Vetus VF4 Service Manual
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Vetus VF4 Service Manual

Vf4/vf5 series marine diesel engine
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Marine Diesel Engine
VF4
VF5
Service Manual
VF4.140E
VF4.170E
VF5.220E
VF5.250E

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Summary of Contents for Vetus VF4

  • Page 1 Marine Diesel Engine VF4.140E VF4.170E Service Manual VF5.220E VF5.250E...
  • Page 2 Copyright © 2009 Vetus N.V. Schiedam Holland Reproduction of text and illustrations, in whole or in part, is strictly prohib- ited. The information contained in this manual is not binding and providing the basic specification of the model described herein is not affected VETUS...

  • Page 3: Table Of Contents

    4.13 Variable geometry turbocharger ..... 70 4.14 Pressure pump support VF4 ......73 4.15 Pressure pump support VF5 .

  • Page 4: Specifications

    + . . . = = CR Compression ratio 18 : 1 18 : 1 kW (CEE) Maximum output CEE hp (CEE) 1/min 4000 4000 Nm (CEE) Maximum torque CEE kgm (CEE) 30.1 34.5 1/min 2400 2400 402102.01 Service manual VF4 VF5...
  • Page 5 + . . . = = CR Compression ratio 18 : 1 18 : 1 kW (CEE) Maximum output CEE hp (CEE) 1/min 4200 4200 Nm (CEE) Maximum torque CEE kgm (CEE) 40.1 45.4 1/min 2400 2600 402102.01 Service manual VF4 VF5...

  • Page 6: Performance Curves

    2500 3000 3500 4000 4500 1000 1500 2000 2500 3000 3500 4000 4500 1000 1500 2000 2500 3000 3500 4000 4500 1000 1500 2000 2500 3000 3500 4000 4500 Performance curves according to ISO 8178. 402102.01 Service manual VF4 VF5...
  • Page 7 2500 3000 3500 4000 4500 1000 1500 2000 2500 3000 3500 4000 4500 1000 1500 2000 2500 3000 3500 4000 4500 1000 1500 2000 2500 3000 3500 4000 4500 Performance curves according to ISO 8178. 402102.01 Service manual VF4 VF5...

  • Page 8: Values And Fits

    63.705 ÷ 63.718 ∅ Ø Cylinder liner seat 82.000 ÷ 82.010 ∅ ∅ Cylinder liner 82.010 ÷ 82.020 82.020 ÷ 82.030 ∅ 1 Ø1 Ø2 Cylinder liner ∅ 2 2 - 1 Cylinder liner - Crankcase 402102.01 Service manual VF4 VF5...
  • Page 9 3 - 1 Piston – Cylinder liner 0.070 ÷ 0.090 3 - 2 Piston – Cylinder liner Ø 25.982 ÷ 25.987 Piston pin ∅ 4 - 3 Piston pin - Seat pin 0.012 ÷ 0.022 402102.01 Service manual VF4 VF5...
  • Page 10 Ø1 Small end bush I.D. 26.006÷ 26.014 ∅ Ø2 Big end I.D. 53.897 ÷ 53.909 Connecting rod weight difference ± 2.5 g Ø1 29.018 ÷ 29.038 ∅ ∅ Small end bush ∅ 25.279 ÷ 25.512 402102.01 Service manual VF4 VF5...
  • Page 11 1.530 ÷ 1.534 Connecting rod bearing 1.533 ÷ 1.537 ∅ 0.127 10 - 8 Connecting rod bearing - Pin 0.030 ÷ 0.056 Thrust washer 2.469 ÷ 2.485 0.127 11 - 8 Thrust crankshaft 0.059 ÷ 0.221 402102.01 Service manual VF4 VF5...

  • Page 12: Cylinder Head And Valve Gear

    30.045 ÷ 30.070 43.846 ÷ 43.871 43.646 ÷ 43.671 Camshaft support end exhaust dia. 43.446 ÷ 43.471 ∅ 43.246 ÷ 43.271 43.046 ÷ 43.071 30.045 ÷ 30.070 Ø Tappet housing bore dia. 37.010 ÷ 37.030 ∅ 402102.01 Service manual VF4 VF5...
  • Page 13 Valve – Valve guide 0.030 ÷ 0.066 Internal valve spring 20.47 ÷ 21.84 34.0 External valve spring 44.81 ÷ 47.59 24.5 Ø 26.000 ÷ 26.015 Journal camshaft and exhaust ∅ 19.250 ÷ 19.330 Cam lift intake / exhaust 402102.01 Service manual VF4 VF5...
  • Page 14 36.975 ÷ 36.991 ∅ 19 - 12 Tappet - Cylinder head 0.019 ÷ 0.065 Shim 3.25 ÷ 4.90 0.05 0.50 For timing check 0.50 17 - 20 0.30 ± 0.05 Normal cold 0.35 ± 0.05 402102.01 Service manual VF4 VF5...

  • Page 15: Valve Timing Diagram

    Fit the cylinder head, the gasket should have the thickness indicated below in order to maintain compression ratio within the prescribed limits: Piston protrusion (mm) Gasket thickness (mm) Identification notches -0.020 ÷ +0.100 0.82 ± 0.05 +0.101 ÷ +0.200 0.92 ± 0.05 +0.201 ÷ +0.295 1.02 ± 0.05 402102.01 Service manual VF4 VF5...

  • Page 16: Lubrication

    0.016 ÷ 0.086 gears and the cover pump Between the gear and the conductor 0.30 @ minimal rpm > 1 bar Operation pressure @ 4000 / min > 4 ÷ 4.5 bar temperature of 100°C @ maximum 402102.01 Service manual VF4 VF5...

  • Page 17: Cooling System

    Rpm maximal engine to empty 5000 ± 20 1/min Supercharging Supercharging (Gas exhaust turbocharger) Turbocharger to variable geometry Garret GT 17 59V Garret GT 22 56 V Pressure of the maximum supercharging to 2400/min 1.05 bar 402102.01 Service manual VF4 VF5...

  • Page 18: Repair Data

    Repair data Cylinder head 4.1.1 Camshaft housing Position the camshaft housing (1 a) in a vice using the tool (1b) Undo the bolt (1 a) and remove the cam angle sensor (1b). 402102.01 Service manual VF4 VF5...
  • Page 19 Check that the tools are correctly fitted in the housings in the camshaft. Undo the bolts fixing the camshaft gears (1) Undo the bolt (1 a) and remove the exhaust side camshaft toothed drive pulley (1b). 402102.01 Service manual VF4 VF5...
  • Page 20 Using a suitable drift, extract the inlet side camshaft (1 a) and plug (1b). Using suitable drift, extract the exhaust side camshaft (2 a) and oil seal (2b). Undo and remove the engine oil lubrication duct plugs (1). 402102.01 Service manual VF4 VF5...

  • Page 21: Lower Cylinder Head

    Position the cylinder head (1 a) in a vice using the tool (1b). Remove the hydraulic tappets. Loosen the band (1 a), undo the bolts (1b) and remove the ther- mostat (1c) complete with O-ring. 402102.01 Service manual VF4 VF5...
  • Page 22 Remove the valve guide oil seal with integrated lower valve shim. Carry out the same operations on the other valves. Remove the wooden stand and recover the valves. Remove the lower cylinder head from the support tool. Replace the valve guide. 402102.01 Service manual VF4 VF5...
  • Page 23 Check that the valves do not show signs of scoring or seizing. Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves. Inlet valve stem diameter 5.982 ÷ 6.000 Exhaust valve stem diameter 5.972 ÷ 5.990 402102.01 Service manual VF4 VF5...
  • Page 24 • Diameter II bearing 43.600 ÷ 43.615 • Diameter III bearing 43.400 ÷ 43.415 • Diameter IV bearing 43.200 ÷ 43.215 • Diameter V bearing 43.000 ÷ 43.015 • Diameter VI bearing 30.000 ÷ 30.015 402102.01 Service manual VF4 VF5...
  • Page 25 • Diameter II support 43.646 ÷ 43.671 • Diameter III support 43.446 ÷ 43.471 • Diameter IV support 43.246 ÷ 43.271 • Diameter V support 43.046 ÷ 43.071 • Diameter VI support 30.045 ÷ 30.070 402102.01 Service manual VF4 VF5...
  • Page 26 Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts. Place the valve guide oil seal (1 a) in position using the tool (1b extractor/fitting tool). 402102.01 Service manual VF4 VF5...
  • Page 27 Thermostat Bolt M8 value (da Nm) cylinder head side 2.5 Place the hydraulic tappets in their housings. Remove the lower cylinder head from the support tool. 402102.01 Service manual VF4 VF5...

  • Page 28: Camshaft Housing

    Check that the tools are correctly fitted in the housings in the camshaft. Tighten the camshaft gear fixing bolts to the recommended torque. Camshaft gears Bolt M12 (da Nm) camshaft side 2.9 ÷ 3.2 + 40° 402102.01 Service manual VF4 VF5...
  • Page 29 Position the cam angle sensor (1 a) in its housing and secure it tightening the bolt (1b) to the recommended torque . Cam angle sensor Bolt M6 (da Nm) 0,8 ÷ 1,0 402102.01 Service manual VF4 VF5...

  • Page 30: Crankshaft

    Undo bolts (2 a) and remove crankshaft front oil seal cover with built-in oil pump (2b). Remove the gasket. Undo bolt (3 a) and remove timing belt fixed tensioner (3b). Undo bolt (4 a) and remove timing belt tensioners mounting (4b) 402102.01 Service manual VF4 VF5...
  • Page 31 Crankshaft end play 0.049 ÷ 0.211 mm If the value for the crankshaft end play does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable oversize thrust washer. 402102.01 Service manual VF4 VF5...
  • Page 32 Fit the water/oil sealing plugs in the crankcase using suitable fit- ting, tools. Lubricate all the mechanical components with engine oil. Check that the cylinder head support surface does not have cracks or surface grooves. 402102.01 Service manual VF4 VF5...
  • Page 33 82.010 ÷ 82.020 Grade C 82.020 ÷ 82.030 Check that the taper and ovality of the cylinder liners/bores is within the recommended limits. Cylinder liner taper < 0.005 mm Cylinder liner ovality < 0.05 mm 402102.01 Service manual VF4 VF5...
  • Page 34 Fit the bearing caps. The bearing caps have progressive references (from zero to five VF4, or zero to six VF5, starting from the timing system side) which define the fitting position. Tighten bearing cap bolts (1 a) to the recommended torque, use torque wrench (1b).
  • Page 35 Check that the diameter of the crank pins corresponds to the rec- ommended figures. Crankpin diameter Category A 50.779 ÷ 50.805 mm Category B 50.793 ÷ 50.799 mm Category C 50.787 ÷ 50.793 mm 402102.01 Service manual VF4 VF5...
  • Page 36 Bearing caps Bolt M12 (da Nm) 2.4 ÷ 2.6 + 100° The bearing caps have progressive references (from zero to five starting from the timing system side) which define the fitting po- sition. 402102.01 Service manual VF4 VF5...
  • Page 37 Small end bush inner diameter 26.006 ÷ 26.014 mm Check that the outer diameter of the gudgeon pins is within the recommended limits; if not, replace the worn gudgeon pins. Gudgeon pin outer diameter 25.982 ÷ 25.987 mm 402102.01 Service manual VF4 VF5...
  • Page 38 Check that backlash (1 a) between rings (1b) and the seats in pistons(1c) corresponds to the recommended figures. Cylinder compression piston ring I piston ring 0.105 ÷ 0.150 mm II piston ring 0.050 ÷ 0.090 mm Scraper ring 0.030 ÷ 0.070 mm 402102.01 Service manual VF4 VF5...
  • Page 39 The crankshaft supplied by the parts dept, comes without half- bearings and the main journals and crankpins are the “normal” size; the half-bearings to be fitted must therefore be selected identifying the class of each main journal crankpin for the new crankshaft. 402102.01 Service manual VF4 VF5...
  • Page 40 59.994 for the first timing-side bearing which, as indicated in the table, identifies Grade A (red); the same method should be applied for other groups of two digits for the same reference 3 (97 – 95 – 94 – 95). 402102.01 Service manual VF4 VF5...

  • Page 41: Main Journal Identification

    By quoting the order no. The above is designed to guarantee the optimum operational clearances. 402102.01 Service manual VF4 VF5...
  • Page 42 1.9 ÷ 2.1 + 100° Bolt M12 (da Nm) 2.4 ÷ 2.6 + 100° The bearing caps have progressive references (from zero to five starting from the timing system side) which define the fit- ting position. 402102.01 Service manual VF4 VF5...
  • Page 43 Test the crankpin clearance by applying plastigage to measure crankpin installation clearance. Tighten connecting rod cap bolts to the recommended torque. Connecting rod big end bearing caps Bolt M9 (da Nm) 2.4 ÷ 2.6 + 60° 402102.01 Service manual VF4 VF5...
  • Page 44 Place the crankcase rear cover with integrated oil seal in posi- tion and secure it by tightening the bolts to the recommended torque. Flywheel side oil seal cover Bolt (pre-treated to be re- M6 (daNm) 0.8 ÷1.0 placed.) (engine block side) 402102.01 Service manual VF4 VF5...
  • Page 45 Place the oil sump back in its housing. Tighten the bolts securing the oil sump to the crankcase to the recommended torque using the tool (spanner). Engine oil sump Bolts front and rear M8 (daNm) 402102.01 Service manual VF4 VF5...
  • Page 46 32.3 ÷ 35.7 (crankshaft side) (daNm) Measure the piston projection in two places at 180° on the gudg- eon pin axis using the tool and take the average of the two values measured for each piston. (dial gauge support). 402102.01 Service manual VF4 VF5...
  • Page 47 +0.201 ÷ +0.295 mm – thickness 1.02 ÷ 0.05 mm Place the cylinder head centring bushes on the cylinder block. Fit the cylinder head basket selected. Position the cylinder head on the cylinder block/crankcase. 402102.01 Service manual VF4 VF5...
  • Page 48 Place the timing belt fixed tensioner in its housing and secure it using the bolt. Fit the pressure pump mounting complete with pump and secure it using the bolts. Place the timing belt side guard in its housing and secure it using the bolts. 402102.01 Service manual VF4 VF5...
  • Page 49 Loosen the bolt fixing the exhaust side timing belt toothed drive pulley. Undo the bolt fixing the crankcase front cover shown in the dia- gram. Temporarily fit the toothed timing drive belt on the toothed drive pulley. 402102.01 Service manual VF4 VF5...
  • Page 50 Tighten the bolt fixing the exhaust side timing belt toothed drive pulley to the specified torque. Driver toothed pulley Bolt M12 (daNm) 2.9 ÷ 3.2 + 40° (camshaft side) Remove the camshaft timing tools, exhaust and crankshaft side. 402102.01 Service manual VF4 VF5...
  • Page 51 Fit the injectors and brackets in their seats and tighten the nuts. VF4: Start the assembly with the injector on the fourth cylin- der and follow the sequence until the first cylinder. VF5: Start the assembly with the injector on the fifth cylinder and follow the sequence until the first cylinder.
  • Page 52 Place the exhaust manifold assembly, complete with new gasket, back in its housing and secure it by tightening the nuts to the rec- ommended torque. Exhaust manifold Nut M8 (daNm) 2.3 ÷ 2.8 (turbocharger side) 402102.01 Service manual VF4 VF5...
  • Page 53 0.8 ÷ 1.0 (engine block side) Place the alternator in position and secure it by tightening the bolts to the recommended torque. Alternator Bolt M12x1.25x120 (daNm) 6.3 ÷ 7.7 Bolt M10x1,25x100 (daNm) 4.5 ÷ 5.5 402102.01 Service manual VF4 VF5...
  • Page 54 Secure the electrical connection for the timing sensor. Secure the electrical connection for the alternator. Place the alternator power supply cable back in its housing and secure it using the nut. Secure the engine wiring using the various retaining clips. 402102.01 Service manual VF4 VF5...

  • Page 55: Engine Flywheel

    Place the flywheel (1 a) in its housing and secure it tightening the new bolts (1b) to the recommended torque. Engine flywheel Bolt M12 (daNm) 16.0 402102.01 Service manual VF4 VF5...

  • Page 56: Crankshaft Phonic Wheel For Rpm And Timing Sensor Replace With Crankshaft Removed

    (1b) from the crankshaft. Fit a new rpm and timing sensor flywheel on the crankshaft and secure it tightening the bolts to the recommended torque. Phonic wheel on crankshaft Bolt M5 (daNm) 2.3 ÷ 3.3 402102.01 Service manual VF4 VF5...

  • Page 57: Connecting Rod Small End Bush (One) Replace

    (1b) and the tool (1c extractor/fitting tool) constructed as illustrated in the diagram. The bush should be fitted in the small end so that the lubrica- tion port is aligned with the one in the small end. 402102.01 Service manual VF4 VF5...
  • Page 58 Ream the inner diameter of the small end bush to the recom- mended figure. Small end bush Inner diameter 26.006 ÷ 26.014 mm 402102.01 Service manual VF4 VF5...

  • Page 59: Set Of Pistons, Gudgeon Pins And Seals (Replace)

    Set of pistons, gudgeon pins and seals (replace) Remove the piston rings. Release the pin (2 a) and separate the connecting rods (2b) from the piston (2c). Remove the piston rings (1 a) from the pistons using a suitable tool (1b). 402102.01 Service manual VF4 VF5...
  • Page 60 Join the connecting rods to the pistons so that the number print- ed on the connecting rod head (1 a) is facing notch (1b) on the piston skirt for the oil jet housing. Fit the pins and secure them using the cir-clips. 402102.01 Service manual VF4 VF5...

  • Page 61: Toothed Timing Belt

    Position the flywheel retaining tool in its seat (flywheel lock). Undo bolts (1 a) securing crankshaft pulley (1b) and remove. Undo the fixing bolt (2 a) and remove the single drive belt fixed tensioner (2b). 402102.01 Service manual VF4 VF5...
  • Page 62 Fit the tool (2 a template) and fasten it using the calibrated screw (2b). The crankshaft must be rotated, using small movements to allow the locating dowel on the timing drive pulley to be in- serted in the opening in the tool. 402102.01 Service manual VF4 VF5...
  • Page 63 (4b), i.e. ad just to nominal tension position, then tighten nut (4c) securing the belt tensioner to torque. Mobile timing tensioner Nut M8 (daNm) Loosen the bolt retaining the timing pulley. Rotate the crankshaft through two revolutions. Recheck the timing by refitting the timing tools 402102.01 Service manual VF4 VF5...
  • Page 64 Fit the fixed timing belt tensioner for the single engine compo- nent drive belt and tighten the retaining bolt to torque. Remove the flywheel lock. Tighten the bolt fixing the exhaust side camshaft toothed pulley to the recommended torque. 402102.01 Service manual VF4 VF5...

  • Page 65: Fuel Filter Assembly

    To screw the filter in its seat of the bracket. Connect the rapid connectors for the fuel pipes, fuel filter side. Connect the negative battery terminal (-). 402102.01 Service manual VF4 VF5...

  • Page 66: Engine Coolant Temperature Sensor

    Place the engine coolant temperature sensor in its housing and tighten it to the recommended. Engine coolant temperature sensor M ... (daNm) 0.8 Thermostat side Connect the electrical connection to the engine coolant tempera- ture sensor. 402102.01 Service manual VF4 VF5...

  • Page 67: Pressure Relief Sensor

    Position the excess pressure sensor (1 a) in its housing and secure it tightening the bolt(1b) to the recommended torque. Excess pressure sensor Bolt M ... (daNm) Connect the electrical connection for the pressure relief sensor. Connect the negative (-) battery terminal. 402102.01 Service manual VF4 VF5...

  • Page 68: Engine Rpm Sensor

    (1b) to the recommended torque . Rpm sensor Bolt M6 (daNm) 0.6 ÷ 1.0 (engine block side) Connect the electrical connection for the engine rpm sensor. Connect the negative battery terminal (-) . 402102.01 Service manual VF4 VF5...

  • Page 69: Cam Angle Sensor

    (1b) to the recommended torque. Cam angle sensor Bolt M6 (daNm) 0.8 ÷ 1.0 (cylinder head extension side) Connect the electrical connection to the cam angle sensor. Connect the negative battery terminal (-). 402102.01 Service manual VF4 VF5...

  • Page 70: Variable Geometry Turbocharger

    4.13 Variable geometry turbocharger Loosen collar (2 a) and disconnect exhaust pipe (2b) from the tur- bocharger. Undo the engine oil delivery pipe connector turbocharger side. 402102.01 Service manual VF4 VF5...
  • Page 71 Undo the nuts securing the turbocharger on the exhaust mani- fold. Remove the gasket. Undo connector (1 a) and remove turbocharger engine oil supply pipe (1b). Undo bolts (2 a) and remove turbocharger oil return pipe (2b). 402102.01 Service manual VF4 VF5...
  • Page 72 2.3 ÷ 2.8 (turbocharger side) Tighten the bolts securing the engine oil return pipe, turbocharg- er side, to the specified torque. Engine oil supply pipe from turbocharger Bolt M6 (daNm) 0.8 ÷ 1.0 (turbocharger side) 402102.01 Service manual VF4 VF5...

  • Page 73: Pressure Pump Support Vf4

    4.14 Pressure pump support VF4 Position the pressure pimp support in a vice fitted with protective jaws. Lock the rotation of the pressure pump drive pulley using two bolts. Undo the pressure pump drive pulley nut. Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously.
  • Page 74 Undo the nuts (1 a) and remove the pressure pump (1b) from the support. Place the pressure pump (1 a) on the support and secure it tight- ening the nuts (1b) to the recommended torque . Injection pressure pump mount Nut M8 (daNm) 2.3 ÷ 2.8 402102.01 Service manual VF4 VF5...
  • Page 75 Tighten the nut fixing the pressure pump drive pulley to the rec- ommended torque. Pressure pump control pulley Nut M14 (daNm) 4.2 ÷ 6.6 Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously. 402102.01 Service manual VF4 VF5...

  • Page 76: Pressure Pump Support Vf5

    Undo the pressure pump drive pulley nut. Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously. Remove the pressure pump drive pulley (1 a) using the tools (1b extractor). 402102.01 Service manual VF4 VF5...
  • Page 77 Tighten the nut fixing the pressure pump drive pulley to the rec- ommended torque. Pressure pump control pulley Nut M14 (daNm) 4.2 ÷ 6.6 Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously. 402102.01 Service manual VF4 VF5...
  • Page 78 402102.01 Service manual VF4 VF5...
  • Page 79 402102.01 Service manual VF4 VF5...
  • Page 80 FOKKERSTRAAT 571 - 3125 BD SCHIEDAM - HOLLAND vetus TEL.: +31 (10) 4377700 - TELEFAX: +31 (10) 4372673 - 4621286 n.v. INTERNET: http://www.vetus.com E-MAIL: sales@vetus.nl 402102.01 12-09 Printed in the Netherlands...

This manual is also suitable for:

Vf5Vf4.140eVf4.170eVf5.220eVf5.250e

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