nut 24 4 10 1 10 1 2 4 0 4 1 0 0 1 1 0 0 1 M10x1 5 flange head nuts pre torque fina...

Page 130: ...25x16 24 4 2 4 0 4 Alternator to alternator support M8x1 25x30 24 4 2 4 0 4 Alternator to water inlet conn assy M8x1 25x30 24 4 2 4 0 4 Lower alternator mounting M10x1 25x25 24 4 2 4 0 4 Alternator u...

Page 131: ...SECTION 5 TOOLS 1 F4GE N SERIES Print P2D32N010 E Base February 2009 SECTION 5 Tools Page TOOLS 3...

Page 132: ...2 SECTION 5 TOOLS F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 133: ...2205 Revolving stand for overhauling units 1000 daN capacity 120 daN m torque 99340035 Injection pump gear extractor 99340055 Tool to remove output shaft front gasket 99340056 Tool to remove output sh...

Page 134: ...46253 Tool for fitting output shaft rear gasket 99360076 Tool to remove oil filter engine 99360183 Pliers for removing refitting piston rings 65 110 mm 99360268 Tool for removing refitting engine valv...

Page 135: ...r stopping the engine flywheel 99360362 Beater for removing refitting camshaft bushes to be used with 99370006 99360500 Tool for lifting the output shaft 99360595 Lifting rig for engine removal refitt...

Page 136: ...ng engine to revolving stand 99322205 99363204 Tool to remove gaskets 99370006 Interchangeable willow handgrip 99370415 Gauge base for different measurements to be used with 99395603 99395097 Tool to...

Page 137: ...P2D32N010 E Base February 2009 TOOL NO DESCRIPTION 99395216 Pair of gauges with and square head for angle tightening 99395603 Dial gauge 0 5 mm 99395604 Dial gauge 0 10 mm 99395682 Diesel fuel engine...

Page 138: ...8 SECTION 5 TOOLS F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 139: ...APPENDIX 1 F4GE N SERIES Print P2D32N010 E Base February 2009 Appendix Page SAFETY PRESCRIPTIONS 3...

Page 140: ...2 APPENDIX F4GE N SERIES Base February 2009 Print P2D32N010 E...

Page 141: ...y better if provided with elastics at the ends Use protection cream for hands Change wet cloths as soon as possible In presence of current tension exceeding 48 60 V verify efficiency of earth and mass...

Page 142: ...tightening may seriously damage engine s components affecting engine s duration Avoid priming from fuel tanks made out of copper alloys and or with ducts not being provided with filters Do not modify...

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