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MCCORMICK B-POWER F4GE0404 Service Manual

Mechanical injection 6 cylinder (tier 2) engines
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Service Manual
Mechanical Injection
6 Cylinder (Tier 2) Engines
© 2004 McCormick Tractors International Limited.
SM 8-13001
April 2004
i

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Summary of Contents for MCCORMICK B-POWER F4GE0404

  • Page 1 Service Manual Mechanical Injection 6 Cylinder (Tier 2) Engines © 2004 McCormick Tractors International Limited. SM 8-13001 April 2004...
  • Page 2 This publication provides the features, data and correct method of repair operations that can be performed on every single component of the engine. Followingthe instructionsgiven andusing thespecial toolswill ensure correct repairing, within the scheduled times, while also protecting operators against possible accidents. Before starting any repair work, make sure that all accident-prevention equipment is close at hand and in efficient conditions.
  • Page 3 ISSUED APRIL 2004 CONTENT OF SECTIONS Section General specifications Fuel Duty - Industrial applications Mechanical injection Engines Overhaul and technical specifications Tools Appendix Safety prescriptions PREFACE TO USER’S GUIDELINE MANUAL Section 1 describes the Bpower engine illustrating its features and working in general. Section 2 describes the type of fuel feed.
  • Page 4 ISSUED APRIL 2004...

  • Page 5: Special Remarks

    ISSUED APRIL 2004 SPECIAL REMARKS Where possible, the same sequence of procedures has been followed for easy reference. Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see next page) instead of giving descriptions of some operations or procedures.
  • Page 6 ISSUED APRIL 2004 Graph and symbols Removal Intake Disconnection Refitting Exhaust Connection Removal Operation Disassembly Fitting in place Compression ratio Assembly ρ Tolerance Tighten to torque Weight difference Tighten to torque + angle value Rolling torque α Replacement Press or caulk Original spare parts Regulation Rotation...
  • Page 7 ISSUED APRIL 2004 UPDATING Section Description Page Date of revision...
  • Page 8 ISSUED APRIL 2004...
  • Page 9 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 SECTION 1 General Specifications Page ENGINE IDENTIFICATION CODE ..SPECIFIC ENGINE CODE ....LUBRICATION .
  • Page 10 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004...

  • Page 11: Engine Identification Code

    SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 ENGINE IDENTIFICATION CODE Exhaust emiss. level Homologation power Duty No. Feed/Injection Cylinder No. Engine cycle — cylinder position Engine 0= 4-stroke, Range evolution vertical A =Not struct. Engine series B = Not struct. C =Struct 4 = 4 cylind.
  • Page 12 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 SPECIFIC ENGINE CODE Engineering code Exhaust emiss. level C = Euro3. E = E (NRMM) U = EPA USA Power: G = Gas A = Not superch. M =Marine S = Supercharging T = Supercharging with aftercooler Engine block:...
  • Page 13 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 LUBRICATION Lubrication involves the heat exchanger (2,3), the Lubrication by forced circulation is achieved through oil turboblower for turbocompressed versions, and for any rotary expansion pump (4), placed in the front part of the compressed air system.
  • Page 14 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 Figure 2 Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil 76212 LUBRICATION SYSTEM LAYOUT (6 cyl. engines) 1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Heat exchanger - 4. Oil rotary expansion pump - 5.
  • Page 15 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 OIL VAPOUR RECIRCULATING SYSTEM Figure 3 003240t 1. Valve - 2. Breather pipe - 3. Tappet Cap On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity, to the Tappet cap underneath.
  • Page 16 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004...

  • Page 17: Cooling System

    SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 COOLING SYSTEM - Heat exchanger to cool the lubrication oil: even this The engine cooling system, closed circuit forced circulation component is part of the engine’s specific equipment. type, generally incorporates the following components: - Centrifugal water pump, placed in the front part of the - Expansion tank;...
  • Page 18 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 Figure 5 TO RADIATOR FROM RADIATOR 76216 Water coming out from thermostat Water recirculating in engine Water coming into pump COOLING SYSTEM LAYOUT (6 cyl. engines)

  • Page 19: Air Induction Boost Diagram

    SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004 AIR INDUCTION BOOST DIAGRAM Figure 6 TURBOCHARGER AIR FILTER EXHAUST RADIATOR 74195 TURBOCHARGER AIR FILTER EXHAUST RADIATOR 74195 Description The turbocharger is composed by the following main parts: The turbocharger is equipped with a transforming valve to one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust feeding pressure , one main body and one compressor.
  • Page 20 SECTION 1 - GENERAL SPECIFICATIONS ISSUED APRIL 2004...

  • Page 21: Table Of Contents

    SECTION 2 - FUEL ISSUED APRIL 2004 SECTION 2 Fuel Page INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP ..... . . - 4 cylinder engines .
  • Page 22 SECTION 2 - FUEL ISSUED APRIL 2004...

  • Page 23: Injection Feed System By Mechanical Rotary Pump

    SECTION 2 - FUEL ISSUED APRIL 2004 INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP 4 cylinder engines General information 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...

  • Page 24: Description Of Working Principles

    SECTION 2 - FUEL ISSUED APRIL 2004 Figure 2 75807 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 fuel tank by the priming pump. This The fuel arrives therefore to the valve gauging the pressure last one is placed on the engine basement and is driven by inside feed pump.

  • Page 25: Example Of Identification

    SECTION 2 - FUEL ISSUED APRIL 2004 FEED PUMP The rotary type pump is driven by a gear mating the camshaft’s one. Example of identification = Distribution rotary plunger = Pump dimensions = 4 cylinders engine = Distribution plunger in mm. 1150 = N°.

  • Page 26: Priming Pump

    SECTION 2 - FUEL ISSUED APRIL 2004 PRIMING PUMP 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 basement and driven by the camshaft. The picture here following shows the pump (1) and the position that the pump drive lever assumes depending on the camshaft rotation (2) and on its eccentricity.

  • Page 27: Fuel Filter

    SECTION 2 - FUEL ISSUED APRIL 2004 FUEL FILTER 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 base (4) there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing (1) for those equipment applications requiring it (cold climate areas), there can be a heater assembled to (2) and a tempe- rature sensor (5).
  • Page 28 SECTION 2 - FUEL ISSUED APRIL 2004...

  • Page 29: Injection Feed System By Mechanical Rotary Pump

    SECTION 2 - FUEL ISSUED APRIL 2004 INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP 6 cylinder engines General information 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 pump body - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed pump...

  • Page 30: Description Of Working Principles

    SECTION 2 - FUEL ISSUED APRIL 2004 Figure 7 88139 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 fuel tank by the priming pump. This Fuel is delivered to the pressure gauge valve within feed last one is placed on the engine basement and is driven by pump.

  • Page 31: Fuel Filter

    SECTION 2 - FUEL ISSUED APRIL 2004 FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separa- tion of water from fuel. On the filter cartridge base (4) there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing (1) for those equipment applications requiring it (cold climate areas), there can be a heater assembled to (2) and a tempera- ture sensor (5).
  • Page 32 SECTION 2 - FUEL ISSUED APRIL 2004...
  • Page 33 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 HYDRAULIC SYSTEM - BRAKES SECTION 3 Duty - industrial application Page GENERAL INFORMATION ....- Version equipped with mechanical feed pump - Clearance data - 4 cyl.
  • Page 34 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Page Page - Rotary feed pump disassembly and - Alternator ......assembly procedure .

  • Page 35: General Information

    Setter will follow and Bpower engines have been developed for McCormick c ompl y wi th al l i nstal l ati on pr esc r i pti ons pr ovi ded by specifically for farming equipment usage.

  • Page 36: Clearance Data - 4 Cyl

    Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based McCormick. on which the engine has been designed.
  • Page 37 Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based McCormick. on which the engine has been designed.
  • Page 38 Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based McCormick. on which the engine has been designed.
  • Page 39 Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based McCormick. on which the engine has been designed.

  • Page 40: Clearance Data - 6 Cyl

    Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based McCormick. on which the engine has been designed.
  • Page 41 Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based McCormick. on which the engine has been designed.
  • Page 42 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...

  • Page 43: Part One - Mechanical Components

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 DIAGNOSI PART ONE - MECHANICAL COMPONENTS...
  • Page 44 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 DIAGNOSI...

  • Page 45: Overhaul Of The 4 Cylinder Engine Provided With Mechanical Rotary Pump

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface Figure 3 Part of the operations illustrated within this section 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.
  • Page 46 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 5 Figure 6 75673 75674 - Assemble the second bracket 99361037 throughout the On the left hand side: screw-threaded ports (1). - Disassemble oil filter (1) and bracket as well (for versions - Lift the engine using the rocker arm 99360595 and put with engine oil filter not directly assembled on to the it on the turning stand 99322205.

  • Page 47: Disassembly Of Application Components

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Disassembly of application components Figure 9 Figure 7 70126 75675 For turbocompressed versions To disconnect fuel pipelines (2 and 3, Figure 8), in proceed disassembling the supercharger: low pressure from the relating pipe fittings, it is - loosen the fixing nut (1) and remove the lubrication pipe Necessary to press the locking fastener (1) as shown from the supercharger.
  • Page 48 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 11 1. Rear bracket fixing screw (on suction collector 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).
  • Page 49 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 14 Figure 16 75683 - Disassemble rocker arm bearings; loosen the two fixing screws (2) and remove the complete rocker arm bearing; withdraw tappet rods. Repeat the operation for all the remaining rocker arm bearings.
  • Page 50 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 For applications with traditional belt stretcher Figure 20 Figure 18 75686 - Properly hold the alternator (1) separating it from its bearing by loosening the screw (2); remove screw nut and washer.
  • Page 51 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 23 Figure 25 75692 - Use the tool 99360339 (2) to operate on the flywheel cover box (1) in order to block flywheel rotation (3). (Utilise starter holding down studs and fixing screw nuts). - Loosen the flywheel fixing screws (4) to engine drive shaft.
  • Page 52 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 27 Figure 29 70149 - Loosen the screws (1) and remove the front cover (2). 00900t Take note of the screw (1) assembly position, since - Remove the engine drive shaft fixing ring from the front the screws have different length.
  • Page 53 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 32 Figure 34 70153 - Loosen the screws (2) and remove the flywheel cover 75690 box (1). - Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist.
  • Page 54 ISSUED APRIL 2004 SECTION 3 - DUTY - INDUSTRIAL APPLICATION Version with suction rose type A Figure 39 Figure 36 70155 - Loosen the screws (1) and disassemble the oil suction rose pipe (3). - Loosen the screws (2) and remove the stiffening plate 70156 (4).

  • Page 55: Installation Of Application Components

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Installation of application components Figure 42 Figure 41 75711 DIAGRAM SHOWING SCREW 75712 TIGHTENING TO FIX REAR GEARBOX - Reassemble to box (1) to the engine block. DIAGRAM SHOWING SEALING LOCTITE 5205 - Tighten the fixing screws in the same position as found APPLICATION WITHIN GEARBOX AREAS out during disassembly and fix the screws to the locking...
  • Page 56 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 44 It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm.
  • Page 57 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 48 Figure 50 75690 - Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling . - Using a hoist, handle the flywheel to place it in its housing 0901t inside the flywheel cover box.
  • Page 58 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 52 Figure 54 α 75695 70221 Tighten the engine flywheel (1) fixing screws (2) in two - Apply to the water pump (1) a new fixing ring (2). phases: - 1st phase;...
  • Page 59 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 57 Figure 59 00902t - Apply on engine drive shaft front tang (6) the detail (4) of the tool 99346252, fix it with the screws (5) and key the new holding ring on it (7). - Place the detail (2) on the detail (4), screw-up the threaded nut until carrying out the complete assembly of the holding ring (7) to the front cover.

  • Page 60: Assembly Of Additional Masses

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Assembly of additional masses Fit the additional masses (2) and tighten the screws (3) on the engine block. Figure 62 Remove the lock pin (1) of the additional masses. 86578 Timing of additional masses Match the signs (A) engraved on the gears for timing, insert the pin in the hole (B) on the balancing mass.
  • Page 61 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 64 Figure 66 - Provide for new gasket replacement (1) of the oil pan (2). The pictures illustrating the pan and of the rose pipe may not correspond to the ones of your model. However the procedures described are applicable anyway.
  • Page 62 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 68 Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Figure 70 76113 - Lubricate the fixing ring (2) using engine oil and place it on the oil filter (3).
  • Page 63 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 72 Figure 74 75705 75688 - Place the head (3) over the block and insert screws (1) - Carry out the assembly of the rocker arms after previous and (2). check of the components.
  • Page 64 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 77 Figure 79 32655 Before executing assembly, check the Rocker Arm driving 75683 - Tighten the screws (2) to the prescribed couple and rods: these shall not be deformed; the spherical ends in assemble water temperature sensor (1).
  • Page 65 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 81 Always replace the gaskets using new ones. Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation. In such case provide for replacement with new nods.
  • Page 66 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 For applications with traditional belt stretcher Figure 85 Figure 86 88090 - In order to connect the POLY-V belt carry out the operations described on pages 18 and 19 vice versa. For belt stretching turn the alternator as indicated in the figure, tighten screw (1) and the bolt that fixes the alternator to the support.
  • Page 67 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 88 Figure 89 75701 - Apply on the surface joining the suction manifold plate (1) a sufficient coat of Loctite 5999 and provide. fixing the screws to the prescribed couple. - If the pipe (6) of the suction manifold plate (1) has been removed, reassemble it after having fit a new gasket (5).
  • Page 68 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 91 1. Rear bracket fixing screw (on suction collector 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) Figure 92 Figure 93...
  • Page 69 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 94 Figure 96 75675 75676 - Assemble the fuel filter bearing (4) to the bracket fixed For turbocompressed versions to the engine head. proceed assembling the turbocharger: - Connect the fuel pipelines (2 and 3) respectively from - Hold the turbocharger and place it on the exhaust priming pump to filter bearing and from this last one to manifold after having interposed the gasket.

  • Page 70: Completion Of The Engine

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Completion of the engine Figure 98 Figure 97 75670 On the right hand side: - reassemble the pipes (1) from the union (2) to the lubrication oil filter (placed on the opposite side): tighten the pipe rings (1) and connect them to the union In some cases, the oil filter (3) is directly placed on the heat exchanger: in this case it shall be assembled...
  • Page 71 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 99 Figure 100 75717 75673 - Reassemble the starter; properly hold the starter (1) and On the left hand side: tighten the fixing screws to the prescribed couple. - Assemble oil filter (1) together with bracket (for the versions with engine oil filter not directly assembled to the exchanger);...

  • Page 72: Rotary Feed Pump Disassembly And Assembly Procedure

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Rotary feed pump disassembly and assembly In case feed pump replacement is necessary, this shall be procedure supplied pre-set already as spare part. On the other hand, in case the pump shall be disassembled This procedure prescribes that: and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine...
  • Page 73 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 103 75698 - Rotate with caution the flywheel following its own rotation sense to annul the gear slacks and at the same Flywheel rotation shall be carried out with extreme time keep the (→) pin pressed until when this last one caution.
  • Page 74 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 105 Figure 107 75694 75721 - Partially loosen the lateral screw (2) locking the pump - From the pump side, loosen the fixing nuts (1) without shaft and remove the slip washer (2). Absolutely keep removing them in order to enable moving the pump the slip washer (it is recommended to fix it with stripe backwards using 99340035 extractor.
  • Page 75 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 108 Figure 110 75694 75721 - Assemble the pump pre-set in its housing on the engine, - Partially loosen the screw (2) locking the pump shaft fitting the shaft into the gear port (not provided with rotation and fit the slip washer (1).

  • Page 76: Power Take-Off Disassembly And Assembly Procedure

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Feed system bleed procedure - Vary out the assembly fitting the power take-off in its housing, providing new gasket and checking the sprocket Figure 111 gear meshing. - Assemble cover and gasket and tighten the screws to the prescribed couple.

  • Page 77: Overhaul Of The 6 Cylinder Engine Provided With Mechanical Rotary Pump

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 OVERHAUL OF THE 6 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface For turbo-compressed versions Part of the operations illustrated within this section can be Figure 114 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.
  • Page 78 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 - Remove the oil level rod together with guide pipe (2); Figure 116 (loosen the guide pipe disassembling from the block); properly pipe the screw-threaded port to avoid inlet of foreign matters.

  • Page 79: Disassembly Of Application Components

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Disassembly of application components Figure 121 Figure 119 76143 70126 For turbo-compressed versions To disconnect fuel pipelines (2 and 3, picture 8), in proceed disassembling the supercharger: low pressure from the relating pipe fittings, it is - loosen the fixing nut (1) and remove the lubrication pipe Necessary to press the locking fastener (1) as shown from the supercharger.
  • Page 80 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 123 Figure 126 76149 88143 - Disconnect the supply pipe unit from the injectors (1). - Remove tappet caps: Loosen the fixing screws (1) and lift the caps (2); - Remove fuel exhaust pipe (2) from the injectors by remove the gaskets.
  • Page 81 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 For applications with automatic belt stretcher Figure 128 Figure 130 76151 74171 - Disassemble suction and exhaust manifolds: loosen the - Unloose the screws fixing the alternator’s protection to screws (1) fixing the suction manifold plate to the the support and remove it.
  • Page 82 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 132 Figure 135 75685 - Disassemble thermostat unit; loosen the three fixing screws (1) and disassemble the thermostat unit (2) 70141 together with the bracket (3); remove the gasket (4) and - Loosen the screws (4) and disassemble the oil the thermostat (5).
  • Page 83 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 137 Figure 139 75692 70148 - Apply the suitable tool (2) described on page 70 on the - Remove the screws (1) and disconnect the water pump flywheel covering box (1) in order to lock flywheel (3) (2).
  • Page 84 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 141 Figure 143 75811 75688 - Using the specially provided tie rod (3) for the tool - Loosen the screws (1) and remove oil pump (2). 99363204 and the lever (4), withdraw the external holding ring (2) from the front cover (1).
  • Page 85 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 145 Figure 147 70153 75690 - Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. - Loosen the screws (2) and remove the flywheel cover Throughout two guide pins (2) previously screwed up box (1).
  • Page 86 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Version with suction rose type A Figure 151 Figure 149 70156 - Loosen the screws (1) and disassemble the gear from the camshaft (2). 88074 - Loosen the screws (1) and disassemble the oil suction rose pipe (3).

  • Page 87: Installation Of Application Components

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Installation of application components Figure 154 Figure 153 75711 DIAGRAM SHOWING SCREW 75712 TIGHTENING TO FIX REAR GEARBOX - Reassemble to box (1) to the engine block. DIAGRAM SHOWING SEALING LOCTITE 5205 - Tighten the fixing screws in the same position as found APPLICATION WITHIN GEARBOX AREAS out during disassembly and fix the screws to the locking...
  • Page 88 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 156 It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm.
  • Page 89 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 160 Figure 162 75690 - Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling . - Using a hoist, handle the flywheel to place it in its housing 0901t inside the flywheel cover box.
  • Page 90 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 164 Figure 166 α 75695 70221 Tighten the engine flywheel (1) fixing screws (2) in two - Apply to the water pump (1) a new fixing ring (2). phases: - 1st phase;...
  • Page 91 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 169 Figure 171 00902t - Apply on engine drive shaft front tang (6) the detail (4) of the tool 99346252, fix it with the screws (5) and key the new holding ring on it (7). - Place the detail (2) on the detail (4), screw-up the threaded nut until carrying out the complete assembly of the holding ring (7) to the front cover.
  • Page 92 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 174 Figure 176 74175 - Assemble the pulley (1) and the dumping flywheel (2) to the driving shaft. 88075 - Tighten the fixing screws (3) and clamp them to the couple 68 ±...
  • Page 93 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 179 Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Figure 181 76113 - Lubricate the fixing ring (2) using engine oil and place it on the oil filter (3).
  • Page 94 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 184 Figure 186 74178 - Refit the automatic belt tensioner (2). 76152 - Tighten the screw (3) to the specified torque. - Place the head (3) over the block and insert screws (1) and (2).
  • Page 95 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 188 Figure 190 19.00 16.00 75702 ROCKER ARM ADJUSTMENT SCREW If unscrewed, check adjustment quota. 75705 Tighten the screw-threaded nut (1) to the i 0.25 - 0.75 Nm couple. ROCKER ARM UNIT COMPONENTS: 1.
  • Page 96 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 192 Figure 194 75703 - Insert the tappet driving rods and the Rocker Arm unit. Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: D1 - D2 <...
  • Page 97 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 195 Always replace the gaskets using new ones. Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation. In such case provide for replacement with new nods.
  • Page 98 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 199 Figure 200 76207 76208 - Apply on the surface joining the suction manifold plate - Also assemble the brackets (1) fixing the fuel pipelines (1) the gasket (3) and provide. Fixing the screws (2) to to the injectors: use the same screws (2) fixing the the prescribed couple.
  • Page 99 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 202 Figure 204 76148 Figure 203 88146 - Assemble the supply pump pipes (1). Figure 205 76150 - Fix the pipes to the injectors throughout the brackets previously assembled (fixing screw 1, Figure 202 and 2, Figure 203).
  • Page 100 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 206 Figure 208 76143 76141 - Assemble the fuel filter bearing (4) to the bracket fixed For turbo-compressed versions to the engine head. proceed assembling the turbocharger: - Connect the fuel pipelines (2 and 3) respectively from - Hold the turbocharger and place it on the exhaust priming pump to filter bearing and from this last one to manifold after having interposed the gasket.

  • Page 101: Completion Of The Engine

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Completion of the engine Figure 210 Figure 209 75670 On the right hand side: - reassemble the pipes (1) from the union (2) to the lubrication oil filter (placed on the opposite side): tighten the pipe rings (1) and connect them to the union In some cases, the oil filter (3) is directly placed on the heat exchanger: in this case it shall be assembled...
  • Page 102 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 211 Figure 212 76146 76144 - Reassemble the starter; properly hold the starter (1) and On the left hand side: tighten the fixing screws to the prescribed couple. - Assemble oil filter (1) together with bracket (for the versions with engine oil filter not directly assembled to the exchanger);...

  • Page 103: Rotary Feed Pump Disassembly And Assembly Procedure

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Rotary feed pump disassembly and assembly In case feed pump replacement is necessary, this shall be procedure supplied pre-set already as spare part. On the other hand, in case the pump shall be disassembled This procedure prescribes that: and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine...
  • Page 104 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 215 88147 - Rotate with caution the flywheel following its own rotation sense to annul the gear slacks and at the same Flywheel rotation shall be carried out with extreme time keep the (→) pin pressed until when this last one caution.
  • Page 105 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 217 Figure 219 88149 - From the pump side, loosen the fixing nuts (1) without removing them in order to enable moving the pump 88148 backwards using 99340035 extractor. - Partially loosen the lateral screw (2) locking the pump - Assemble the 99340035 extractor throughout the two shaft and remove the slip washer (2).
  • Page 106 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Figure 220 Figure 222 88149 - Assemble the pump pre-set in its housing on the engine, fitting the shaft into the gear port (not provided with 88148 wrench). - Partially loosen the screw (2) locking the pump shaft - Tighten the fixing nuts (1) locking the pump flange in the rotation and fit the slip washer (1).

  • Page 107: Feed System Bleed Procedure

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Feed system bleed procedure - Vary out the assembly fitting the power take-off in its housing, providing new gasket and checking the sprocket Figure 223 gear meshing. - Assemble cover and gasket and tighten the screws to the prescribed couple.
  • Page 108 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...

  • Page 109: Part Two

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 DIAGNOSI PART TWO - ELECTRICAL EQUIPMENT...
  • Page 110 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 DIAGNOSI...

  • Page 111: Electrical Componet Layout

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 ELECTRICAL COMPONET LAYOUT (4 CYL. ENGINES WITH ROTARY POMP) Figure 225 75724 The electrical components provided with NEF F4GE04--- Engine are listed here following: 1. Cooling liquid temperature sensor; 2. Starter; 3.

  • Page 112: Cooling Liquid Temperature Sensor

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Cooling liquid temperature sensor Starter Figure 226 Figure 227 75717 Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch assembled to the starter itself. Specifications: BOSCH 3 kW - 12V KSB Water temperature sensor...

  • Page 113: Electromagnets Assembled To Feed Pump

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Electromagnets assembled to feed pump Fuel filter Figure 229 Figure 231 75724a 1 - Hydraulic head Electro-magnet; 2 - KSB 75716 Electro-magnet 1 - Fuel temperature sensor; 2 - Resistor for filter heating;...

  • Page 114: Pre-Post Heating Resistor

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Pre-post heating resistor Pre-post heating unit Figure 234 Figure 233 6 GH 75723 1.2W It is a resistor assembled to the suction collector and is utilised to heat the air during pre-post heating operations. 88153 It is fed by a tele-switch usually placed very close to the engi- Legend...

  • Page 115: Electrical Componet Layout

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 ELECTRICAL COMPONET LAYOUT (6 CYL. ENGINES WITH ROTARY PUMP) Figure 235 88152 The electrical components provided with NEF F4GE06--- En- gine are listed here following: 1. Cooling liquid temperature sensor; 2.

  • Page 116: Cooling Liquid Temperature Sensor

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Cooling liquid temperature sensor Starter Figure 236 Figure 237 75717 Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch assembled to the starter itself. Specifications: BOSCH 4 kW - 24V KSB Water temperature sensor...

  • Page 117: Oil Pressure Sensor

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Oil pressure sensor Alternator Figure 239 Figure 241 75722 75725 It is assembled to the block on the engine’s left hand side. It is place front view on the right hand side of the engine, and is driven by tooth belt.

  • Page 118: Pre-Post Heating Resistor

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Pre-post heating resistor Pre-post heating unit Figure 243 Figure 242 6 GH 75723 1.2W It is a resistor assembled to the suction collector and is utilised to heat the air during pre-post heating operations. 88153 It is fed by a tele-switch usually placed very close to the engi- Legend...

  • Page 119: Part Three - Troubleshooting

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 DIAGNOSI PART THREE - TROUBLESHOOTING...
  • Page 120 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 DIAGNOSI...
  • Page 121 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...
  • Page 122 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...
  • Page 123 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...
  • Page 124 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...
  • Page 125 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...
  • Page 126 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...

  • Page 127: Part Four - Maintenance Planning

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 DIAGNOSI PART FOUR - MAINTENANCE PLANNING...
  • Page 128 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 DIAGNOSI...

  • Page 129: Maintenance Planning

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 MAINTENANCE PLANNING Recovery To ensure optimised 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.

  • Page 130: Checks Not Included In Maintenance Planning-Daily Checks

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 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 inconven- iences, even serious, during engine running.

  • Page 131: Check Of Fuel System

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Check of fuel system Lubricating system check The check must be executed both when the engine discon- The check must be executed both when the engine discon- nected and when it is running. nected and when it is running.

  • Page 132: Check Of Drive Belt Tensioning

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Check of drive belt tensioning In order to more quickly perform the operating clear- Some applications are equipped with an automatic tensioner ance adjustment for rocker arms — valves, proceed as that provides correcting belt tensioning.

  • Page 133: Oil Motor And Filter Replacement

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Oil motor and filter replacement Whereas you replace the lubrication oil, it is necessary to re- place the filter. According to the application the filter can be located in different Warning: We recommend to wear proper protec- positions: the following procedure is a valid guide for all applica- tions because of high motor service temperature.

  • Page 134: Fuel Filter Replacement

    SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 Fuel filter replacement Alternator belt replacement Due to several applications the belt run can change very much. During this operation don’t smoke and don’t use free We describe the replacement of a belt mounted on a 4-cylin- flames.
  • Page 135 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004 For applications with automatic belt stretcher Figure 248 74171 - Unscrew the screws which fix the belt guard (2) to the support and dismount it. - Operate on the tightener (1) and withdraw the belt (3) from the alternator and water pumps from pulleys and from the returns pumps.
  • Page 136 SECTION 3 - DUTY - INDUSTRIAL APPLICATION ISSUED APRIL 2004...
  • Page 137 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 HYDRAULIC SYSTEM - BRAKES SECTION 4 Overhaul and technical specifications Page GENERAL SPECIFICATIONS ....CLEARANCE DATA .
  • Page 138 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Page Page - Checking connecting rods ....- Checking cylinder head supporting surface . . . - Checking torsion .

  • Page 139: General Specifications

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 GENERAL SPECIFICATIONS Type 4 CYLINDERS 6 CYLINDERS Cycle Four-stroke diesel engine Power See properties described in Section 3 Injection Direct Number of cylinders 4 in-line 6 in-line Bore ∅ Stroke Total displacement 4485 6728...

  • Page 140: Clearance Data

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 CLEARANCE DATA Type 4 CYLINDERS 6 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅ 1 104.000 to 104.024 Cylinder barrels ∅1 Spare pistons ∅ 1 type: Size 55.9 Outside diameter ∅ 1 103.730 to 103.748 Pin housing ∅...
  • Page 141 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Type 4 CYLINDERS 6 CYLINDER CYLINDER UNIT AND CRANKSHAFT COMPONENTS 2.705 to 2.785 Split ring slots 2.440 to 2.460 4.030 to 4.050 2.560 to 2.605 Split rings 2.350 to 2.380 3.970 to 3.990 0.100 to 0.175 Split rings - slots...
  • Page 142 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Type 4 CYLINDERS 6 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS Size Max. tolerance on connecting rod axis alignment Journals ∅ 1 82.99 to 83.01 Crankpins ∅ 2 68.987 to 69.013 ∅...
  • Page 143 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Type 4 CYLINDERS 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM ∅ 1 Valve guide seats on cylinder head ∅ 1 8.019 to 8.039 Valves: ∅ ∅ 4 7.943 to 7.963 60º...
  • Page 144 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Type 4 CYLINDERS 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM Valve spring height: free spring 63.05 under a load equal to: 329 N 49.02 641 N 38.20 Injector protrusion Camshaft bush 59.222 to 59.248 housings No.
  • Page 145 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Type 4 CYLINDERS 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM ∅ 1 Tappet cap housing on block ∅ 1 Tappet cap outside ∅2 diameter: ∅ 2 15.924 to 15.954 ∅ ∅...
  • Page 146 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004...

  • Page 147: Engine Overhaul

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH The following instructions are prescribed on the Figure 3 understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well.

  • Page 148: Repair Operations

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 REPAIR OPERATIONS CYLINDER UNIT Checks and measurements Figure 6 Figure 9 70163 Remove the screws (1) and disconnect camshaft (3) retaining plate (2). 70166 Once engine is disassembled, clean accurately the Take note of plate (2) assembling position.

  • Page 149: Checking Head Supporting Surface On Cylinder Unit

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Check main bearing housings as follows: Figure 11 - fit the main bearings caps on the supports without +0.024/-0 bearings; - tighten the fastening screws to the specified torque; Rz = 1.5 DIN OR ISO 1997 CUT OFF 2.5 mm - use the proper internal gauge to check whether the housing diameter is falling within the specified value.

  • Page 150: Checking Cam Lift And Pin Alignment

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Figure 13 70512 MAIN DATA ABOUT CAMSHAFT PINS (6 CYL.) Camshaft pin and cam surfaces shall be absolutely smooth; camshaft and the bushes. if they show any traces of seizing or scoring replace the Checking cam lift and pin alignment BUSHES Set the camshaft on the tailstock and using a 1/100 gauge set...
  • Page 151 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Figure 16 Sec. A-A 70173 CAMSHAFT BUSH AND HOUSING MAIN DATA * Value to be obtained after driving the bushes. Figure 17 sec. A-A 70513 MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS *Height to be obtained after driving the bushes.

  • Page 152: Bush Replacement

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Bush replacement Fitting tappets — camshaft Figure 20 Figure 18 70176 70174 Lubricate the tappets (1) and fit them into the relevant housings on the engine block. To replace front and rear bushes (1), remove and refit them using the beater 99360362 (2) and the handgrip 99370006 Figure 21 (3).

  • Page 153: Output Shaft

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 OUTPUT SHAFT Measuring journals and crankpins Figure 23 Figure 25 70179 70182 Grind journals and crankpins if seizing, scoring or excessive Check camshaft end float (1). ovalisation are found. Before grinding the pins (2) measure It shall be 0.23 ±...
  • Page 154 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Figure 27 measured on > 45.5 mm radius between adjacent journals 70183 OUTPUT SHAFT MAIN TOLERANCES TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL Roundness SHAPE Cilindricity Parallelism Verticality DIRECTION Straightness POSITION Concentricity or coaxiality Circular oscillation Total oscillation OSCILLATION...
  • Page 155 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Measuring journals and crankpins (6 cylinders) Figure 28 FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES 70514 *Rated value Figure 29 Measured on a radius greater than 45.5 mm 0.500 between adjacent main journals 70577...
  • Page 156 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Figure 30 INTERMEDIATE MAIN MAIN BEARING ON TIMING FIRST MAIN BEARING ON BEARINGS SYSTEM CONTROL SIDE FRONT SIDE 70237 TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL Roundness SHAPE Cilindricity Parallelism Verticality DIRECTION Straightness POSITION Concentricity or coaxiality...

  • Page 157: Replacing Oil Pump Control Gear

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Finding journal clearance Replacing oil pump control gear Figure 33 Figure 31 70161 Refit the output shaft (2). Check the backlash between output shaft main journals and the relevant bearings as follows: 70184 Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3).

  • Page 158: Checking Output Shaft Shoulder Clearance

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Checking output shaft shoulder clearance Figure 36 Figure 38 α 70188 stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90° ± 5° angle. 70190 This check is performed by setting a magnetic-base dial gauge (2) on the output shaft (3) as shown in the figure, standard...

  • Page 159: Pistons

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Pistons Measuring piston diameter Figure 40 Figure 43 32615 32613 Remove split rings (1) from piston (2) using pliers 99360183 Using a micrometer (2), measure the diameter of the piston (3).

  • Page 160: Piston Pins

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Piston pins Figure 48 Figure 45 18857 32620 To measure the piston pin (1) diameter use the micrometer Check the clearance between the sealing rings (3) of the 2 (2). and 3 slot and the relevant housings on the piston (2), using a feeler gauge (1).

  • Page 161: Connecting Rods

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Figure 50 Figure 52 CONNECTING ROD BODY 1234 CONNECT- WEIGHT ING ROD No. 0001 ↓ 9999 70194 Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3). Connecting rods CONNECTING ROD CAP 1234...

  • Page 162: Checking Connecting Rods

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Checking connecting rods Checking bending Figure 53 Figure 55 61695 Check connecting rod (5) bending by comparing two points C and D of the pin (3) on the vertical plane of the connecting 61696 Check that the axes of the connecting rods (1) are parallel rod axis.

  • Page 163: Fitting Split Rings

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Figure 57 Split rings are supplied spare with the following sizes: standard, yellow marking; 0.5 mm oversize, yellow/green marking; Figure 60 70199 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 (5) are read as shown in the figure.

  • Page 164: Finding Crankpin Clearance

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Figure 62 Figure 64 α 70204 - Lubricate the screws (1) with engine oil and then tighten 70202 them to the specified torque using the dynamometric wrench (2). DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL Figure 65 - Split ring openings shall be displaced with each other by...

  • Page 165: Checking Piston Protrusion

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Checking piston protrusion Figure 67 Figure 68 70207 If a different clearance value is found, replace the half bearings and repeat the check. 70208 Once connecting rod-piston assemblies refitting is over, use Once the specified clearance has been obtained, lubricate dial gauge 39395603 (1) fitted with base 99370415 (2) to the main half bearings and fit them by tightening the...

  • Page 166: Cylinder Head

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 CYLINDER HEAD Figure 70 Removing the valves Figure 69 75751 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 75750 cap (3) and the springs (4).

  • Page 167: Checking Cylinder Head Wet Seal

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Checking cylinder head wet seal Figure 73 Figure 72 0,4 C 0,025 / ¯ 25,4 0,4 TOTAL 0,01 / ¯ 50 75756 75753 This check shall be performed using the proper tools. The rated thickness A for the cylinder head is 95 ±...

  • Page 168: Valves

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 VALVES Figure 76 Figure 74 INTAKE EXHAUST VALVE VALVE 18882 Check the valve stem (1) using a micrometer (2), it shall be 6.960 to 6.980. 42.13 45.13 41.87 44.87 70326 INTAKE AND EXHAUST VALVE MAIN DATA Removing carbon deposits, checking and Checking clearance between valve stem and...

  • Page 169: Valve Guide

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 VALVE GUIDE VALVE SEATS Regrinding — replacing the valve seats Figure 78 Figure 79 75754 Check the valve seats (2). If slight scoring or burnout is found, regrind seats using tool 99305018 (1) according to the angle INTAKE EXHAUST values shown in Figure 80.

  • Page 170: Valve Springs

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 FITTING CYLINDER HEAD Figure 81 Figure 83 75758 75759 After regrinding, check that valve (3) sinking value is the specified one by using the base 99370415 (2) and the dial Lubricate the valve stems (1) and fit them into the relevant gauge 99395603 (1).

  • Page 171: Refitting The Cylinder Head

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 Refitting the cylinder head Before re-utilising the fixing screws for the cylinder Figure 85 head, verify there is no evidence of wear or deformation and in that case replace them. 87759 Check cleanness of cylinder head and engine block coupling surface.

  • Page 172: Tightening Torque (For 4 And 6 Cyl.)

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 TIGHTENING TORQUE (FOR 4 AND 6 CYL.) COMPONENT TORQUE Cooling Nozzles (M8x1.25x10) 15 ± 3 1.5 ± 0.3 Main bearing cap 1st stage 50 ± 6 5.0 ± 0.6 2nd stage 80 ±...
  • Page 173 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004 COMPONENT TORQUE Rear lifting bracket (M12x1.75x30) 77 ± 12 7.7 ± 1.2 Crankshaft pulley (M12x1.75x10.9) 110 ± 5 11.0 ± 0.5 Flywheel housing 85 ± 10 8.5 ± 1.0 (M12x120) (M12x80) 85 ±...
  • Page 174 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ISSUED APRIL 2004...
  • Page 175 SECTION 5 - TOOLS ISSUED APRIL 2004 HYDRAULIC SYSTEM - BRAKES SECTION 5 Tools Page TOOLS ........
  • Page 176 SECTION 5 - TOOLS ISSUED APRIL 2004...
  • Page 177 SECTION 5 - TOOLS ISSUED APRIL 2004 TOOLS TOOL No. DEFINITION 99305019 Kit for valve seat regrinding 99305047 Spring load tester Revolving stand for overhauling units (700 daN/m capacity, 120 99322205 daN/m torque) 99340035 Injection pump gear extractor. 99340055 Tool to remove output shaft front gasket 99340056 Tool to remove output shaft rear gasket...
  • Page 178 SECTION 5 - TOOLS ISSUED APRIL 2004 TOOLS TOOL No. DEFINITION 99340205 Tool to remove injectors 99346252 Tool for fitting output shaft rear gasket 99346253 Tool for fitting output shaft rear gasket 99360076 Tool to remove oil filter (engine) 99360183 Pliers for removing/refitting piston rings (65 —...
  • Page 179 SECTION 5 - TOOLS ISSUED APRIL 2004 TOOLS TOOL No. DEFINITION 99360330 Flywheel crank handle (*) 99360339 Tool for stopping the engine flywheel (**) 99360344 Adapter, cylinder compression test (use with 99395682) 99360351 Tool for flywheel holding (***) Beater for removing/refitting camshaft bushes (to be used with 99360362 993700069) 99360500...
  • Page 180 SECTION 5 - TOOLS ISSUED APRIL 2004 TOOLS TOOL No. DEFINITION 99360595 Lifting rig for engine removal/refitting 99360605 Band for fitting piston into cylinder barrel (60 — 125 mm) 99361037 Brackets for fastening engine to revolving stand 99322205 99363204 Tool to remove gaskets 99367121 Tool to remove gaskets 99370006...
  • Page 181 SECTION 5 - TOOLS ISSUED APRIL 2004 TOOLS TOOL No. DEFINITION 99370415 Gauge base for different measurements (to be used with 99395603) 99395097 Tool to check top dead centre (use with 99395604) Dial gauge holder for rotary injection pump timing (use with 99395100 99395603) 99395216...
  • Page 182 SECTION 5 - TOOLS ISSUED APRIL 2004 TOOLS TOOL No. DEFINITION 99395603 Dial gauge (0 — 5 mm) 99395604 Dial gauge (0 — 10 mm) 99395682 Diesel fuel engine cylinder compression control device (*) for engines F4GE0404B*D650 (***) for engines F4GE0484G*D666 F4GE0404H*D651 F4GE0684F*D601...
  • Page 183 APPENDIX ISSUED APRIL 2004 HYDRAULIC SYSTEM - BRAKES Appendix Page SAFETY PRESCRIPTIONS ....
  • Page 184 APPENDIX ISSUED APRIL 2004...

  • Page 185: Safety Prescriptions

    APPENDIX ISSUED APRIL 2004 SAFETY PRESCRIPTIONS Standard safety prescriptions - Do not execute any intervention if not provided with necessary instructions. Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different must be followed absolutely in a standard working area and operation from the ones they’ve been designed and whose non fulfillment will make any other measure useless or...
  • Page 186 APPENDIX ISSUED APRIL 2004 GENERALMANUTENZIONE Respect of the Environment - Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration. - Respect of the Environment shall be of primary importance: all necessary precautions to ensure - Avoid priming from fuel tanks made out of copper alloys personnel’s safety and health shall be adopted.

This manual is also suitable for:

B-power f4ge0454B-power f4ge0484B-power f4ge0654B-power f4ge0684

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