580 M Series 3 F4C Engine Service Training Manual 0407 87630273 PDF

REPAIR MANUAL
F4GE9454H
F4GE9454J
F4GE9484D
F4HE9484A
Issued 04-2007 - Service Training Edits

Book/Form Number 87630273 NA
Copyright 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. Bur
Source Code No. unknown
ENGINE REPAIR MANUAL
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer
Revision History
Issue
First Edition
Issue Date
Applicable Machine
Remarks
04-2007
F4GE9454H, F4GE9454J, F4GE9484D,

F4HE9484A
87630273 NA

TABLE OF CONTENTS
CHAPTER 1
DIAGNOSTICS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHAPTER 2
445TA ENGINE OVERHAUL

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
F4GE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
COUNTER BALANCER- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
ENGINE LUBRICATION FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
ENGINE LUBRICATION FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . 2-54
KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION FOR F4GE ENGINES . . . . . . . . . . 2-56
HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES . . . . . . . . . . . . . . . . 2-59
EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
FUEL SUPPLY SYSTEM- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
SPECIAL DISASSEMBLY FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
SPECIAL DISASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . 2-97
CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
INJECTION PUMP TIMING FIRST PHASE FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
ASSEMBLING COUNTER BALANCER FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123
MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137
87519803 NA
Issued 04-07
Bur
SECTION 1 - ENGINE REPAIR MANUAL
INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD ASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-138
2-138
2-141
2-144
2-145
2-147
2-149
2-150
2-153
2-153
2-154
2-157
2-158
2-158
2-159
CHAPTER 3
ELECTRICAL, CHARGING AND START-UP

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . 3-3
LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . 3-6
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
II
Issued 04-07
Bur
87519803 NA
CHAPTER 1
445TA
TIER III
DIAGNOSTICS
Issued 04-2007
CHAPTER 1 - DIAGNOSTICS
Revision History
Issue
First Edition
1-II
Issue Date
Applicable Machines
Remarks
04-2007
F4GE9454H, F4GE9454J,
F4GE9484D, F4HE9484A
87630273 NA
Issued 04-07
Bur
87630273 NA
CHAPTER 1
DIAGNOSTICS
TABLE OF CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine Wont Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Engine Lacks Power and Runs Erratically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Engine lacks power and runs erratically (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine Exhaust Smoke Black or Dark Grey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine exhaust smoke black or dark grey (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Engine Exhaust Smoke Grey (Verging On White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Engine Exhaust Smoke Light Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Engine Knocks Irregularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Engine Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Engine Exceeds Max. Revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Engine Wont Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
87630273 NA
Issued 04-07
Bur
1-1
NOTES
1-2
Issued 04-07
Bur
87630273 NA
TROUBLESHOOTING
ENGINE WONT START
No
Batteries fully charged.
Perform the checks described in the electrical

section of the shop manual.
Yes
Connections to battery terminals are tight and clean.
No
Inspect, clean, tighten nuts or replace terminals if

excessively corroded.
No
Perform the checks described in the electrical

section of the repair manual.
No
Check using multi meter replace or repair. Refer to

Chapter 3 pages 3-5 and 3-14.
No
Refuel tank.
Yes
Replace.
No
Verify timing described in Chapter 2 page 2-120 and

2-141 for mechanical injection. Common rail pump
bring to certified pump shop.
No
On common rail engines check using Electronic

Service Tool (EST). Mechanical injection loosen
(crack) injection lines.
Yes
Check and repair air leaks. For mechanical injection

see Chapter 2 page 2-56
Yes
Check and clean the fuel system including the fuel

tank.
No
Check fuel pump and replace if necessary.
No
Check and replace defective parts. See Chapter 2

page 2-55
No
Check cylinders for proper compression, overhaul

engine or make repairs on defective parts,.
Yes
Starter motor working properly.
Yes
Grid heater system working properly.
Yes
Fuel in tank.
Yes
Fuel filters plugged.
No
Injection pump timed properly.
Yes
Injectors working properly.
Yes
The fuel system or injection pump shows signs of air
in system.
No
The fuel system shows traces of water.
No
Fuel pump working properly.
Yes
Cold start advance solenoid and shut off solenoid
both in working order.
Yes
Compression good on all cylinders.
87630273 NA
Issued 04-07
Bur
1-3
ENGINE OVERHEATS
Coolant level correct.
No
Check for leaks, repair leaks and refill to

proper level.
Yes
Fan working properly.
No
Replace.
No
Replace.
No
Check for leaks, bad bearing, overhaul or

replace.
No
Replace.
Yes
Wash down, repair leaks and flush out

radiator. If necessary replace radiator.
Yes
Clean or replace faulty parts.
Yes
Clean thoroughly.
No
Check and adjust for correct valve

clearance.
No
Verify correct timing described in Chapter 2

page 2-120 and 2-141 for mechanical
injection. Common rail pump bring to
certified pump shop.
Yes
Replace.
Yes
Drive belts serviceable.
Yes
Water Pump working properly.
Yes
Thermostat working properly.
Yes
Radiator plugged or leaking.
No
Air to Air Cooler and hoses leaking.
No
Openings for coolant flow within the cylinder
head and engine block plugged.
No
Valve clearance correct.
Yes
Injection pump timed correctly.
Yes
Cylinder head gasket leaking.
1-4
Issued 04-07
Bur
87630273 NA
ENGINE LACKS POWER AND RUNS ERRATICALLY
Correct tie rod length between hand throttle
and accelerator pedal.
No
Adjust rod length.
Yes
Replace.
Yes
Clean or replace filter.
Yes
Check and clean the fuel system including

the fuel tank.
No
Replace.
No

injection. High pressure pump bring to
No
Check and if defective repair or replace.

Refer to Chapter 2 page 2-55
No
Power to KKSB solenoid repair or replace if

defective.
No
Replace.
No
On common rail engines check using

Electronic Service Tool (EST) .Mechanical
injection loosen (crack) injection lines.
No
Bring to a certified pump shop for repair.
Yes
No
Air filter plugged.
No
The fuel system shows impurities and or
traces of water.
No
Thermostat working properly.
Yes
Injection pump timed correctly
Yes
Cold start solenoid (in injection pump) KKSB
working properly.
Yes
Timing plunger (in injection pump) working
properly.
Yes
Fuel pump working properly.
Yes
Injectors working properly
Yes
Injection pump rate correct.
Yes
Speed governor (in injection pump) in
working order at all speeds.
No
Yes
87630273 NA
Issued 04-07
Bur
1-5
Engine lacks power and runs erratically (continued)
Circuit and L.D.A.device both in working
order.
No
Yes
Injection pump peak adjusted.
No
No
Adjust clearance for proper value.
No
Check each cylinder for proper compression,

overhaul the engine or make repairs on
defective parts (valves, piston rings, etc.)
No
Repair or replace unit.
Yes
Correct valve clearance.
Yes
Yes
Turbocharger working properly.
1-6
Issued 04-07
Bur
87630273 NA
ENGINE EXHAUST SMOKE BLACK OR DARK GREY
Fresh clean diesel fuel in tank.
No
Clean the tank and replace the fuel filter.
Yes
Clean replace if necessary.
No
Check using multi meter replace or repair.

Refer to Chapter 3 pages 3-5 and 3-14.
No
Cold start solenoid (KKSB) working properly.

Remove connector measure solenoid 4.8
0.2 ohms. See Chapter 2 page 2-55
No

No

No
No
Yes
Air filter plugged.
No
Grid heater system working properly.
Yes
KKSB solenoid working properly.
Yes
Yes
Yes
Circuit and L.D.A.device both in working
order.
Yes
Injection pump adjusted properly.
Yes
87630273 NA
Issued 04-07
Bur
1-7
Engine exhaust smoke black or dark grey (continued)
Injection pipes intact.
No
Check the condition of pipes and replace

them if necessary.
No

defective parts (valves, piston rings, etc.).
Yes
ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)

Grid heater working properly.
No
Check using multi meter replace or repair.

Refer to Chapter 3 pages 3-5 and 3-14.
Yes
Coolant level correct.
No
Possible flow of coolant into the combustion

chamber. Replace the cylinder head gasket
or overhaul the engine.
No

No

Yes
Yes
Yes
Fresh clean diesel fuel in tank.
No
Clean the tank and replace the fuel filter.
ENGINE EXHAUST SMOKE LIGHT BLUE
Excessive oil consumption.
1-8
Yes
Check: oil vapor breather, cylinder

compression. Leaks into or out of
turbocharger. Leaks from valve guides.
Overhaul cylinder head or engine if
necessary.
Issued 04-07
Bur
87630273 NA
ENGINE KNOCKS IRREGULARLY
Knock detected in the crankshaft.
Yes
Check the following items: Journal play and

out-of -roundness, bolt torque for main
journal caps and engine flywheel, oil
pressure. Replace the defective parts or
overhaul the engine.
No
Knock detected in the connecting rods.
Yes
Check the following items: Rod journal end

play and out-of -roundness, bolt torque for
connecting rod caps, connecting rod torsion,
straightness. Replace defective parts or
Yes
Check the following items: Play between the

pistons and the cylinder liners, integrity of
piston rings, play between the pins and the
piston hubs. Replace the defective parts or
Yes
Check the following items: Play between the

rocker arms and the valves, injection pump
timing, valve timing. Adjust to proper
specification.
Yes
Check and replace if necessary the gears.

Inspect for broken springs, excessive play
between the stems and guides, and the
tappets and seats. Adjust the clearance.
Yes

Yes
Replace loose bolts and tighten all bolts to

the specified torque and angles.
Yes

No
Knock detected in pistons.
No
Knock detected in the cylinder head.
No
Knock detected in valve gear.
No
Knock detected in injectors.
No
Knock detected in the engine flywheel.
No
Knock detected in the injection pump.
87630273 NA
Issued 04-07
Bur
1-9
ENGINE STOPS
Fuel in tank.
No
Refuel and drain if necessary.
Yes
Replace.
No
Check the solenoid replace if defective.
No
Check and if defective bring to a certified

pump shop for repair.For common rail refer
to Chapter 2 page 2-77. For mechanical
injection refer to Chapter 2 page 2-53
No

pump shop for repair.
No
Adjust.
No
Adjust play to proper specifications.
No
Replace broken valves.
Yes
No
Fuel Shut Off (FSO) solenoid working
properly.
Yes
Regular injection pump rate.
Yes
Injection pump controls working properly.
Yes
Regular idle speed.
Yes
Correct play between the valves and rocker
arms.
Yes
Valves intact.
EXCESSIVE OR INSUFFICIENT OIL PRESSURE
Oil pressure control valve working properly.
No
Check and replace if necessary.
Yes
Oil level correct and proper engine oil SAE
viscosity.
No
Check to see if contaminated or proper

viscosity and fill to proper level if low.
No
Check and replace if necessary.
No
Replace the bearings and reface if

necessary the crankshaft.
Yes
Oil pump and delivery lines in working
properly
Yes
Main bearings and connecting rod bearings
in acceptable condition.
Yes
1-10
Issued 04-07
Bur
87630273 NA
Excessive or Insufficient Oil Pressure continued
Low oil pressure caused by fuel dilution.
Yes
Check for leaking shaft seal or leaking

injection pump.
No
Replace the bearings and reface if

necessary the crankshaft.
Yes
Repair leaks (if any) and replace the worn

parts.
Yes
Replace.
No

pump shop for repair.For common rail refer
to Chapter 2 page 2-77. For mechanical
injection refer to Chapter 2 page 2-53
No

injection loosen injection lines.
No
Check and if wrong adjust to proper value.
No

defective parts (valves, piston rings, etc.).
No
Replace.
No

pump shop for repair.
No
Main bearings and connecting rod bearings
working properly.
EXCESSIVE FUEL CONSUMPTION
Fuel tank and lines leaking.
No
Air filter plugged.
No
Injection pump operating properly.
Yes
Electronic fuel injection system operating
properly.
Yes
Valve adjustment correct.
Yes
ENGINE WONT STOP

Fuel Shut Off solenoid working properly.
Yes
Speed governor working properly.
87630273 NA
Issued 04-07
Bur
1-11
NOTES
1-12
Issued 04-07
Bur
87630273 NA
CHAPTER 2
445TA
TIER III
Issued 04-2007
CHAPTER 2 - 445TA ENGINE OVERHAUL
Revision History
Issue
First Edition
2-II
Issue Date
Applicable Machines
Remarks
04-2007
F4GE9454H, F4GE9454J, F4GE9484D

F4HE9484A
87630273 NA
Issued 04-07
Bur
87630273 NA
CHAPTER 2

TABLE OF CONTENTS
F4GE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
F4GE9454H and F4GE9454J Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
F4GE9484D Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
F4HE9484A Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EGR Exhaust Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Control for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Control for F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head for F4GE9454h and f4GE9454J Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head for F4GE9484D Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head for F4HE9484A Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Valve Seats for F4GE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Valve Seats for- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-24
2-24
2-25
2-25
2-26
2-27
2-28
2-28
2-29
2-30
2-31
2-32
2-33
2-34
2-36
2-37
ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

COUNTER BALANCER- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
ENGINE LUBRICATION FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
ENGINE LUBRICATION FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan (Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Vapor Recirculation for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Vapor Recirculation for- F4HE Engines with Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blow-By Recirulation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Vapor Recirculation for- F4HE Engines without Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-41
2-42
2-42
2-42
2-43
2-43
2-44
2-45
2-45
2-46
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

87630273 NA
Issued 04-07
Bur
2-1
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Boosting Version Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
Inter-Cooled Engine Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Mechanical Fuel lift Pump- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Mechanical Injection Working Principles- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . . . . . 2-54
KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
MECHANICAL INJECTION FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION . . . . . . . . . 2-56
Parts needed for pressure/ vacuum testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57
Normal system operating observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . 2-59
EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Engine Preheating Element Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Phase Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Injection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Injection Pressure Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Pilot and Main Injection Advance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Idle Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Overheating Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Maximum Engine Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Cut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Smoke Control Under Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
After Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Control Of Working Speed In Normal Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Recover Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61
FUEL SUPPLY SYSTEM- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Fuel Supply System Diagram- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64
Mechanical Feed Pump- Normal Operating Condition- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65
Mechanical Feed Pump- Outlet Overpressure Condition In Exhaust Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65
Fuel System Bleeding Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
High Pressure Pump Type CP3.3- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67
High Pressure Pump Inside Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69
Operating Principal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Injection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74
Electro-Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75
Pressure Limiter for Fuel Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76
CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Low Pressure Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77
Low - Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78
Test On Pressure Relief Valve On Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79
Test On Fuel Backflow From the Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80
SPECIAL DISASSEMBLY FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82
Crank Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84
2-2
Issued 04-07
Bur
87630273 NA
Removing Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85

Removing Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
SPECIAL DISASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Checking Crankcase Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Checking Eccentric Lift and Bearing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Cam Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Tappets and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-102
2-102
2-103
2-103
2-103
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring Bearing Journals and Connecting Rods Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Oil Pump Drive Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Crankshaft Shoulder Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-105
2-105
2-107
2-107
2-109
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions for Correct Pin/Piston Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Twisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Flexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling Piston To Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Connecting Rod-Piston Assemblies In Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring Crank Pin Assembly Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Piston Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-109
2-111
2-111
2-112
2-113
2-113
2-114
2-114
2-114
2-115
2-116
2-116
2-118
VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118

INJECTION PUMP TIMING FIRST PHASE FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
ASSEMBLING COUNTER BALANCER FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
Counter Balancer Timing- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123
Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124
MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Descaling, Check and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Valve Guide Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seats Regrinding- Replacing Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-131
2-131
2-131
2-132
2-132
2-133
2-134
MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134

Installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
87630273 NA
Issued 04-07
Bur
2-3
Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135

Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135
Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136
Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137
INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137
INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
CYLINDER HEAD ASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147
Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147
Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
Checking Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149
Valve Cleaning, Checks and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149
Checking Valve guide wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150
Valve Seats- Regrinding, Replacing, Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
Fitting Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154
Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154
INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154
Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156
Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156
LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157
ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158
INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158
INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159
Injector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160
Installing Tappet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160
Exhaust Manifold/Turbo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-161
Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162
Fuel Filter Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162
Wiring Harness Connections to the Engine- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-163
2-4
Issued 04-07
Bur
87630273 NA
F4GE- ENGINES
Figure 2-1
BS06N188
F4GE9454H & F4GE9454J ENGINE
Figure 2-2
BS06N189
F4GE9484D ENGINE
The NEF F4GE engines are characterized by a four

stroke atmospheric or turbocharged two valves per
cylinder.
Fuel feed is provided by rotary mechanical injection
pump.
87630273 NA
Issued 04-07
Bur
It differs from other applications because of the

provision of different power, power take-off, for
different collector configurations, boost turbine and
after cooler.
2-5
F4HE- ENGINES
Figure 2-3
BS07D071
F4HE9484A ENGINE
The NEF F4HE engines are characterized by a four

stroke diesel, turbocharged, four valves per cylinder.
They have high pressure injection fueling
(common rail) and are entirely electronically driven in
order to optimize the fuel efficiency and performance.
Also limiting emissions as much as possible.
BS07D072
Figure 2-4
F4HE9484A ENGINE SHOWING THE EDC7UC31

CONTROL BOX (1).
2-6
Issued 04-07
Bur
87630273 NA
CODING OF SOURCE ENGINES

ENGINE MODEL BREAKDOWN DISCRIPTION
1= Common Rail 4 valve

2= Common Rail 2 valve
3= In Line 4 valve
4= In Line 2 valve
5= Rotary 4 valve
6= Rotary 2 valve
Emissions Level: J= Tier 3
Approved power rating
Application:
4= Agricultural. machinery - Earth moving
Fuel / Injection / Induction
0= Diesel injection - naturally aspirated
5= Diesel injection - Turbocharged
8= Diesel injection - Turbo - after cooler
Number of Cylinders
4= 4 cylinders
6= 6 cylinders
9= Internal EGR
E= Engine
Type of crankcase:
A= Non-structural crankcase 102 mm - 4 valves - 3.9 or 5.9 liter
B= Non-structural crankcase 102 mm - 2valves - 3.9 or 5.9 liter
C= Structural crankcase 104 mm - 2 valves - 4.5 or 6.8 liter
D= Structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter
E= Structural crankcase 102 mm - 4 valves - 3.9 or 5.9 liter
F= Structural crankcase 104 mm - 2 valves - 3.9 or 5.9 liter
G= Non-structural crankcase 104 mm - 2 valves - 4.5 or 6.8 liter
H= Non-structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter
Engine Family: Includes 4 cylinder and 6 cylinder in both 2 valves and 4 valves per cylinder
mechanical and common rail fuel systems
87630273 NA
Issued 04-07
Bur
2-7
ENGINE PROPERTIES
A F4GE9454H F4GE9454H F4GE9454J F4GE9454J F4GE9484D F4GE9484D
B
*J601
*J602
*J600
*J601
*J601
4 Cylinders
4485 cm (273.7 cubic inches)
74 kW
(100 h.p.)
2000 rpm
74 kW
(100 h.p.)
2000 rpm
66 kW
(90 h.p.)
2000 rpm
F
G
H
66 kW
(90 h.p.)
2000 rpm
93 kW
(126 h.p.)
2200 rpm
F4HE9484A
*J602
* J101
93 kW
(126 h.p.)
2200 rpm
104 kW
(141 h.p.)
2200 rpm
Direct Injection
High pressure
Common rail
EDC7UC31
Rotary Injection pump

T.C. (Boosted)
T.A.A.- (Boosted by Intercooler)
A. Type of engine
B. Engine model
C. Number of cylinders
D. Total displacement
E. Maximum power currently available
F. Type of Injection
G. Injection system
H. Air supply system
2-8
Issued 04-07
Bur
87630273 NA
GENERAL ENGINE FEATURES
10
11
Figure 2-5
BS06K013
REF.
NO.
ENGINE TYPE
F4GE9454H
J601
J602
F4GE9484D
J600
J601
J601
Boosted
Air
Direct
Number of cylinders
Bore
104 mm (4.1 in.)
Stroke
132 mm (5.2 in)
Total displacement
Compression ratio
Maximum Torque
No-load idle
10
No-load peak rpm
11
4 in-line
4485cm (273.7 cubic inches)

17.5: 1
Maximum power rating (net power at flywheel ISO 14396)
Issued 04-07
Bur
16.5: 1
74 kW
66 kW
93 kW
104 kW
2000 rpm
2000 rpm
2200 rpm
2200 rpm
100 hp
90 hp
126 hp
141 hp
2000 rpm
2000 rpm
2200 rpm
2200 rpm
400 Nm
375 Nm
510 Nm
608 Nm
1250 rpm
1250 rpm
1250 rpm
1600 rpm
295 lb.-ft.
277 lb.-ft.
376 lb.- ft.
448 lb.-ft.
1250 rpm
1250 rpm
1250 rpm
1600 rpm
without intercooler
HOLSET HX25
Boosting (type of turbocharger)
87630273 NA
J101
Boosted by intercooler
Injection
J602
F4HE9484A
4- Stroke diesel engine
Cycle
1
F4GE9454J
with
with intercooler intercooler
HOLSET HX25 HOLSET
HX27W
2-9
12
13
14
15
16
17
18
19
Figure 2-6
BS06K014
REF.
NO.
ENGINE TYPE
Lubrication.
12
Cooling.
F4GE9454J
J600
F4GE9484D
J601
J601
J602
F4HE9484A
J101
Forced by means of gear pump, pressure relief valve, oil filter.

0.70 bar (10 psi)
3.50 bar (50 psi)
4.0 bar (58 psi)
By centrifugal pump, regulated by thermostat, heat exchanger,

intercooler
By means of Belt
Water pump drive.

Thermostat start of opening temperature.
14
J602
Oil pressure with hot engine: at idle rpm.

Oil pressure with hot engine: at peak rpm.
13
F4GE9454H
J601
79 to 83 C (174 to 181 F)
Oil capacity engine sump.
Refer to Owners Manual
Oil capacity engine sump + filter.
Refer to Owners Manual
15
Fuel feed type
Rotary Bosch - VE4 / 12 F
High Pressure
Common Rail,
EDC7UC31
16
Pump setting
0 0.5
N.A.
17
Start of delivery
0.95 to 1.05 mm (0.0374 to 0.0413 in.)
N.A.
Type of injector
N.A.
CRIU 2
18
Injection sequence
19
Injection pressure
2-10
1 -3 -4 -2
250 to 1600 bar
N.A.
3626 to 23206 psi
Issued 04-07
Bur
87630273 NA
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY
44
10
Figure 2-7
BS06K015
REF.
NO.
1
ENGINE TYPE
Cylinder bore.
F4GE9454H
F4GE9454J
F4GE9484D
J601
J600
J601
J602
J601
F4HE9484A
J602
J101
104.000 to 104.024 mm. (4.0945 to 4.0954 in.)
Pistons:
2
Measurement dimension.
X=
55.90 mm. (2.20 in.)
Outer diameter.
1=
103.714 to 103.732 mm. (4.0832 to 4.0839 in.)

38.010 to 38.016 mm. (1.4965 to 1.4967 in.)
Pin seat.
2=
Piston - cylinder liners.
0.252 to 0.294 mm. (0.0099 to 0.0116 in.)
Piston diameter.
Protrusion of pistons from crankcase.
Piston pin.
3=
Piston pin-Pin seat.
0.01 to 0.022 mm. (0.0004 to 0.0009 in.)
Piston ring grooves

(measured on of 99.0mm 3.898 in.)
8
Piston rings
(measured 1.5 mm 0.05905 in. away from external ).
9
10
Piston rings - Slots.

Piston rings.
87630273 NA
0.4 mm. (0.0157 in.)

0.28 to 0.52 mm (0.01102 to 0.02047 in.)
37.994 to 38.000 mm. (1.4958 to 1.4961 in.)
X1=
2.705 to 2.735 mm. (0.1065 to 0.1077 in.)
X2=
2.44 to 2.46 mm. (0.0961 to 0.0969 in.)
X3=
4.03 to 4.05 mm. (0.1587 to 0.1594 in.)
S1=
2.560 to 2.605 mm. (0.1008 to 0.1026 in.)
S2=
2.350 to 2.380 mm. (0.0925 to 0.0937 in.)
S3=
3.970 to 3.990 mm. (0.1563 to 0.1571 in.)
1=
0.100 to 0.175 mm. (0.0039 to 0.0069 in.)
2=
0.060 to 0.110 mm. (0.0024 to 0.0043 in.)
3=
0.040 to 0.080 mm. (0.0016 to 0.0031 in.)
0.40 mm. (0.0157 in.)
Issued 04-07
Bur
2-11
11
12
14
13
15
17
16
Figure 2-8
BS06K016
REF.
NO.
ENGINE TYPE
F4GE9454H
J601
J602
F4GE9454J
J600
J601
F4GE9484D
J601
J602
X1=
0.30 to 0.40 mm. (0.0118 to 0.0157 in.)
X2=
0.60 to 0.80 mm. (0.0236 to 0.0315 in.)
X3=
0.30 to 0.55 mm. (0.0118 to 0.0217 in.)
Connecting rod small-end bearing seat.
1=
40.987 to 41.013 mm. (1.6137 to 1.6147 in.)
Connecting rod large-bearing seat.
2=
72.987 to 73.013 mm. (2.8735 to 2.8745 in.)
Inner
3=
38.019 to 38.033 mm. (1.4968 to 1.4974 in.)
Big end half bearings
S=
14
Connecting rod small-end bearing seat.
0.250 to 0.500 mm. (0.0098 to 0.01968 in.)
15
Piston pin - bearing.
0.019 to 0.039 mm. (0.0007 to 0.0015 in.)
11
12
Piston ring gaps in cylinder liner.
F4HE9484A
J101
Connecting rod small-end bearing diameter.

13
16
17
2-12
1.955 to 1.968 mm. (0.0770 to 0.0775 in.)
Measurement dimension.
No Information Available
Maximum error on connecting rod axis parallelism.
Bearing journals
1=
82.990 to 83.010 mm. (3.2673 to 3.2681 in.)
Crank pins
2=
68.987 to 69.013 mm. (2.7160 to 2.7170 in.)
Main half bearings (supplied as spares).
S1=
2.456 to 2.464 mm. (0.0967 to 0.0970 in.)
Connecting rod half bearings.
S2=
1.955 to 1.968 mm. (0.0770 to 0.0775 in.)
Numbers 1, 5
87.982 to 88.008 mm. (3.4638 to 3.4649 in.)
Numbers 2, 3, 4
3=
87.977 to 88.013 mm. (3.4637 to 3.4651 in.)
Main bearing- journals
Issued 04-07
Bur
87630273 NA
18
19
20
22
21
23
Figure 2-9
BS06K017
REF.
NO.
F4GE9454H
ENGINE TYPE
J601
J602
F4GE9454J
J600
J601
F4GE9484D
J601
J602
F4HE9484A
J101
Half bearing- journals.

Numbers 1, 5
18
Numbers 2, 3, 4
Half bearing - crank pins.
0.064 to 0.095 mm. (0.0025 to 0.0037 in.)
0.041 to 0.119 mm. (0.0016

to 0.0047 in.)
0.059 to 0.100 mm. (0.0023 to 0.0039 in.)
0.041 to 0.103 mm. (0.0016

to 0.0041 in.)
0.064 to 0.090 mm. (0.0025 to 0.0035 in.)
0.033 to 0.041 mm. (0.0013

to 0.0016 in.)
19
+0.250 mm. (0.0098 in.)

Main half bearings
Big end connecting rod half bearings. +0.500 mm. (0.0197 in.)
20
Main journal of thrust bearing.
X1= 37.475 to 37.550 mm. (1.4754 to 1.4783 in.)
21
Main bearing housing of thrust

bearing.
X2= 32.180 to 32.280 mm. (1.2669 to 1.2709 in.)
22
Shoulder half ring.
X3= 37.280 to 37.380 mm. (1.4677 to 1.4716 in.)
23
Crankshaft shoulder.
0.095 to 0.270 mm. (0.0037 to 0.0106 in.)
87630273 NA
Issued 04-07
Bur
2-13
VALVE GEAR - CYLINDER ASSEMBLY
8
Figure 2-10
BS06K018
REF.
NO.
1
ENGINE TYPE
Valve guide seats on cylinder head.
Valves - Intake.
F4GE9454H
F4GE9454J F4GE9484D
F4HE9484A
J601
J600 J601 J601 J602
J101
J602
1= 8.019 to 8.039 mm.

(0.316 to 0.317 in.)
7.042 to 7.062 mm.

(0.277 to 0.278 in.)
4= 7.960 to 7.980 mm.

(0.313 to 0.314 in.)
6.970 to 6.990 mm.

(0.274 to 0.275 in.)
angle=
60 0.25
60 0.25
2
4= 7.960 to 7.980 mm.
(0.313 to 0.314 in.)
Valves - Exhaust.
Angle=
3
6.970 to 6.990 mm.

(0.274 to 0.275 in.)
Angle=
45 0.25
45 0.25
Valve stem and respective guide.
0.059 to 0.086 mm (0.002 to 0.003 in.) 0.052 to 0.092 mm (0.002 to 0.003 in.)
Seat on head for valve seat. -
Intake.
46.987 to 47.013 mm
(1.850 to 1.851 in.)
34.837 to 34.863 mm
(1.371 to 1.373 in.)
Seat on head for valve seat. -
Exhaust.
43.637 to 43.663 mm.

(1.718 to 1.719 in.)
34.837 to 34.863 mm
(1.371 to 1.373 in.)
2= 47.063 to 47.089 mm.

(1.853 to 1.8534 in.)
34.917 to 34.931 mm.

(1.374 to 1.375 in.)
Valve seat outer diameter; angle of valve

seats on cylinder head.
Intake.
angle=
angle=
7
8
2-14
angle= 60
34.917 to 34.931 mm.
(1.374 to 1.375 in.)
2= 43.713 to 43.739 mm.

(1.7210 to 1.7220 in.)
Exhaust.
60
45
angle= 45
Recessing.
Intake valve
1.00 to 1.52 mm. (0.039 to 0.060 in.)
0.59 to 1.11 mm. (0.023 to 0.044 in.)
Recessing.
Exhaust valve
1.00 to 1.52 mm. (0.039 to 0.060 in.)
0.59 to 1.11 mm. (0.023 to 0.044 in.)
0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)
Between valve seat and head-
Intake
Between valve seat and head-
Exhaust 0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)
Valve seats
Issued 04-07
Bur
87630273 NA
11
10
15 18 22
17
16
14
13
12
21
20
19
Figure 2-11
BS06K019
REF.
NO.
F4GE9454H
ENGINE TYPE
J601
F4GE9454J
J602
J600
J601
F4GE9484D
J601
J602
F4HE9484A
J101
Valve spring height: Free spring.
H=
63.5 mm. (2.500 in.)
47.75 mm (1.880 in.)
Under load of: 329 N (74 lbf).
H1=
49.02 mm. (1.930 in.)
35.33 mm (1.391 in.)
Under load of: 641 N (144 lbf).
H2=
38.20 mm. (1.504 in.)
25.2 mm (0.992 in.)
X=
Injector protrusion.
Not Adjustable
Seats camshaft bearing.- number - 1

(flywheel side)
7= 59.222 to 59.248 mm.

(2.332 to 2.333 in.)
Seats camshaft bearings.numbers - 2, 3, 4, 5
1-6= 54.089 to 54.139 mm.

(2.130 to 2.132 in.)
11
Camshaft main bearing journals:

1 through 5
1, 2, 3, 4, 5 = 53.995 to 54.045 mm.

(2.126 to 2.128 in.)
12
Camshaft bushing outside diameter
= N.A.
13
Camshaft bearing inner diameter.
=54.083 to 54.147 mm. (2.129 to 2.132 in.)
14
Bearing and seats in crankcase.
N.A.
15
Bearing and main journals.
0.038 to 0.162 mm. (0.002 to 0.006 in.)
Useful cam lift- Intake.
10.74 mm. (0.423 in.)
7.5282 mm (0.296 in.)
Useful cam lift- Exhaust.
11.02 mm. (0.434 in.)
6.045 mm (0.238 in.)
Tappet plate seat in crankcase.
1= 16.000 to 16.030 mm. (0.630 to 0.631 in.)
10
16
2= 15.924 to 15.954 mm. (0.627 to 0.628 in.)
17
Tappet plate outside diameter.
18
3= 15.965 to 15.980 mm.(0.629 to 0.629 in.)
15.960 to 15.975 mm
(0.628 to 0.629 in.)
Between tappets and seat.
19
Tappets.
20
Rocker arm shaft.
1= 18.963 to 18.975 mm.

(0.747 to 0.747 in.)
21.965 to 21.977 mm
(0.8647 to 0.8652 in.)
21
Rocker arms
2=
22.001 to 22.027 mm
(0.866 to 0.867 in.)
22
Between rocker arm and spindle
87630273 NA
Issued 04-07
Bur
19.000 to 19.026 mm. (0.748 to 0.749 in.)

0.025 to 0.063 mm.
(0.001 to 0.003 in.)
0.024 to 0.162 mm
(0.00094 to 0.0064 in.)
2-15
TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES

PART ...................................................................................................................................... TORQUE - Nm (lb.-ft.)
Cylinder head fastening bolts.
1st phase. (pre lubricated with oil)

Bolts M12x1.75x70 .................................................................................45 to 55 Nm (33.2 to 40.6 pound-feet)
Bolts M12x1.75x140 ...............................................................................35 to 45 Nm (25.8 to 33.2 pound-feet)
Bolts M12x1.75x180 ...............................................................................65 to 75 Nm (47.9 to 55.3 pound-feet)
2nd phase (additional rotation)..........................................................................................90 degrees 5 degrees
3rd phase (only for bolts 140 and 180 mm long additional rotation) .................................90 degrees 5 degrees
Crankshaft main bearings.
1st phase (pre lubricate with oil). ................................................................44 to 56 Nm (32.5 to 41.3 pound-feet)
2nd phase ...................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet)
3rd phase. (additional rotation). ......................................................................................................90 5 degrees
Bolts fastening the pulley on the crankshaft ................................................105 to 115 Nm (77.4 to 84.8 pound-feet)
Connecting rod cap bolts.
1st phase. (pre lubricate with oil). ...............................................................27 to 33 Nm (19.9 to 24.3 pound-feet)
2nd phase ...................................................................................................55 to 65 Nm (40.5 to 47.9 pound-feet)
3rd phase. additional rotation ..........................................................................................................60 5 degrees
Engine flywheel fastening bolts. M12x1.5
1st phase. (pre lubricate with oil) ................................................................26 to 34 Nm (19.2 to 25.1 pound-feet)
2nd phase. (additional rotation).......................................................................................................60 5 degrees
Flywheel housing
M12x120 .....................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet)
M12x80 .......................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet)
Assembly rear cover plate to flywheel housing (M8x1.25x16).........................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel injectors. ..................................................................................................55 to 65 Nm (40.6 to 47.9 pound-feet)
Sump (oil pan) M8x1.25. .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Sump (oil pan) M18x1.5 ..................................................................................51 to 69 Nm (37.6 to 50.9 pound-feet)
Oil pan drain plug ............................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Oil filter............................................................................................................................................ Contact + 3/4 turn
Oil bypass valve to lube filter head ..................................................................72 to 88 Nm (53.1 to 64.9 pound-feet)
Fuel filter. ........................................................................................................................................ Contact + 3/4 turn
Injection pump fastening bolts. ........................................................................20 to 30 Nm (14.8 to 22.1 pound-feet)
Injection pump gear (drive gear nut)
1st stage......................................................................................................15 to 20 Nm (11.0 to 14.8 pound-feet)
2nd stage ....................................................................................................85 to 90 Nm (62.7 to 66.4 pound-feet)
Valve gear cover and case fastening bolts (front cover). .................................20 to 30 Nm (14.8 to 22.1 pound-feet)
Intake manifold fastening bolts. .......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Assembly air intake connection M8x1.25 ........................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel pump fastening bolts M8 bolt...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel pump fastening bolts M6 bolt.........................................................................9 to 11 Nm (6.6 to 8.1 pound-feet)
Fuel pump M6 nut..................................................................................................9 to 11 Nm (6.6 to 8.1 pound-feet)
Exhaust manifold fastening bolts. .....................................................................37 to 49Nm (27.3 to 36.1 pound-feet)
Valve cover fastening nuts. ..............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Rocker arm support fastening bolts.................................................................40 to 56 Nm (29.5 to 41.3 pound-feet)
Rocker arm adjusting nut.................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft shoulder plate fastening bolts..........................................................20 to 30 Nm (14.8 to 22.1 pound-feet)
Camshaft retaining plate bolts M8 ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet.)
Fan support fastening bolts M10x1.5x20.........................................................28 to 38 Nm (20.7 to 28.0 pound-feet)
Fan pulley fastening bolts
M6 ....................................................................................................................8 to 12 Nm (5.9 to 8.8 pound-feet)
M10 .............................................................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
Turbocharger fastening bolts. ..........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
Starter motor fastening bolts. ..........................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)
2-16
Issued 04-07
Bur
87630273 NA

Alternator fastening bolts.
Alternator to alternator support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Alternator to water inlet M8 bolt ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Alternator lower mount M10 ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Alternator upper pivot M10 bolt ...................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)
Alternator mounting hardware M12x1.75x120 .............................................37 to 49Nm (27.3 to 36.1 pound-feet)
Alternator wiring M6 nut ....................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Water pump fastening bolts. ............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Water outlet connection
M8x1.25x35.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
M8x1.25x70.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Heat exchanger fastening bolts .......................................................................20 to 30 Nm (14.8 to 22.1 pound-feet)
Camshaft gear bolt M8 ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet)
Rear gear housing assembly
M8 ...............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Cylinder lubricating nozzles M8x1.25x10 ..........................................................12 to 18 Nm (8.9 to 13.3 pound-feet)
Engine counter balancer................................................................................. 40 to 56 Nm (29.5 to 41.3 pound-feet)
Engine coolant temperature sensor fastening bolt ......................................... 17 to 23 Nm (12.5 to 17.0 pound-feet)
87630273 NA
Issued 04-07
Bur
2-17
TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES

PART .............................................................................................................................TORQUE - Nm (pound-feet)
Camshaft sensor M6 studs....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet)
Feed pump M8 studs .......................................................................................... 10 to 14 Nm (7.4 to 10.3 pound-feet
Rear gear case M12 bolts ...............................................................................65 to 89 Nm (47.9 to 65.6 pound-feet)
Rear gear case M10 bolts ...............................................................................42 to 52 Nm (31.0 to 38.4 pound-feet)
Rear gear case M8 bolts .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft sensor M6 nut .......................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Oil pump M8 bolts
1st stage ..................................................................................................................7 to 9 Nm (5.2 to 6.6 pound-feet)
2nd stage.........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Front cover M8 bolts ........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft gear M8 bolts ..................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet)
Crankcase plate M10 bolt................................................................................38 to 48 Nm (28.0 to 35.4 pound-feet)
High pressure pump gear M18 nut ..............................................................100 to 110 Nm (73.6 to 81.1 pound-feet)
Fuel pump M8 nuts..........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
1/2 inch plug on cylinder head.........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
1/4 inch plug on cylinder head.........................................................................31 to 41 Nm (22.9 to 30.2 pound-feet)
3/4 inch plug on cylinder head...........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet)
Injector fastening M6 bolts
1st stage ........................................................................................................8.15 to 8.85 Nm (6.0 to 6.5 pound-feet)
2nd stage (additional rotation) ....................................................................................................................... 75 5
Injector feed connector fastening nut................................................................ 45 to 55 Nm 33.2 to 40.6 pound-feet)
Grid heater grill on intake manifold M6 nut ............................................................6 to 10 Nm (4.4 to 7.4 pound-feet)
Intake manifold M8 bolts..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fastening brackets (rear) for engine lifting M12 bolts ......................................65 to 89 Nm (47.9 to 65.6 pound-feet)
Fastening brackets (front) for engine lifting M8 bolts .......................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Common rail M8 bolts......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
High pressure fuel line connectors M14 ..........................................................18 to 22 Nm (13.3 to 16.2 pound-feet)
High pressure fuel line connectors M8 ............................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Cylinder head M12x1.75x130 and 150
1st stage ..........................................................................................................30 to 40 Nm (22.1 to 29.5 pound-feet)
2nd stage (additional rotation) ........................................................................................................................ 90 5
3rd stage (additional rotation)......................................................................................................................... 90 5
Rocker arm bracket .........................................................................................31 to 41 Nm (22.9 to 30.2 pound-feet)
Valve clearance adjusting nuts ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel line from high pressure pump to Common Rail, M14 nut ........................18 to 22 Nm (13.2 to 16.2 pound-feet)
Wiring bulkhead M6 bolt ........................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Electrical wiring support for injector feed.........................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Wiring on each injector -nuts ................................................................ 1.25 to 1.75 Nm (11.1 to 15.5 pound-inches)
Fuel filter bracket
M12 bolts .........................................................................................................69 to 85 Nm (50.9 to 62.7 pound-feet)
M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel filter......................................................................................................................................... Contact + 3/4 turn
Oil pressure relief valve on oil filter support M22 bolt......................................72 to 88 Nm (53.1 to 64.9 pound-feet)
Radiator seal and oil filter support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Oil filter ........................................................................................................................................... Contact + 3/4 turn
Connection on oil filter support for turbine lubrication .....................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Turbine lubrication pipe M12 nut............................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Engine coolant inlet connection M10 bolt ........................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
90 elbow (if required) to engine coolant inlet connection ...............................20 to 28 Nm (14.8 to 20.7 pound-feet)
Line on cylinder head for compressor cooling .................................................20 to 24 Nm (14.8 to 17.7 pound-feet)
Engine coolant drain connector M6 bolt ................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Engine block exhaust manifold pin ........................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Exhaust manifold to cylinder head M10 bolt ....................................................48 to 58 Nm (35.4 to 42.8 pound-feet)
2-18
Issued 04-07
Bur
87630273 NA
Damper adapter and damper on crankshaft M12 bolt

2nd stage (additional rotation) ........................................................................................................................90 5
Crankshaft pulley M10 bolts ............................................................................61 to 75 Nm (45.0 to 55.4 pound-feet)
Water pump M8 bolts.......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Auxiliary component control belt tensioner M10 bolt .......................................37 to 49 Nm (27.3 to 36.1 pound-feet)
Fixed pulleys for auxiliary component control belt M10 bolts ..........................37 to 49 Nm (27.3 to 36.1 pound-feet)
Flywheel housing
Heat exchanger for EDC7UC31 control unit
M6 bolts ....................................................................................................................... 8 to 12 (5.9 to 8.9 pound-feet)
M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel inlet-outlet on heat exchanger ...................................................................10 to 14 Nm (7.4 to 10.3 pound-feet)
Valve cover fastening nut M8 nut .....................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft sensor M6 bolt.......................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet)
Crankshaft sensor M6 bolt.....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet)
Coolant temperature sensor M14 bolt .............................................................17 to 23 Nm (12.5 to 17.0 pound-feet)
Oil pressure/temperature sensor M5 bolt ................................................................5 to 7 Nm (3.7 to 5.2 pound-feet)
Fuel pressure sensor fastening bolt......................................... 30 to 40 Nm (22.1 29.5 Nm (22.1 to 29.5 pound-feet)
Fuel temperature sensor M14 bolt...................................................................17 to 23 Nm (12.5 to 17.0 pound-feet)
Air temperature/pressure sensor on intake manifold ...............................................5 to 7 Nm (3.7 to 5.2 pound-feet)
Engine oil level sensor M12 bolt ........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet)
Turbine to exhaust manifold
M8 pins ....................................................................................................................6 to 8 Nm (4.4 to 5.9 pound-feet)
M8 nuts............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Adapter on turbine for lubricant oil lines (inlet) M12 adapter ...........................30 to 40 Nm (22.1 to 29.5 pound-feet)
Adapter on line on turbine for lubrication M10 adapter....................................30 to 40 Nm (22.1 to 29.5 pound-feet)
Adapter on oil line for turbine lubrication to block M10 adapter.......................37 to 49 Nm (27.3 to 36.1 pound-feet)
Oil drain pipe on turbine M8 bolt......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Connector attaching oil return from cylinder head to flywheel housing .................8 to 12 Nm (5.9 to 8.9 pound-feet)
Flywheel fastening bolts M12 bolts
1st stage ........................................................................................................... 26 to 34 Nm 19.2 to 25.1 pound-feet)
2nd stage (additional rotation) ........................................................................................................................60 5
Oil pan (sump) M8 bolts ..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Cylinder bore lubricating nozzles M8 bolts ........................................................12 to 18 Nm (8.9 to 13.3 pound-feet)
Crankshaft output bearings M12 bolts
2nd stage.........................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet)
3rd stage (additional rotation).........................................................................................................................90 5
Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft gear M8 bolt ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet)
Connecting rod caps M11 bolts
1st stage ........................................................................................................... 55 to 65 Nm 40.6 to 47.9 pound-feet)
2nd stage (additional rotation) .......................................................................................................................60 5
Alternator bracket attaching to water feed pipe fitting M10 bolts .....................37 to 49 Nm (27.3 to 36.1 pound-feet)
Alternator fastening M10 bolts.........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
Starter fastening bolts M10 bolts .....................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
87630273 NA
Issued 04-07
Bur
2-19
SPECIAL TOOLS
380000665............................................................................................... Tool for removing the crankshaft front seal.
380000663................................................................................................ Tool for removing the crankshaft rear seal.
380000671..................................................................................................... Tool for removing mechanical injectors.
380000666..........................................................................................Coupler for installing the crankshaft front seal.
380000664...........................................................................................Coupler for installing the crankshaft rear seal.
380000228........................................................................................................................... Dial indicator (0 - 5 mm).
380001601...........................Dial indicator holder tool for rotary injection pump timing (to be used with 380001004).
380002729..................................................................................................................... Engine TDC positioning tool.
380000979................................................................................................................ Injection pump drive gear puller.
380000158............................................................................................................................. 1 to 6 Nm torque driver.
380001099......................................................................................................... Tool for removing electrical injectors.
2-20
Issued 04-07
Bur
87630273 NA
F4GE - ENGINES
F4GE9454H AND F4GE9454J ENGINE
9
8
7
4
5
Figure 2-12
BS06N188
-
1. TURBOCHARGER
2. BLOW-BY
3. ROTARY INJECTION PUMP
87630273 NA
Issued 04-07
Bur
4. FUEL FILTER
5. PRIMING PUMP
6. CRANKSHAFT PULLEY
7. FIXED GUIDE PULLEY

8. WATER PUMP
9. FAN PULLEY
2-21

F4GE9484D ENGINE
9
8
7
4
5
Figure 2-13
BS06N189
1. TURBOCHARGER
2. BLOW-BY
3. ROTARY INJECTION PUMP
2-22
4. FUEL FILTER
5. PRIMING PUMP
6. CRANKSHAFT PULLEY
7. FIXED GUIDE PULLEY

8. WATER PUMP
9. FAN PULLEY
Issued 04-07
Bur
87630273 NA
F4HE- ENGINES
F4HE9484A ENGINE
5
6
Figure 2-14
BS07D071
1.
2.
3.
4.
5.
6.
TURBOCHARGER
COMMON RAIL
FAN PULLEY
FIXED GUIDE PULLEY
DAMPING FLYWHEEL
WATER PUMP
7.
8.
9.
10.
11.
EDC7UC31 CONTROL UNIT

REAR OF CRANKSHAFT
FLYWHEEL
HIGH PRESSURE PUMP
FUEL FILTER
8
11
10
9
Figure 2-15
BS07D072
87630273 NA
Issued 04-07
Bur
2-23
DESCRIPTION OF MAIN ENGINE COMPONENTS

ENGINE BLOCK
4
2
Figure 2-16
BS06N190
1. CYLINDER BORE
2. SEATS FOR CAMSHAFT BEARINGS AND TAPPETS
3. MAIN BEARING HOUSINGS

4. OIL PUMP
5. WATER PUMP
The engine block consists of a cast iron structure

containing the cylinder bores (1), the main bearing
housings (3), and the following seats: for camshaft
bearings (2), water pump (5), and oil pump (4). The
block also incorporates the water jackets for cooling
and the oil galleys for lubrication.
2-24
Issued 04-07
Bur
87630273 NA

CRANKSHAFT
4
3
2
1
Figure 2-17
BS06K022
1. FLYWHEEL ATTACHMENT HUB
2. TIMING DRIVE GEAR
The crankshaft is made of steel and rests on five

induction hardened bearing journals. Drilled inside
the crankshaft are a series of lubricating oil ducts.
The following items are pressed onto the front of the
crankshaft: oil pump drive gear (4), phonic wheel, the
vibration damper, and auxiliary equipment drive
pulley.
3. CRANKSHAFT
4. OIL PUMP DRIVE GEAR
CRANKSHAFT OIL SEALS

The front and rear seals are box type with radial seal.
R e m o ve w i t h s p e c i a l t o o l s 3 8 0 0 0 0 6 6 5 a n d
380000663. Install with special tools 380000666 and
380000664.
The following items are pressed onto the rear of the

crankshaft: timing gear (2), and the flywheel
mounting hub (1).
The main bearing shells are made of steel with a
antifriction alloy plating.
One of the main bearing shells is equipped with
shoulders to limit crankshaft endplay.
The timing drive gear (2) and the flywheel attachment
hub (1) are installed on the rear of the crankshaft with
a force-fit and cannot be replaced.
87630273 NA
Issued 04-07
Bur
2-25

CONNECTING RODS
Figure 2-18
BS06K023
T h e c o n n e c t i n g r o d s a r e fo r g e d s t e e l , T h e
connecting rod crankshaft ends are made with an
oblique angle, with separation of rod and cap
obtained by means of the innovative fracture splitting
system rather than the conventional machining
process.
The connecting rod crankshaft bearing shells are
made of steel plated with an antifriction alloy.
2-26
Each connecting rod is marked:

By a number on the connecting rod body and
on the cap indicating the match and the cylinder
in which they are assembled.
By a letter on the connecting rod body
indicating the weight class of the connecting rod
installed in production.
Issued 04-07
Bur
87630273 NA

PISTONS
1
2
3
4
Figure 2-19
BS06K024
The piston crown features a high turbulence

combustion chamber. The underside of the piston
crown is cooled by engine oil delivered by a spray
nozzle installed in the crankcase.
The following reference data is engraved into the

piston crown:
There are three piston ring grooves with different

functions and different geometry.
2. Stamping (facing the crankcase front side)

indicating the mounting direction of the piston in
the cylinder bore.
1st piston ring with trapezoidal (keystone)

section, ceramic chrome plating.
2nd piston ring with torsional conical rectangular
section.
1. Spare part number and design modification

number.
3. Date of manufacture.
4. Stamping indicating 1st recess insert testing.
3rd piston ring with double oil ring wiper with

internal spring.
87630273 NA
Issued 04-07
Bur
2-27

CAMSHAFT
NOTE: The camshaft below is a 6 cylinder camshaft.

BS06K025
A
D
B
C
D
Figure 2-20
BS06K026
A. CRANKSHAFT OUTPUT GEAR
B. JOURNAL
The camshaft is installed on five bearing journals (B)

in the engine block.
The front and rear bearing housings are equipped
with steel bearings plated with antifriction material
assembled by means of a force-fit.
The camshaft is controlled directly by the crankshaft
by means of gear (A).
EGR EXHAUST GAS RECIRCULATION SYSTEM
In the TIER 3 version, the profile of the exhaust lobe
has been modified in order to allow the par tial
opening of the exhaust valve during the intake cycle.
The exhaust gases can be partially returned back
into the cylinders to lower the maximum combustion
temperature which is responsible for the production
of nitrogen oxides (NOx).
2-28
C. INTAKE VALVE LOBE
D. EXHAUST VALVE LOBE
The exhaust gas recirculation system (EGR), lowers

the combustion temperature by decreasing the
concentration of oxygen in the combustion chamber.
Creating an effective system to control the emission
of NOx.
The internal EGR system exhaust lobe design is not
equipped with any electronically controlled elements,
the system is always active. Its configuration does
not need additional elements such as check valves,
piping or heat exchangers.
The exhaust lobe (D) has an additional lobe apart
from the major lobe see cross sectional view of
exhaust valve (D), as compared to the configuration
of a cam without EGR.
With the additional lobe during the intake stroke of a
cylinder, this lobe permits a brief opening of the
exhaust valve. Recirculation is generated in the
cylinder during the intake stroke due to the greater
pressure of exhaust compared to the intake gases.
Issued 04-07
Bur
87630273 NA

VALVE CONTROL FOR F4GE ENGINES
9
3
8
7
4
Figure 2-21
BS06N193
1. ROCKER ARM
2. ROCKER ARM SUPPORT
3. ADJUSTING SCREW
87630273 NA
Issued 04-07
Bur
4. PUSH ROD
5. TAPPET
6. CAM SHAFT
7. SPRING
8. SPRING SEAT
9. VALVE SPRING RETAINER (KEEPERS)
2-29

VALVE CONTROL FOR F4HE ENGINES
2
1
10
9
8
7
Figure 2-22
BS06K027
1.
2.
3.
4.
5.
2-30
ROCKER ARM
ROCKER SPINDLE
VALVE BRIDGE
TAPPET
CAMSHAFT
6.
7.
8.
9.
10.
SPRING
SPRING SEAT
VALVE SPRING RETAINER (KEEPERS)
PUSH ROD
VALVE LASH ADJUSTER SCREW
Issued 04-07
Bur
87630273 NA

CYLINDER HEAD FOR F4GE9454H AND F4GE9454J ENGINES
6
3
Figure 2-23
BS06N194
DETAIL OF CYLINDER HEAD FOR F4GE9454H/J ENGINE WITH INSERTED VALVE SEATS
1. EXHAUST MANIFOLD
2. INTAKE MANIFOLD
3. GRID HEATER
4. VALVE SEAT
The cast iron cylinder head is machined to

accommodate the following parts:
Valve seats (4).
Injectors (6).
Thermostat (5).
87630273 NA
Issued 04-07
Bur
5. THERMOSTAT
6. INJECTOR
The cylinder head is also fitted for the following

components to be installed on to the cylinder head.
Exhaust manifold (1).
Intake manifold (2) with seat for grid heater (3).
2-31

CYLINDER HEAD FOR F4GE9484D ENGINES
4
5
Figure 2-24
BS06N195
DETAIL OF CYLINDER HEAD FOR F4GE9484D ENGINE WITH INSERTED VALVE SEATS
1. EXHAUST MANIFOLD
2. INTAKE MANIFOLD
3. GRID HEATER
4. VALVE SEAT

valve seats (4).
injectors (6).
thermostat (5).
2-32
5. THERMOSTAT
6. INJECTOR

components to be inserted on to the head.
exhaust manifold (1).
intake manifold (2) with seat for grid heater (3).
Issued 04-07
Bur
87630273 NA

CYLINDER HEAD FOR F4HE9484A ENGINES
1
3
4
6
Figure 2-25
BS07D063
DETAIL OF CYLINDER HEAD FOR F4HE9484A ENGINE WITH INSERTED VALVE SEATS
1. EXHAUST MANIFOLD
2. INTAKE MANIFOLD
3. GRID HEATER
4. VALVE SEAT
5. INJECTOR
6. THERMOSTAT

Valve seats (4).

components to be installed on the cylinder head.
Exhaust manifold (1).
Injectors (2).
Thermostat (6).
Intake manifold (2) with seat for grid heater (3).
87630273 NA
Issued 04-07
Bur
2-33

VALVES AND VALVE SEATS FOR F4GE ENGINES
2
3
1
Figure 2-26
BS06N196
1. EXHAUST SIDE
2. EXHAUST VALVE
3. INTAKE VALVE
4. INTAKE SIDE
Valve seats inserted in the head have the following

angles:
45 - Exhaust valves.
60 - Intake valves.
NOTE: The exhaust valves (2) differ from the intake
valves (3) in that they have only one notch at the
stem end.
(A) Shows the oil seals mounted on valve stems.
2-34
Issued 04-07
Bur
87630273 NA
Figure 2-27
BS06N197
DETAIL OF VALVE GUIDES AND SEATS F4GE ENGINES
87630273 NA
Issued 04-07
Bur
2-35

VALVES AND VALVE SEATS FOR- F4HE ENGINES
3
Figure 2-28
BS06K030
1. INTAKE VALVES
2. INTAKE SIDE
3. EXHAUST SIDE
4. EXHAUST VALVES
Valve seats have the following angles:
3
Figure 2-30
BS06K032
Exhaust valves- 45
Intake valves- 60
NOTE: Exhaust valves (4) have a distinctive
identification at the center of the head of the valve.
1. 7.042 TO 7.062 MM (0.277 TO 0.278 INCHES)

2. INTAKE VALVE
3. EXHAUST VALVE
The cylinder head does not have guide inserts. The

valve guide is machined directly into the head
casting.
1
1
2
BS06K031
Figure 2-29
Oil seals (1) installed on valve stems.

Figure 2-31
BS06K033
1. JUMPER
2. PUSH RODS
NOTE: When installing the cylinder head, the

orientation of valve bridges must be positioned with
marks (1) towards exhaust manifold.
2-36
Issued 04-07
Bur
87630273 NA

ENGINE FLYWHEEL
The flywheel (2) is not timed to the crankshaft and
does not have any stamping, notch or reference hole
for sensors or timing.
Equal distance of fastening bolt holes (1) allows it to

be installed in any position.
Figure 2-32
BS06N198
FLYWHEEL FOR- F4GE ENGINES
Figure 2-33
BS07D076
FLYWHEEL FOR- F4HE ENGINES
87630273 NA
Issued 04-07
Bur
2-37
ACCESSORY EQUIPMENT DRIVE

2
Figure 2-34
BS06K038
1. ALTERNATOR
2. AUTOMATIC BELT TENSIONER
3. FAN PULLEY
4. CRANKSHAFT
5. WATER PUMP
6. POLY-V-BELT
A Poly-V-belt (6) transmits the rotation of the

crankshaft (4) to water pump (5), fan pulley, and to
the alternator (1). The tension of the belt is controlled
by the automatic belt tensioner (2).
2-38
Issued 04-07
Bur
87630273 NA
COUNTER BALANCER- F4GE ENGINES
10
6
Figure 2-35
BS06N200
COUNTER BALANCER FOR F4GE ENGINES

1.
2.
3.
4.
5.
FASTENING BOLTS
SUPPORT
FASTENING BOLTS
GEAR
BALANCING MASS
Inside the oil pan (sump), secured to the cylinder

block is the counter balancer.
The counter balancer is timed as shown above.
87630273 NA
Issued 04-07
Bur
6.
7.
8.
9.
10.
HALF BEARINGS
COUNTER-ROTATING SHAFT
GEAR
RING
O-RING
Match alignment marks (A) engraved on the gears for

timing, insert pin in hole (B) on the balancing mass to
stop rotation temporarily.
2-39
ENGINE LUBRICATION FOR- F4GE ENGINES
A
B
C
Figure 2-36
BS06N236
LUBRICATION SYSTEM LAYOUT FOR F4GE ENGINES

A. GRAVITY OIL RETURN PATH
B. PRESSURIZED OIL PATH
C. OIL SUPPLY
Pressurized lubrication is performed by the following

components:
By-pass valve to cut out clogged oil filter, built into the
cooler unit.
Gerotor oil pump housed in the front of the engine

block, driven by the spur tooth gear force fitted on the
crankshaft.
Cartridge- type oil filter.
Water / oil cooler, housed in the engine block.
2-40
Issued 04-07
Bur
87630273 NA
ENGINE LUBRICATION FOR- F4HE ENGINES
1
2
3
4
5
A
B
6
Figure 2-37
BS07D132
LUBRICATION SYSTEM LAYOUT FOR- F4HE ENGINES

(NOTE: THE ILLUSTRATION IS A 6 CYLINDER)
1. TURBO OIL PRESSURE CONTROL VALVE
2. BY-PASS VALVE
3. CARTRIDGE- TYPE OIL FILTER
4. HEAT EXCHANGER
5. OIL PUMP
6. OIL PAN (SUMP)
A. PRESSURIZED OIL PATH

B. GRAVITY OIL RETURN PATH
Pressurized lubrication is done with the following

components:
Gerotor oil pump (5) housed in the front of the
engine block, driven by the spur tooth gear force
fitted on the crankshaft.
Heat exchanger (4) housed in the engine block,

under the oil filter support.
By-pass valve (2) for clogged oil filter cut off.

Cartridge type oil filter (3)
Oil pan (sump) (6)
87630273 NA
Issued 04-07
Bur
2-41

HEAT EXCHANGER
1
2
Figure 2-38
BS06N237
1. HEAT EXCHANGER BODY 3. WATER / OIL COOLER

2. INNER GASKET
4. GASKET (BETWEEN COOLER AND ENGINE BLOCK)
BY-PASS VALVE
OIL PRESSURE CONTROL VALVE
1
2
3
A
Figure 2-40
BS06K042
BS06K041
Figure 2-39
1. 66 MM (2.59 INCHES)
2. 41.25 MM (1.62 INCHES)
3. 136.9 10.5 N (30.8 2.36 LBF)
Calibration at 100 C (212 F) oil temperature.
A. DIRECTION OF FLOW
Blow-by max:
20 cm/min (.68 oz/min) with 0.83 bar (12 psi)
pressure at 26.7 C (80 F) oil temperature.
Minimum pressure 1.2 bar (17.4 psi)

Maximum pressure 3.8 bar (55.1 psi)
2-42
Issued 04-07
Bur
87630273 NA

OIL PAN (SUMP)
OIL PUMP
Figure 2-41
BS06K043
OIL PUMP
Figure 2-43
BS06N238
OIL PAN (SUMP) FOR F4GE ENGINES
2
Figure 2-42
BS06K044
1. Crankshaft with oil pump drive gear.
Figure 2-44
BS06K045
OIL PAN (SUMP) FOR F4HE ENGINES
2. Oil pump.
The oil pan (sump) (2) is bolted to the cylinder block.

The gasket (1), fitted on the oil pan reduces noise
and in addition to improve tightness.
87630273 NA
Issued 04-07
Bur
2-43

OIL VAPOR RECIRCULATION FOR F4GE ENGINES
1
2
Figure 2-45
BS06N238
Oil vapor recirculation takes place by means of valve

(1) placed above the tappet cover (3) on F4GE
engines.
2-44
The vapor condensed within the valve falls into the

tappet cover (3) due to gravity. The remaining vapor
is recovered by vent (2) and recirculated to the
engine intake.
Issued 04-07
Bur
87630273 NA

OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITH BLOW-BY FILTER
A
B
Figure 2-46
BS06K048
1. PRE-SEPARATOR
2. RECIRCULATION TO INTAKE
3. BLOW-BY FILTER
4. RETURN TO ENGINE
BLOW-BY RECIRULATION:
The rocker cover has a blow-by pre-separator (1),
designed to increase the outlet velocity of blow-by oil
vapor while condensing them partially. Condensed oil
returns to the oil pan (sump) while residual vapors
are collected and routed through the blow-by filter
(3).
87630273 NA
Issued 04-07
Bur
A. OIL CONDENSATE
B. OIL VAPORS
In blow-by filter (3) a portion of the vapors partially

condense and return to the oil pan (sump) through
line (4), while the remaining is recirculated to the
engine intake by line (2).
2-45

OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITHOUT BLOW-BY FILTER
A
B
Figure 2-47
BS07D070
The tappet cover houses the pre-separator (1),

whose shape and position increases the outlet
velocity of the blow-by vapors and condenses part of
the vapors at the same time.
The condensed oil returns to the oil pan (sump),
where the residual vapor is collected and discharged
into the open air through the bleeder on the side (2).
2-46
Issued 04-07
Bur
87630273 NA
COOLING SYSTEM
B
Figure 2-48
BS06N240
1. THERMOSTAT
2. HEAT EXCHANGER
3. WATER PUMP
A. WATER FLOWING OUT OF THERMOSTAT
The engine cooling system is a closed circuit, forced

c i r c u l a t i o n t y p e i n c o r p o r a t i n g t h e fo l l ow i n g
components:
Radiator- Dissipates the heat from the engine by
circulating coolant through a long row of tubes and
air flowing across them decreasing the
temperature.
Expansion tank- Collects the overflow of coolant

as it expands and contracts.
87630273 NA
Issued 04-07
Bur
B. WATER RECIRCULATING IN THE ENGINE

C. WATER FLOWING INTO WATER PUMP
Fan- Increases heat dissipating power of the

radiator by flowing more air across the radiator.
Heat exchanger- Cools the lubricating oil.

Centrifugal water pump- placed on the front of the
engine block. Circulates the coolant through the
engine and radiator and is driven by a Poly-V belt.
Thermostat- Regulates the circulation of the

coolant.
2-47

WATER PUMP
Figure 2-51
BS06K052
Figure 2-49
BS06K050
THERMOSTAT
Engine temperature is controlled by a thermostat.
WATER PUMP
Thermostat opening 79 to 83 C (174 to 181 F).

(1)- Goes towards engine block.
BS06K051
Figure 2-50
CROSS SECTIONAL VIEW OF WATER PUMP
The water pump is housed in a cavity in the front of

the engine block. and is driven by a Poly-V belt. The
water pump is sealed to the block by a rubber ring.
2-48
Issued 04-07
Bur
87630273 NA
AIR INDUCTION BOOST DIAGRAM

BOOSTING VERSION ENGINES
Figure 2-52
BS07C435
4 CYLINDER BOOSTED VERSION

1. AIR FILTER
2. TURBOCHARGER
The turbocharger is composed of the following parts:

turbine, transforming valve to regulate the boost
pressure, main body, and compressor.
When engine is running, the exhaust emission flow
through the body of the turbine makes the turbine
disk rotate.
3. EXHAUST
4. PISTONS
T h e i n d u c t i o n c o l l e c t o r d i r e c t s t h e ex h a u s t
emissions, releasing part of them directly to the
exhaust tube when the boost feeding pressure of the
compressor, reaches the prescribed pressure value.
The cooling process and lubrication of the
turbocharger and bearings is done by the engine oil.
The compressor rotor connected by a shaft to the

turbine disk rotates, compressing the air drawn
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 regulate the pressure, located on the
exhaust collector before the turbine and connected
by piping to the induction collector.
87630273 NA
Issued 04-07
Bur
2-49

INTER-COOLED ENGINE VERSION
4
5
Figure 2-53
BS07C436
4 CYLINDER BOOSTED / INTERCOOLED VERSION

1. AIR FILTER
2. TURBOCHARGER
3. EXHAUST
The turbocharger is composed of the following parts:

turbine, transforming valve to regulate the boost
pressure, main body, and compressor.
When engine is running, the exhaust emission flow
through the body of the turbine makes the turbine
disk rotate.
4. CHARGE AIR COOLER
5. PISTONS
T h e i n d u c t i o n c o l l e c t o r d i r e c t s t h e ex h a u s t
emissions, releasing part of them directly to the
exhaust tube when the boost feeding pressure of the
compressor, reaches the prescribed pressure value.
The cooling process and lubrication of the
turbocharger and bearings is done by the engine oil.
The compressor rotor connected by a shaft to the

turbine disk rotates, compressing the air drawn
through the air filter.
The air is then cooled by the charge air cooler and
sent via the intake manifold to the pistons.
The turbocharger is equipped with a transforming
valve to regulate the pressure, located on the
exhaust collector before the turbine and connected
by piping to the induction collector.
2-50
Issued 04-07
Bur
87630273 NA
MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES

FUEL FILTER
2
6
3
Figure 2-54
BS06N241
FUEL FILTER
1. FUEL FILTER BRACKET
2. AIR BLEEDING SCREW
3. FUEL HEATING RESISTOR

4. WATER DRAIN
5. FUEL FILTER
6. FUEL TEMPERATURE SENSOR
The fuel filter is located close to the feed and priming

pump. The fuel filter provides a barrier trap for
impurities and to separate water from the fuel.
On the filter bracket base there is a water drain
screw, equipment used in cold climate areas there
can be a heater assembled into the bracket (to
prevent the fuel from jelling), and a fuel temperature
sensor. On some versions there is a water presence
sensor located on the filter cartridge base.
87630273 NA
Issued 04-07
Bur
2-51

MECHANICAL FUEL LIFT PUMP- F4GE ENGINES
Figure 2-55
BS06N242
MECHANICAL FUEL PUMP

1. FUEL OUTLET TO FILTER
2. CONTROL LEVER
3. FUEL INLET FROM TANK

4. FUEL PUMP
The fuel pump is mounted on the left side of the

engine. It draws fuel from the fuel tank and feeds it to
the rotary injection pump. It is driven by the camshaft.
2-52
5. CONTROL LEVER
6. CAMSHAFT
Specifications for fuel lift pump:

Static pressure at 1800 r/min. (rpm).
0.47 to 0.61 bar (6.8 to 8.8 psi).
Issued 04-07
Bur
87630273 NA

MECHANICAL INJECTION WORKING PRINCIPLES- F4GE ENGINES
Figure 2-56
BS07D011
1. Fuel filter
3. Feed pipeline from priming pump to filter
2. Feed pipe line from fuel pump to fuel filter
4. Rotary injection pump
5. Fuel pump
Fuel is drawn from the fuel tank by the fuel pump (5)
and is driven by the camshaft.
To check fuel pressure for engines with mechanical

fuel system.
Fuel flows through pipeline (2) to the fuel filter (1) and
is piped to the vacuum chamber of the injection pump
via pipeline (3), (for applications to be operated in
cold climates the fuel filter is provided with a heater).
The fuel supply pressure specification is 0.27 bar

(4 psi) minimum and 0.34 to 0.48 bar (5 to 7 psi) at
full load rated rpm. To check fuel pressure, purchase
a fuel supply line for the four cylinder engine. Cut the
fuel line and install a tee fitting to measure the fuel
pressure.
Transfer pump is placed inside the injection pump (4),

and is a rotary type. It increases fuel pressure with
the increase in the number of engine revolutions.
The fuel arrives to the valve gauging the pressure
inside injection pump.
The distribution plunger increases the pressure and
delivers fuel throughout the delivery pipe to the
injectors.
The fuel drawn from the injectors is recovered and
delivered to the fuel tank again.
87630273 NA
Issued 04-07
Bur
2-53
ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES
2
1
10
7
8
9
Figure 2-57
BS06N243
INJECTION ASSEMBLY
1. INJECTOR 1 FUEL PIPE

5. PIPE FOR FUEL DISCHARGE FROM
INJECTORS
6. CONNECTOR FOR MEASURING PRESSURE
INSIDE THE L.D.A. INTAKE MANIFOLD
Fuel feed system is composed of:
Fuel tank (placed on the machine).

Fuel delivery and back-flow to tank.
Fuel pre-filter (if available, it is usually placed
7. THERMAL BULB FOR KSB
10. INJECTOR
8. INJECTION PUMP
9. SOLENOID VALVE
Fuel feed rotary injection pump.

Injector feed pipeline (from injection pump to
injectors).
Injectors
close to the engine on the machine frame).
Priming pump, assembled to the engine driven by

the camshaft.
Fuel filter
2-54
Issued 04-07
Bur
87630273 NA
KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES
Figure 2-58
BS07F331
1. TEMPERATURE SWITCH
2. ADVANCE SOLENOID
Theory of operation:
When the engine is cold (coolant temperature below
50 C (122 F) the injection pump is in timing
advance state. When engine gets to between 60 and
66 C (140 to 151F), the thermo switch in the
cylinder head opens and system voltage is no longer
sent to the solenoid on the injection pump. This
allows the timing to retard to "normal" operating
position.
Units equipped with the Bosh VE rotary injection
pump do not require a relay for the pull in circuit. The
pump uses a simple shut off solenoid built into the
pump.
87630273 NA
Issued 04-07
Bur
3. FUEL SHUT OFF SOLENOID
4. WIRE HARNESS
There is one wire connected to the main harness that

goes to the ignition terminal of the key switch. This
wire feeds power to the injection pump shut off
s o l e n o i d . A s e c o n d w i r e fe e d s p o w e r t o a
temperature switch in the head. A third wire routes
from the temperature switch to an additional solenoid
on the injection pump.
An additional solenoid ensures that the pump will go
to full advance timing during cranking and upon initial
cold start up. Once the engine warms to 71 C
(160 F), the temperature switch opens and power to
the solenoid on the side of the injection pump is
removed. This allows the injection pump to retard the
timing according to engine rpm.
2-55

To troubleshoot the system:
1. With the engine temperature below 50 C
(122 F), the key switch on, battery voltage
should be present at both solenoids on the
injection pump. If battery voltage is not present,
troubleshoot the temperature switch circuit.
2. To check the temperature switch, when engine
temperature is below 50 C (122 F), battery
voltage should be present at both terminals.
Warm the engine to 60 to 66 C (140 to 151 F).
Battery voltage should be present at only one
terminal of the temperature switch when engine
is warmed to 71 C (160 F) or higher.
3. Disconnect the connector at the temperature
switch. Short across the two terminals of the
connector with a jumper wire and start engine.
After a short time, remove the jumper wire the
engine should change sound and run smoother
as the injection pump time is retarded. This
signifies that the cold starting advance system is
operating properly.
FUEL SYSTEM TEST FOR RESTRICTION

OR AIR INFILTRATION FOR F4GE
ENGINES
NOTE: If possible, test the fuel system as described
before removing the Bosch VE fuel injection pump for
repair. If leakage is too severe, complete the test
procedure following the pump repair or replacement.
Failure to test the system may result in continued
pump leakage.
To determine if the low pressure fuel supply is
restricted, or if air is entering the system, follow these
steps.:
STEP 1
Install a clear poly-vinyl tube between the outlet of
the fuel filter and the inlet of the Bosch VE fuel
injection pump. Tee connector into the test line a
pressure gauge which can read both 0 to 762 mm
(0 to 30 inches) of Hg vacuum and 0 to 2.07 bar (0 to
30 psi) positive pressure. See figure 2-59 on
page 2-57
NOTE: For more information, see further procedures
in this section which describe how to build test lines,
and describe normal system operating observations.
STEP 2
Run the engine to purge all possible air from the
system which was caused by test line installation.
STEP 3
When air is no longer visible in the clear test line,
measure and record the operating pressures, while
continually observing for air in the fuel, under the
following conditions:
Low idle- apply no load to the engine.

High idle- apply no load to the engine.
High idle- apply load to the engine using
hydraulics over relief, hydrostatic stall or converter
stall, depending upon the unit being tested. Load
the engine to its rated engine operating rpm.
Run multiple tests while observing fuel pressure

and looking for air in the fuel.
STEP 4
If the fuel pressure is below 0.276 bar (4.0 psi) at any
time during the previous Step 3, check the following,
and replace as needed:
The fuel pre-filter (replace).

NOTE: some applications do not use a fuel pre-filter.
The primary fuel filter.
2-56
Issued 04-07
Bur
87630273 NA
The lines and connections from the fuel supply
Parts needed for pressure/ vacuum testing
pump inlet back to the fuel tank, checking for

damaged lines (kinks and rub marks) and leakage
at the Voss o-ring fittings.
Debris in the tank, clean as required.

The fuel pick-up tube in the fuel tank, checking for
1
3
cracks, plugging, or contact with the bottom or side

walls of the tank.
The fuel tank cap, assuring that a vacuum is not

being formed in the fuel tank, which would reduce
the fuel supply pressure to the injection pump inlet.
NOTE: Vacuum in the fuel tank might not be

observed during short-term running.
These instructions apply only to engines with

external electrical fuel shutoff valve assemblies.
Ensure that fuel supplied to and from the valve
assembly is properly plumbed. Fuel supplied from
the fuel filter enters the shutoff valve at port
number 1. Port number 2 supplies fuel to the inlet
of the Bosch VE injection pump.
STEP 5
If the checks in Step 4 were made and all necessary
corrective actions were taken, Retest. If the pressure
is still low, preform the following tests:
From the gauges previously used to measure

pressure, remove one section of test line and a
barbed fitting from the tee. Install in there place a
gasket and a connector. This will allow installation
of the gauges between the supply pump inlet and
the fuel supply line from the tank. After installation
of the gauges, run the engine and observe the
clear tube remaining on the gauges to ensure that
air is not entering. The vacuum here should not
exceed 50.8 mm (2.0 inches) of Hg under full load.
If the vacuum is greater than that, look for a
plugged fuel supply line or debris in the fuel tank.
An alternative vacuum test method would be to

supply fuel from an alternate fuel source, such as
a five gallon container, with a known good supply
line. Fit it directly to the supply pump inlet fitting,
then rerun the test. If the pressures return to
normal, check the fuel supply line and tank of the
vehicle for leaks or restrictions.
Figure 2-59
BS07F316
SETUP FOR MEASURING PRESSURE
To build a fuel system test set for pressure testing,

obtain the following :
NOTE: Voss o-ring type connectors can be obtained
either by purchasing the connectors, or by
purchasing a fuel line for the application being
worked on, then carefully removing the plastic Voss
type connectors (1), from the plastic tube for re-use
with poly-vinyl tubing.
Quan.
Description
ID #
Voss type brass barbed hose

connectors
6.35 mm (1/4 inch)- NPT tee fitting
6.35 mm (1/4 inch)- NPT to 7.54

mm (5/16 inch) barb connectors
Five feet of 7.54 mm (5/16 inch)

O.D. poly-vinyl tubing
Dampened compound gauge

which will measure 0 to 762 mm (0
to 30 inches) of Hg and 0 to 2.07
bar (0 to 30 psi).
Upon completion of the diagnostic procedures,

remove the test line and the gauge, and reinstall
the standard fuel line.
87630273 NA
Issued 04-07
Bur
2-57

Normal system operating observations
1. Fuel supply pressures between the fuel filter and
the inlet to the injection pump should be 0.276 to
0.414 bar (4 to 6 psi) with the engine loaded or
unloaded.
2. Perform a "wiggle test" on each fuel line. A

steady stream of bubbles or foam Should Not be
seen moving through the fuel system. Very small
random bubbles are allowable.
3. A small, high intensity flashlight can aid in
observing air in the fuel lines.
2
Figure 2-60
BS07F317
SETUP FOR MEASURING VACUUM
4. The suction pressure between the inlet of the

fuel supply and the tank should not exceed
50.8 mm (2 inches) of Hg vacuum.
To build a fuel system test set for vacuum testing,

obtain the following :
Quan.
Description
ID #
Connector Voss type M12 x 1.5
Sealing washer between connector

(1) and tee fitting
NOTE: If the gauges are not equipped with a

dampening device, install a small needle valve
between the gauge and the test line. the needle valve
can be adjusted to control gauge reading
fluctuations.
2-58
Issued 04-07
Bur
87630273 NA
HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES

1
2
3
11
10
9
4
8
7
6
5
Figure 2-61
BS06K053
1.
2.
3.
4.
HARNESS TO INJECTORS
ELECTRO- INJECTOR
COOLANT TEMP. SENSOR
ENGINE OIL AND PRESSURE SENSOR
5.
6.
7.
8.
CRANKSHAFT SENSOR
9. CAMSHAFT SENSOR
EDC7UC31 CONTROL UNIT
10. FUEL PRESSURE SENSOR
PRESSURE REGULATOR
11. BOOST TEMP. PRESSURE SENSOR
FUEL HEATER AND TEMP. SENSOR
Extremely high injection pressures are necessary in

order to reduce PARTICULAR emissions.
The common rail system makes it possible to inject
fuel at pressures of up to 1450 - 1600 bar (21030 23206 psi), while the injection precision obtained by
EDC7UC31 electronic control of the system serves
to optimize operation of the engine while limiting
emissions and fuel consumption.
NOTE: 6 cylinder version is shown in figure above,

operation is the same.
For engines more powerful than 152 kW (203 hp.),

the CRIN2 injectors have DLLA nozzles that work up
to a pressure of 1600 bar (23206 psi), while engines
less powerful than 152 kW (203 hp.) are fitted with
DSLA nozzles which work with pressures up to 1450
bar (21030 psi.).
87630273 NA
Issued 04-07
Bur
2-59
EDC7UC31- ELECTRONIC CONTROL

UNIT OPERATION
ENGINE PREHEATING ELEMENT CONTROL
Pre-post heating is activated when even just one of
the water, air or fuel temperature sensors detects a
temperature of less than 5 C (41 F).
MAXIMUM ENGINE SPEED LIMITING

Depending on the application, the control unit
memory can contain appropriate engine speed limits.
When the engine speed surpasses these limits, the
control unit activates power reduction by controlling
tur n on time of the electro-injectors. In some
applications, the maximum limiting response consists
in stopping the engine.
PHASE RECOGNITION
Signals transmitted by the camshaft and crankshaft
sensors determine the cylinder which fuel must be
injected.
INJECTION CONTROL
Information transmitted by the sensors, the control
unit determines and regulates pressure and modifies
the pre-injection and main injection mode.
INJECTION PRESSURE CLOSED LOOP
CONTROL
CUT OFF
Fuel cut-off release is managed by the control unit
with the following logical interventions:
deactivation of the electro-injectors.

reactivation of electro-injectors immediately prior
to arrival at idle speed.
control of fuel pressure regulator.

SMOKE CONTROL UNDER ACCELERATION
Engine load, determined by processing of data

transmitted by the various sensors, and the control
unit. Governs the regulator to maintain injection
pressure at constant optimal values.
With intense load demands, signals received from

the boost temperature pressure sensor and the
crankshaft sensor, the control unit manages the
pressure regulator and modulates the activation time
of the electro-injectors to prevent the emission of
smoke from the exhaust.
PILOT AND MAIN INJECTION ADVANCE

CONTROL
AFTER ENGINE SHUT DOWN
Signals transmitted by various sensors to the control

unit, determines the optimum injection point on the
basis of internal mapping.
Afte r the engine is stopped, the contro l un it

microprocessor saves various parameters to the
EEPROM memory, including the fault log so that they
will be available the next time the engine is started.
IDLE SPEED CONTROL

The control unit processes signals transmitted by the
various sensors and adjusts the quantity of fuel
injected.
It also controls the pressure regulator and modulates
injection duration of the electro-injectors. Within
specific limits, the control unit also monitors battery
voltage.
CONTROL OF WORKING SPEED IN NORMAL

OPERATING CONDITIONS
Each time work load varies, the control unit adjusts
torque to maintain the engine in maximum power
conditions. If the load causes a reduction in power,
the control unit increases torque i.e. it increases the
amount of fuel injected in order to restore the engine
to maximum power.
OVERHEATING PROTECTION
If the water temperature reaches 110 C (230 F) the
control unit reduces engine performance.
When the temperature returns below 100 C (212 F)
the engine resumes normal operation. In some
applications, the intake manifold temperature is the
reference temperature.
2-60
Issued 04-07
Bur
87630273 NA

RECOVER STRATEGIES
Control of fuel leaks.

In the case of fuel supply problems, the system
controls the engine with suitable constant power
values obtained with a low number of rev and high
torque values in order to inject the maximum quantity
of fuel.
Control of pressure in the rail.

When the pressure in the rail exceeds safety values,
the engine reduces power.
Synchronism problems
In the case of synchronism problems, faulty rev
s e n s o r s, t h e s y s t e m c o n t r o l s t h e e n g i n e by
increasing the number of revs in order to improve
interpretation of the signals.
When the temperature of the supercharging air rises

above 88 C (190 F), power reduction is started,
when a temperature of 120 C (248 F) is reached,
performance is further reduced and is comparable to
that of the same engine if it were aspirated.
Reduction of power as reference temperature

varies
In normal operating conditions, the system knows the
supercharging air, oil and water temperatures.
If the temperature of the engine water is not
available, the system takes the temperature of the oil
as reference and when this reaches the threshold of
103 C (217 F), it star ts to reduce the power
available. On reaching 113 C (235 F), power is
reduced to 50%.
Power restrictions as operating temperature

increases.
87630273 NA
Issued 04-07
Bur
2-61
FUEL SUPPLY SYSTEM- F4HE ENGINES
2
1
4
6
D
8
5
7
A
B
C
Figure 2-62
BS06K054
1. ELECTRO-INJECTOR
2. BACK PRESSURE REGULATOR
FOR FUEL RETURN
3. COMMON RAIL PRESSURE
RELIEF VALVE
4. PRE-FILTER
7. LOW PRESSURE GEAR TYPE

B. LOW PRESSURE
CHARGE PUMP
5. FUEL FILTER
8. HIGH PRESSURE PUMP
C. FUEL RETURN
6. COMMON RAIL
A. HIGH PRESSURE
D. HIGH PRESSURE FROM

PUMP TERMINAL
The common rail system has a high pressure pump

that constantly keeps the fuel supply at a very high
pressure, not dependent on the phase of the cylinder
that must receive the injection. The high pressure
fuel is stored in a pipeline (the common rail) that is
shared by all electro- injectors.
This means that there is always a supply of fuel
available at the electro- injector inlet at the injection
pressure determined by the EDC7UC31 electronic
control unit.
When the solenoid valve of an electro- injector is
energized by the EDC7UC31 electronic control unit,
fuel taken directly from the common rail is injected
into the corresponding cylinder.
The fuel system is composed of a low pressure
circuit and a high pressure circuit.
2-62
The high pressure circuit consists of the following

lines:
Line connecting the high pressure pump outlet to

the common rail.
Lines supplying the electro-injectors from the

common rail.
The low pressure circuit is composed of the following
lines:
Fuel line from fuel tank to prefilter.

Lines supplying the mechanical supply pump
through the heat exchanger of the control unit, the
manual priming pump and the pre filter.
The fuel system is completed by the fuel return from
the common rail, injectors and high pressure pump
cooling circuit.
Issued 04-07
Bur
87630273 NA

FUEL SUPPLY SYSTEM DIAGRAM- F4HE ENGINES
A
B
C
D
3
18
17
8
9
10
16
15
13
11
14
12
Figure 2-63
BS06K055

2. LOW PRESSURE REGULATOR
VALVE ON HIGH PRESSURE PUMP
3. COMMON RAIL SAFETY RELIEF
VALVE
4. BACK PRESSURE VALVE IN FUEL
RETURN LINE FROM INJECTOR
5. COMMON RAIL
6. RAIL PRESSURE SENSOR
7. ELECTRO-INJECTOR
8. ROTOR PUMP PRESSURE SAFETY
BY-PASS
9. MECHANICAL ROTOR PUMP BY-PASS

CHECK VALVE
10. HIGH PRESSURE PUMP AND INJECTOR
RETURN LINE
11. EDC7UC31 CONTROL UNIT HEAT
EXCHANGER
17. HIGH PRESSURE PUMP BYPASS CHECK VALVE

18. RETURN LINE FROM HIGH
PRESSURE PUMP
A. DRAIN
12. MANUAL PRIMING PUMP
B. SUCTION
13. PRE-FILTER
14. FUEL TANK
15. FUEL FILTER
C. LOW PRESSURE
D. HIGH PRESSURE
16. GEAR CHARGE FEED PUMP
The supply pressure regulator controls the flow of

fuel needed in the low pressure system. The high
pressure pump supplies the common rail. This
pressurization of fuel, improves energy efficiency and
limits the heating of the fuel in the system.
The low pressure regulator valve (2) installed on the
high pressure pump maintains the pressure at a
constant level of 5 bars (72 psi.).
Low pressure regulator valve (2) operates to increase
fuel flow in the high pressure pump cooling circuit
through line (18) carrying fluid into and out of line
(10).
In parallel with the mechanical supply pump there are

two by-pass valves.
Rotor pump pressure safety by-pass valve (8) makes
it possible to have the fuel flow back from the
mechanical pump outlet to its inlet, when the
p r e s s u r e a t t h e f u e l f i l t e r i n l e t ex c e e d s t h e
permissible limit. The rotor pump by-pass valve (9)
makes it possible to fill the supply system via the
manual priming pump (12).
The common rail safety relief valve (3) installed in the

cylinder head. Controls the flow of fuel returning from
the electro-injectors at a pressure of 1.3 to 2 bars (19
to 29 psi.).
87630273 NA
Issued 04-07
Bur
2-63

FUEL FILTER
5
4
A
A
C
5
E
Figure 2-64
BS06K056
1.
2.
3.
4.
5.
FUEL FILTER BRACKET

FUEL TEMPERATURE SENSOR
FUEL FILTER
ELECTRIC FUEL HEATER
FUEL TEMPERATURE SENSOR
A.
B.
C.
D.
E.
OUTLET CONNECTION TO HIGH PRESSURE PUMP

COMMON RAIL, CYLINDER HEAD INJECTORS DISCHARGE LINE INLET CONNECTION
CONNECTION TO HIGH PRESSURE PUMP DISCHARGE LINE
INLET CONNECTION FROM FEED PUMP
OUTLET CONNECTION TO FUEL TANK
The fuel filter is installed on the engine cylinder block

in the circuit between supply pump and high pressure
pump (CP3).
2-64
The heater is activated if the fuel temperature is less

than 0 C (32 F) and is heated until the fuel reaches
5 C (41 F). Fuel temperature is monitored by the
EDC7UC31 control unit.
Issued 04-07
Bur
87630273 NA

MECHANICAL FEED PUMP- NORMAL OPERATING CONDITION- F4HE ENGINES
1
A
2
B
Figure 2-65
BS06K057
1. PRESSURE SAFETY VALVE

2. PRIMING BY-PASS VALVE IN CLOSED POSITION
The charge gear pump, installed on the rear of the

high pressure pump, draws fuel from the tank
through the pre-filter and sends it through the main
fuel filter to the high pressure pump.
A. FUEL INLET FROM TANK

B. FUEL OUTLET TO FILTER
The feed pump is driven by the high pressure pump

shaft.
In normal operating conditions the flow in the feed
pump enters port (A), flows around the outside of the
gears and out through port (B).
MECHANICAL FEED PUMP- OUTLET OVERPRESSURE CONDITION IN EXHAUST UNIT
Figure 2-66
BS06K058

2. BY-PASS PORT
Pressure safety valve (1) opens when pump outlet

pressure (B), is excessive due to filter restriction or
charge pressure regulator malfunction. The pressure
of the fuel would then overcome the force exerted by
87630273 NA
Issued 04-07
Bur

spring (1) allowing fuel to flow to the pump inlet

through passage (2).
2-65

FUEL SYSTEM BLEEDING CONDITION
1
A
2
B
Figure 2-67
BS06K059

2. PRIMING BY-PASS VALVE IN CLOSED POSITION
The by-pass valve (2) opens when, the engine is

turned off. The supply system has to be filled with the
manual priming pump.
2-66

When activating the hand pump the by-pass valve (2)

is opened due to inlet pressure, this allows the fuel
flow to outlet (B).
Issued 04-07
Bur
87630273 NA

HIGH PRESSURE PUMP TYPE CP3.3- F4HE ENGINES
1
2
8
6
4
Figure 2-68
BS06K060
HIGH PRESSURE PUMP

1.
2.
3.
4.
5.
6.
7.
8.
MECHANICAL GEAR CHARGE PUMP

FUEL OUTLET CONNECTION FROM MECHANICAL PUMP TO FILTER
FUEL INLET CONNECTION FROM CONTROL UNIT HEAT EXCHANGER
FUEL DRAIN RETURN CONNECTION TO FILTER BRACKET
FUEL INLET CONNECTION FROM FILTER
HIGH PRESSURE REGULATOR
HIGH PRESSURE PUMP
FUEL OUTLET CONNECTION TO COMMON RAIL
The high pressure pump has 3 radial plungers driven

by the cam gear. The pump does not need to be
timed.
On the rear of the high pressure pump is the

mechanical gear feed pump which is driven by the
high pressure pump shaft.
IMPORTANT: The high pressure pump unit can not be overhauled, there are no adjustments.
87630273 NA
Issued 04-07
Bur
2-67
1
9
6
5
Figure 2-69
BS06K061
EXPLODED VIEW OF HIGH PRESSURE PUMP

1. BY-PASS VALVES ON
FEED PUMP
2. PUMP SHAFT
FUEL INLET FROM
FILTER
2-68
4. 5 BAR (72 PSI) LOW PRESSURE

FUEL REGULATOR VALVE
5. HIGH PRESSURE REGULATOR
SOLENOID VALVE
7. HIGH PRESSURE FUEL DELIVERY

VALVE TO COMMON RAIL
6. INDIVIDUAL HIGH PRESSURE

PUMP PLUNGER (1 OF 3)
9. MECHANICAL GEAR CHARGE FEED

PUMP
8. GEAR SET
Issued 04-07
Bur
87630273 NA

HIGH PRESSURE PUMP INSIDE STRUCTURE
3
1
6
Figure 2-72
BS06K161
Figure 2-70
BS06K160
BS06K159
Figure 2-73
2
Figure 2-71
BS06K158
1. LOW PRESSURE FUEL INLET

2. PUMPING ELEMENTS SUPPLYING
FUEL DUCTS
3. CYLINDER
4. THREE LOBE ELEMENT
5. PUMP SHAFT
6. PISTON
7. BALL DELIVERY VALVE
8. CAP INTAKE VALVE
Pumping unit is composed of:

Three pistons (6) which are actuated by a three
lobe element (4) on the pump shaft (5) When the
shaft (5) rotates the three lobe element (4)
actuates the piston (6) pumping high pressure fuel
past the ball delivery valve (7) to the common rail.
87630273 NA
Issued 04-07
Bur
2-69

OPERATING PRINCIPAL
6
5
4
Figure 2-74
BS06K063
Figure 2-75
BS06K160
1. OUTLET FOR RAIL

DELIVERY LINE
2. HIGH PRESSURE
REGULATOR
3. PRESSURE REGULATOR
SUPPLY PASSAGE
4. PLUNGER SUPPLY
PASSAGE
High pressure plunger (3) rides on the cam installed

on the pump shaft (4). In the intake phase the
plunger is supplied with fuel through the supply
passage (5). The quantity of fuel to supply to the
plunger is determined by pressure regulator (7). The
pressure regulator controls high pressure pump
outlet flow based on PWM (pulse width modulated)
command received from the EDC7UC31 control unit.
2-70
5. PUMP SHAFT
7. RAIL DELIVERY
VALVE
6. HIGH PRESSURE
PLUNGER
During the plunger compression phase the fuel

reaches sufficient pressure to open the common rail
delivery valve (2) and is forced through outlet (1) to
the common rail.
Issued 04-07
Bur
87630273 NA
2
1
1
2
3
8
4
7
5
Figure 2-76
BS06K064
1.
2.
3.
4.
5.
6.
7.
8.
9.
INLET TO HIGH PRESSURE PLUNGERS

CHARGE PRESSURE REGULATOR DRAIN PASSAGE
CHARGE PRESSURE 5 BAR (72 PSI) REGULATOR VALVE
FUEL DISCHARGE FROM HIGH PRESSURE REGULATOR
VALVE INLET
HIGH PRESSURE REGULATOR VALVE
MAIN PLUNGER SUPPLY PASSAGE
PUMP LUBRICATION PASSAGES
3
BS06K065
Figure 2-77
1. FUEL EXHAUST FLUE

2. FUEL EXHAUST GALLERY
3. FUEL EXHAUST FLOWING FROM PUMP WITH
CONNECTOR TO HIGH PRESSURE LINE FOR
COMMON RAIL
The figure above shows the fuel flow under high

pressure running through the exhaust galleries of the
pumping elements.
THEORY OF OPERATION
The figure above shows the low pressure fuel

passages inside the pump. The figure shows the
main plungers supply passage (7), the individual
plunger supply passages (1, 8, 2), the passages
utilized for lubrication of the pump (9), the high
pressure regulator (6), the 5 bar (72 psi) pressure
regulator valve (4) and the fuel discharge passage
(3).
The high pressure regulator (6) determines the
quantity of fuel which the high pressure plungers
deliver to the common rail. Excess fuel flows out
through passage (5).
The regulator valve (4), is designed to maintain a
constant pressure of 5 bar (72 psi.) at the high
pressure regulator inlet.
The cylinder is filled through the cap intake valve only

if the supply pressure is suitable to open the delivery
valves set on the pumping elements about
2 bars (29 psi.).
The amount of fuel supplying the high pressure pump
is metered by the high pressure regulator. The high
pressure regulator is controlled by the EDC7UC31
control unit through a PWM (pulse width modulated)
signal.
When fuel is sent to a pumping element, the
corresponding piston is moving downwards (suction
stroke). When the piston stroke is reversed, the
intake valve closes and the fuel in the pumping
element chamber, is compressed into the rail.
The generated pressure makes the exhaust valve
open and the compressed fuel reaches the high
pressure circuit.
The pumping element compresses the fuel till the top
dead center (delivery stroke) is reached. Afterwards,
the pressure decreases till the exhaust valve is
closed.
The pumping element piston goes back towards the
bottom dead center and the remaining fuel is
decompressed.
87630273 NA
Issued 04-07
Bur
2-71

When the pumping element chamber pressure
becomes less than the supply pressure, the intake
valve is again opened and the cycle is repeated.
The rail delivery pressure is modulated between 250
and 1600 bars (3625 to 23206 psi.) by the
EDC7UC31 control unit, through the pressure
regulator solenoid valve.
The pump is lubricated and cooled by the fuel.

The pump replacement time on the engine is highly
reduced in comparison with traditional injection
pumps, because it does not require timing.
IMPORTANT: If the line between the fuel filter and
high pressure pump is to be removed or replaced, be
sure that components are absolutely clean.
COMMON RAIL
Figure 2-78
BS06K066
COMMON RAIL
The common rail volume is a high pressure fuel

storage device. It has a small volume to allow a rapid
pressurization at startup, at slow idle and in case of
high flow rates.
A fuel rail pressure sensor (1) is screwed into the

common rail. The signal sent by this sensor to the
EDC7UC31 control unit, and is then feed back to the
common rail pressure sensor and corrected if
necessary.
It has enough volume to minimize system spikes

caused by injector opening and closings and by the
high pressure pump operation. This function is
further enhanced by a calibrated orifice between the
high pressure pump and the common rail.
2-72
Issued 04-07
Bur
87630273 NA
COMMON RAIL PRESSURE RELIEF VALVE
6
Figure 2-79
BS06K067
COMMON RAIL PRESSURE RELIEF VALVE

1. DIRECT TANK DISCHARGE
3. BODY
5. SMALL PISTON
2. STOP
4. SPRING
6. SEAT ON RAIL
A. NORMALLY, THE TAPERED PISTON (5) END STAYS CLOSED THE
DISCHARGE IS DIVERTED TO THE FUEL TANK.
B. IF 1750 BAR FUEL PRESSURE IS EXCEEDED IN THE RAIL, THE SMALL
PISTON MOVES AND THE EXCESS PRESSURE IS DISCHARGED INTO
THE FUEL TANK.
The common rail pressure relief valve is installed at

one end of the common rail, it is designed to protect
the systems components in case of excessive
increase of pressure buildup.
The valve can be single stage (as the ones shown
above) or two stage with two working limits for
pressure relief 1750 bar and 800 bar (25381 psi. and
11603 psi.).
The relief valve enables engine operation at limited

p e r fo r m a n c e, avo i d i n g f u e l ove r h e a t i n g a n d
safeguarding the system
If the dual stage relief valve opening pressure is
reached, the EDC7UC31 control unit stops operation
of the pressure regulator. The high pressure pump
will then operate at maximum delivery to the common
rail, and a failure code will be stored.
In the second case, when the pressure within the

high pressure system reaches 1750 bar (25381 psi.),
the valve is activated as a single stage one to
exhaust the fuel and consequently reduce the
pressure until reaching the proper pressure. Then it
reduces the pressure into the common rail to
approximately 800 bar (11603 psi.).
87630273 NA
Issued 04-07
Bur
2-73
ELECTRO-INJECTOR
1
14
13
13
12
4
11
11
15
15
2
12
14
6
10
10
7
9
Figure 2-81
BS06K069
Figure 2-80
BS06K068
INJECTOR IN REST POSITION

1. ELECTRICAL
CONNECTION
2. PILOT VALVE
3. CONTROL AREA
4. CONTROL DUCT
5. PRESSURE ROD
6. SUPPLY DUCT
7. PLUNGER
8. NOZZLE
9. PRESSURE CHAMBER
10.
11.
12.
13.
14.
15.
SPRING
CONTROL FUEL OUTLET
HIGH PRESSURE FUEL INLET
COIL
BALL SHUTTER
CONTROL VOLUME
The injector is similar to the conventional injectors,

except for the absence of plunger return springs.
The injector can be considered in terms of two basic
parts:
Actuator- spray nozzle composed of pressure rod
(5), plunger (7) and nozzle (8).
INJECTION START
When coil (13) is energized, it makes ball shutter (14)

move upwards. The control volume (15) fuel flows
towards control fuel outlet (11) making a pressure
drop occur in control volume (15). Simultaneously the
fuel pressure into pressure chamber (9) makes
plunger (7) lift, causing injection of fuel into the
cylinder.
INJECTION END
When coil (13) is de-energized, shutter ball (14) goes
back to its closed position to restore a balance of
forces to make plunger (7) go back to its closed
position and end the injection cycle.
IMPORTANT: The injector has no serviceable parts
inside, so it is not repairable.
Control solenoid valve composed of coil (13) and

pilot valve (2).
The solenoid valve controls spray nozzle plunger lift.
2-74
Issued 04-07
Bur
87630273 NA

ELECTRO-INJECTOR
The NEF Tier III engines use Bosch CRIN 2 electroinjectors. The injection jet used are according to
power developed by the engine.
Figure 2-82
BS06K070
1. JET
Pressures
Injectors
Jet
Power developed
CRIN 2
DLLA
Above 152kW (204 h.p.)
250 bar (3626 psi.)
1600 bar (23206 psi.)
CRIN 2
DSLA
Below 152kW (204 h.p.)
250 bar (3626 psi.)
1450 bar (21030 psi.)
kW / H.P.
87630273 NA
Issued 04-07
Bur
Minimal operating pressure
Nominal operating pressure
2-75

PRESSURE LIMITER FOR FUEL RETURN
BS06K071
Figure 2-83
A. TO FUEL TANK
B. FROM INJECTORS
The pressure limiter for the fuel return is housed on

the rear of the cylinder head, and adjusts the
pressure of the fuel returning from injectors at a
pressure of 1.3 to 2.0 bars (18.9 to 29 psi.). By
maintaining this pressure to the return fuel, the fuel
vapor formation inside the injectors is avoided,
optimizing fuel spraying and combustion.
2-76
Issued 04-07
Bur
87630273 NA
CHECKING THE FUEL SYSTEM

LOW PRESSURE SUPPLY TEST
10
9
11
2
4
12
4
5
1
13
Figure 2-84
BS06K214
DIAGRAM OF SET UP OF COMPONENTS FOR SPECIFIC TEST

1. FUEL TANK
2. PREFILTER

7. HIGH PRESSURE CIRCUIT
3. LOW-PRESSURE PUMP
8. COMMON RAIL
4. FUEL DELIVERY CIRCUIT

5. FUEL FILTER
87630273 NA
11. M1 PRESSURE GAUGE 0-15 BAR FUEL FILTER INLET

12. M2 PRESSURE GAUGE FUEL FILTER OUTLET
13. EXTERNAL CONTAINER PLACED 1M (39 IN.) BELOW
ENGINE
9. FUEL RECIRCULATION
10. INJECTORS
Issued 04-07
Bur
2-77
6
12
11
13
Figure 2-85
BS06K215
LOW - PRESSURE PUMP
Figure 2-86
BS06K216
The function of the gear pump is to supply the high

pressure pump. It is driven by the shaft of the high
pressure pump and is installed on the rear portion of
the high pressure pump.
Under normal operating conditions, the flow of fuel
inside the pump is as shown in the figure above.
2-78
With the fuel system pressurized, a fully charged

battery and an external fuel supply placed 1m (39 in.)
below the engine. The engine must start within 20
seconds of activation of the starter motor. If the pump
is not able to draw fuel to the engine and start the
engine the low pressure pump is probably defective.
Issued 04-07
Bur
87630273 NA

After starting the engine, check the pressure at 1500
rpm.
On pressure gauge M1- (11) it must be between 6
and 9 bar (87 and 130 psi.)
If lower than 6 bar (87 psi.) replace pump
If higher than 9 bar (130 psi.) replace the fuel
filter.
On pressure gauge M2- (12) it must be greater than
5 bar (72.5 psi.)
If lower, replace the fuel filter
If the trouble persists, check the seals on the
couplings of the fuel filter bracket and the high
pressure pump inlet.
87630273 NA
Issued 04-07
Bur
2-79

TEST ON PRESSURE RELIEF VALVE ON COMMON RAIL
Figure 2-87
BS06K217
The pressure relief valve is installed on the end of the

common rail, its function is to protect the systems
components if any malfunction causes and excessive
increase in the pressure of the high pressure system.
Disconnect recirculation line (1) from the pressure
relief valve and plug with the VOSS fitting from the
test set.
If the valve seeps diesel without a fault code, then

replace the valve.
With the common rail pressure sensor disconnected
and a fault code is generated, with the rail pressure is
at 71 0 bar (1 029 8 psi.) m ea sura ble with the
diagnostic instrument, the trouble is in the wiring and
not the component.
No diesel must come out of the valve at any engine

speed. If the diagnostic system signals a fault code
Engine - backfill valve control, it means that the
EDC7UC31 control unit has recognized that the
value has opened after a significant change in the
pressure of the rail greater than 1700 bar (24656
psi.). Since its opening is to be considered a
consequence of abnormal increase in pressure, the
valve is NOT defective even though a great amount
of diesel flows out.
IMPORTANT: Information acquired to date shows that the sensor is rarely defective.
2-80
Issued 04-07
Bur
87630273 NA

TEST ON FUEL BACKFLOW FROM THE RETURN
BS06K219
Figure 2-88
BS06K218
Tests on fuel backflow from the return establishes

the operating status of the injectors. The engine
s p ee d a nd powe r a re c on tr ol l e d th ro ug h t he
injectors. The power required by the user, through
the accelerator, is converted into the quantity of fuel
injected per cycle. This in turn is converted into
microseconds of injector opening according to the
rail pressure.
Figure 2-89
1. INJECTOR DUCT LOCKING NUT
When the EDC7UC31 control unit warning light

comes on during acceleration and/or cold star t
trouble, make sure the following check is done.
Check torque of the nut (1) locking the injector
duct on the cylinder head. The torque setting is
45 - 55 Nm (33.2 - 40.6 lb.- ft.).
NOTE: The injectors may have problems of both a

mechanical and a electrical nature. Therefore before
proceeding with the following analysis, it is wise to
rule out the presence of water in the tank and the fuel
prefilter.
87630273 NA
Issued 04-07
Bur
2-81
Figure 2-90
BS06K220
Proceed with the injector fuel backflow tests as

follows:
Remove the duct (4) from the cylinder head.
Plug it (3)
Install a transparent line (2)
Make sure that the engine idling speed is correct.
Check the quantity of fuel recirculation from the
cylinder head.
The process for measuring the quantity of injector
return fuel is:
Engine idling and without air compressor or air
conditioner on.
engine temperature greater than 50C (122F).
The quantity of fuel that flows out must be no greater
than 80ml. (2.7 oz.) of diesel per minute. Excessive
recirculation more than 80ml. (2.7 oz.) of diesel per
minute could be caused by:
Incorrect coupling between one or more
injectors and the related needles.
Problem of internal leakage of the injector.
2-82
To identify the defective injector, follow the method

as described below:
Measure the quantity of fuel flowing out in one
minute from the coupling on the cylinder head. If
recirculation exceeds 80 ml. (2.7 oz.) per minute,
plug the rail outlet of one injector (1) at a time using
the rail plugs in the test set.
The defective injector is the one when plugged
causes a significant reduction in recirculated fuel.
NOTE: When changing an injector it is necessary to
change the duct.
After identifying the injectors / ducts with high fuel
recirculation, check the torque of the ducts, 45 - 55
Nm (33.2 - 40.6 pound-feet), if they are loose tighten.
Then check the recirculation values again.
If the torque is correct, remove the line and check the
spherical end towards the injector is not out of round,
replace if necessary. Recheck recirculation value.
If the duct is not out of shape, replace the injector
Issued 04-07
Bur
87630273 NA
SPECIAL DISASSEMBLY FOR F4GE ENGINES

STEP 3
DISASSEMBLING ENGINE
STEP 1
13
3
4
12
11
6
7
10
9
1
Figure 2-93
BS06N246
Version F4GE9484D
Figure 2-91
BS06N244
Drain the engine oil by taking the plug off the oil pan
and the oil filling cap of the valve cover.
Remove the fan unit from the fan pulley.
In order to apply the brackets to the engine block to
fix it on the stand for overhaul it is necessary to
remove electrical wiring (1).
STEP 2
Remove the following:
Grid heater (1).

Intake manifold (2).
Oil recovery pipe from blow-by (3).
Pipe for LDA intake manifold (4).
Piping for LDA system (5).
Quick-couplings pipes (6), (7), (10) see step 4.
Fuel filter (8).
Electrical wiring (9).
Fuel filter support (11).
Grid heater control unit (12).
Tappet covers (13).
STEP 4
1
Figure 2-92
BS06N245
Fastening bracket (5) from electrical wiring (1).

Starter (4)
turbine lubrication delivery pipe (2).
Oil filter (3).

BS06K388
Figure 2-94
IMPORTANT: Push clamp (1), as shown in figure B

to disconnect the low pressure fuel lines 6, 7, 10 from
the corresponding connections. After disconnecting
the line, reset the clamp (1) to position in figure A to
prevent distortion to the clamp.
87630273 NA
Issued 04-07
Bur
2-83

STEP 7
STEP 5
2
1
6
5
4
BS06N247
3
Figure 2-95
2
Figure 2-97
BS06N248
Remove the bolts fastening the turbine, and then
Injector feed pipes (3) from injection pump (2).

Brackets fastening feed pipes (1), (5), (6) on the
cylinder head.
remove the turbine (1).
Remove the exhaust manifold (3).

STEP 8
Fuel pump (4).
STEP 6
2
1
3
4
5
6
3
2
BS06N249

Figure 2-96
Fuel feed pipes from the injectors (1).

Remove fuel drain pipe (2) from the injectors by
removing the bolt (4) and the seal (3).
Figure 2-98
BS06N250
Belt tightener (2).

Poly-V belt (4).
Alternator fastening bracket (1).
Alternator (3), water pump (6), fan pulley (5), and
guide pulleys (7).
pulley support (8).

Thermostat housing and thermostat (9) from the
engine block.
2-84
Issued 04-07
Bur
87630273 NA

STEP 11
STEP 9
1
2
1
3
2
Figure 2-99
BS06N251
Lock the flywheel properly to prevent rotation,

remove bolts (2) from pulley (1).
CRANK SEAL REPLACEMENT
STEP 10
Figure 2-101
BS06K244
Using the pry bar (3) of Special Tool 380000996 and

the lever (4), remove the external seal ring (2) from
the front cover
STEP 12
B
1
1
2
2
3
3
4
4
Figure 2-100
BS06K243
Place Special Tool 380000665 (4) to the front of the

crankshaft (2).
Working through the guide holes of Special Tool
380000665 (4), drill into the internal seal ring (1) with
a 3.5 mm (9/64 inches) drill bit (A) to a depth of 5 mm
(3/16 inch) (B).
Secure Special Tool 380000665 (4) to the ring (1) by
screwing down the six bolts supplied with tool to the
crankshaft front cover.
BS07C437
Figure 2-102
Water pump (1)

Bolts (2) and (4)
Crankcase front cover (3)
NOTE: Take note of bolts (2) and (4) position when
removing them because they are different lengths.
Now extract seal ring (1) by tightening bolt (3).
87630273 NA
Issued 04-07
Bur
2-85

STEP 15
STEP 13
2
1
Figure 2-103
BS06K246
Figure 2-105
BS06N254
Remove bolts and take off oil pump (1).
LOCKING INJECTION PUMP IN PRESET CONDITION
IMPORTANT: Oil pump (1) cannot be repaired.

REMOVING INJECTION PUMP
To correctly preset the injection pump prior to

removing it, loosen bolt (2) and remove the
L-shaped spacer (1).
Tighten bolt (2) to 27 to 33 Nm (20 to 24.3 poundfeet) to block rotation of the pump shaft.
STEP 14
IMPORTANT: Keep the L-shaped spacer with the

pump so it does not get misplaced (it is needed for
installation).
STEP 16
2
4
Figure 2-104
BS06N253
LOCKING FLYWHEEL
Rotate the crankshaft until the number 1 cylinder

reaches top dead center (TDC).
When TDC is obtained lock the flywheel by pushing
pin (1) of special tool 380002729 as shown by the
arrow.
1
Figure 2-106
BS06N255
Remove cover (1) from gear case (2).

Loosen nut (3) securing the injection pump drive gear
(4).
2-86
Issued 04-07
Bur
87630273 NA

STEP 19
STEP 17
2
Figure 2-107
BD04A025-01
Attach Special Tool 380000979 (1) to the injection

pump drive gear and remove the gear.
BS06N257
Figure 2-109
Remove bolts (1) securing engine flywheel (2) to the

crankshaft
STEP 18
STEP 20
1
2
4
3
Figure 2-108
BS06N256
Loosen the three nuts (1), (3) and (4) securing the
injection pump (2) to the bell housing (5), then take
the pump out of its housing.
NOTE: Hold the pump drive gear shaft to prevent it
from moving, when removing pump from the engine
block.
87630273 NA
Issued 04-07
Bur
BS06N258
Figure 2-110
Screw two pins (2) of adequate length into crankshaft

holes (3).
Remove engine flywheel (1) so that it can be
harnessed with a hoist and moved out of the way.
2-87

STEP 23
STEP 21
A
1
1
2
2
3
4
BS06N252
Figure 2-111
REMOVING INNER REAR CRANKSHAFT SEAL
Apply Special Tool 380000663 (3) on crankshaft rear

shank (5).
Dr ill inner seal ring (1), through Special Tool
380000663 (3) guide holes, with a 3.5 mm
(9/64 inches) drill bit (A). Drill down to a depth of
5 mm (3/16 inches).
Secure Special Tool 380000663 (3) to ring (1) by
fastening the 6 bolts (4) provided.
Figure 2-113
BS06N259
Remove bolts (2) and then remove the flywheel

housing.
IMPORTANT: Note the installation position of the
bolts (2) because they are different lengths.
STEP 24
Extract seal ring (1) by tightening bolt (2).

STEP 22
2
3
Figure 2-114
BS06N260
Turn the engine upside down, remove bolts (2),

remove oil pan (1).
STEP 25
4
1
BS06K244
Figure 2-112
REMOVING OUTER REAR CRANKSHAFT SEAL
Using the pry bar (3) and lever (4) remove the outer
seal ring (2) as shown in figure above.
Then take the same tool and remove the seal ring
from the flywheel cover case in the same manner.
2
3
4
Figure 2-115
BS06N261
Remove bolts (1) and disassemble gears (3) and (4)

from camshaft (2).
2-88
Issued 04-07
Bur
87630273 NA

STEP 28
STEP 26
2
1
2
Figure 2-116
BS06N262
REMOVING COUNTER BALANCE
Use pin (1) to lock the counter balance (3) at TDC

(top dead center). Remove bolts (2) and remove the
counter balance (3).
Figure 2-118
BS06N264
Remove injectors (2) with Special Tool 380000671

(1).
STEP 29
REMOVING ROCKER ARM ASSEMBLY
STEP 27
1
2
3
4
Figure 2-119
BS06N265
Figure 2-117
BS06N263
For each cylinder, loosen adjusting nuts (3) and

unscrew the adjusters (2).
Remove bolts (1) securing the cylinder head to the

engine block
STEP 30
Remove the bolts (4), remove rocker assembly (1)

and the push rods.
BS06N266
Figure 2-120
Attach harness to brackets (1), and remove cylinder

head from block using a hoist.
87630273 NA
Issued 04-07
Bur
2-89

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REPAIR MANUAL

Issued 04-2007 - Service Training Edits

ENGINE REPAIR MANUAL

F4GE9454H, F4GE9454J, F4GE9484D,

ENGINE REPAIR MANUAL

ENGINE REPAIR MANUAL

445TA ENGINE OVERHAUL

SECTION 1 - ENGINE REPAIR MANUAL

INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL, CHARGING AND START-UP

ENGINE REPAIR MANUAL

ENGINE REPAIR MANUAL

ENGINE REPAIR MANUAL

ENGINE REPAIR MANUAL

ENGINE REPAIR MANUAL

Batteries fully charged.

Perform the checks described in the electrical

Inspect, clean, tighten nuts or replace terminals if

Perform the checks described in the electrical

Check using multi meter replace or repair. Refer to

Verify timing described in Chapter 2 page 2-120 and

On common rail engines check using Electronic

Check and repair air leaks. For mechanical injection

Check and clean the fuel system including the fuel

Check fuel pump and replace if necessary.

Check and replace defective parts. See Chapter 2

Check cylinders for proper compression, overhaul

ENGINE REPAIR MANUAL

Check for leaks, repair leaks and refill to

Check for leaks, bad bearing, overhaul or

Wash down, repair leaks and flush out

Clean or replace faulty parts.

Check and adjust for correct valve

Verify correct timing described in Chapter 2

Injection pump timed correctly.

ENGINE REPAIR MANUAL

Adjust rod length.

Clean or replace filter.

Check and clean the fuel system including

Verify correct timing described in Chapter 2

Check and if defective repair or replace.

Power to KKSB solenoid repair or replace if

On common rail engines check using

Bring to a certified pump shop for repair.

Injection pump timed correctly

Bring to a certified pump shop for repair.

ENGINE REPAIR MANUAL

Bring to a certified pump shop for repair.

Bring to a certified pump shop for repair.

Adjust clearance for proper value.

Check each cylinder for proper compression,

Repair or replace unit.

ENGINE REPAIR MANUAL

Clean the tank and replace the fuel filter.

Clean replace if necessary.

Check using multi meter replace or repair.

Cold start solenoid (KKSB) working properly.

On common rail engines check using

Verify correct timing described in Chapter 2

Bring to a certified pump shop for repair.

Bring to a certified pump shop for repair.

Injection pump timed correctly.