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Copyright © New Holland

PROVEN PERFORMANCE PROVEN PERFORMANCE


Copyright © New Holland

REPAIR MANUAL FOR CNH U.K. ENGINES


F4BE0454B -- F4BE0484D -- F4BE0484E
F4BE0684B -- F4BE0684M
The following models are to integrate repair manuals:
NEW HOLLAND KOBELCO E145 -- E175 -- E195 -- E215 -- E245
NEW HOLLAND MH2.6 -- MH3.6 -- MH4.6 -- MH Plus C

Every information, illustration and specification contained in the present manual is based on the most recent informa--
tion available at the time of printing.
NEW HOLLAND reserves the right, to modify the text at any time without prior communication.

NEW HOLLAND
PRINT NO. 604.13.582
Edition – April 2006
2 WE

MOTORI

2
IN--1

INTRODUCTION

TO THE READER
- This manual was written for a skilled technician - For any question or comment, or should you no--
and contains all the technical information needed tice any mistake concerning the content of this
to repair this vehicle. manual, please contact:
- Read this manual carefully for the information NEW HOLLAND
concerning repairing operations. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax ++39 011 0077357

FURTHER REFERENCES
PAGE NUMBER
- Every page carries a number on the top right corner. Every page contains the following information:

Example:: T 1 -- 2 -- 3

Progressive page number for each group

Group number (if any)

Section number

S: Safety rules
Operation principle
T: Technical section Performance tests
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing

SYMBOLS
This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.

This symbol regards safety.


! Use great care when you see this symbol because possible injuries to the personnel may occur.
Strictly observe the precautions marked with this symbol.
The safety warning symbol is used also to draw attention on the weight of a component or an element.
Make sure you are always using the right equipment and lifting techniques when handling heavy
loads, in order to prevent injuries or damages.
IN--2

INTRODUCTION

UNIT OF MEASURE
This manual adopts the units of measure based on the International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 Mpa (250 kgf/cm2).
The following table converts the International System units of measure in some of the main units belonging to
other systems.

To convert in To convert in
Quantity Multiply by Quantity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min--1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Capacity
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
REPAIR MANUAL
ENGINES

INDEX OF SECTIONS

Section 1 -- Diagnostics EW--1--1

Section 2 -- Engines overhaul: EW--2--1


-- FABE0454B
-- FABE0484D
-- FABE0484E

Section 3 -- Engine overhaul: EW--3--1


-- F4BE0684B
-- F4BE0684M

Section 4 -- Recharging and start--up EW--4--1


4 WE

MOTORI
SECTION 1

DIAGNOSTICS

INDEX
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
INDICE
EW--1--3

DIAGNOSTICS

Main engine operating anomalies:

1 -- Engine won’t start; 6 -- Engine exhaust smoke light blue;


2 -- Engine overheats; 7 -- Engine knocks irregularly;
3 -- Engine lacks power and works erratically; 8 -- Engine stops;
4 -- Engine exhaust smoke black or dark grey; 9 -- Engine exceeds max. revs number;
5 -- Engine exhaust smoke grey (verging on 10 -- Excessive or insufficient oil pressure;
white); 11 -- Excessive fuel consumption;
12 -- Engine won’t stop.

1 ENGINE WON’T START

Connections to battery terminals are in working Clean, check, tighten or replace clamp nuts.
order NO

YES

Batteries in working order Carry out the checks described in the “Electric
NO system” repair manual.

YES

Starter motor in working order Carry out the checks described in the “Electric
NO system” repair manual.

YES

Thermal starter in working order Replace.


NO

YES

Injection pump timed Verify correct timing as described in the relevant


NO chapter.

(to be continued)
EW--1--4

DIAGNOSTICS

Injectors in working order Check operation and adjust.


NO

YES

The feeding circuit or injection pump does not Check and blow off.
show air penetration NO

YES

The feeding circuit or pump does not show traces Check and clean the feeding circuit (including the
of water NO tank).

YES

Prescribed compression ratio Overhaul the engine or make repairs only on


NO
concerned parts (valves, piston rings, etc.).

YES

Fuel filters in working order Replace.


NO

YES

Automatic advance variator and electric STOP Check and replace the concerned parts.
device both in working order NO

YES

Fuel pump fed correctly Check and replace (if necessary) the fuel pump.
NO

YES

Fuel tank supplied correctly Refuel.


NO
EW--1--5

DIAGNOSTICS

2 ENGINE OVERHEATS

Coolant level correct Check for leaks and restore the level.
NO

YES

Fan and water pump drive belts in working order Check for leaks and restore the level.
NO

YES

Water pump in working order Overhaul or replace the unit.


NO

YES

Thermostat in working order Replace.


NO

YES

Radiator in working order Wash down thoroughly, check for fluid leaks, re--
NO place (if necessary) the part.

YES

Air filter and circuit piping both in working order Clean or replace faulty parts.
NO

YES

Openings for coolant flow to the head in working Wash down thoroughly.
order NO
EW--1--6

DIAGNOSTICS

Valve timing correct Check and perform correct timing.


NO

YES

Injection pump timed Check correct timing as described in the relevant


NO paragraph.

YES

Cylinder head gasket in working order Replace.


NO

YES

Fan in working order Replace.


NO

3 ENGINE LACKS POWER AND WORKS


ERRATICALLY

Air filter in working order Clean the unit and replace (if necessary) the filter
NO element.

YES

Fuel filters in working order Replace by following the instructions given in the
NO “Owner Handbook”.

YES

Feeding circuit in working order Check and make (if necessary) the required re--
NO pairs.

(to be continued)
EW--1--7

DIAGNOSTICS

The feeling circuit does not show impurities and/ Take off the pipes and injection pump, clean them
or traces of water NO thoroughly, then clean (if necessary) and dry the
fuel tank.

YES

Thermostat in working order Replace.


NO

YES

Fuel pump in working order Replace.


NO

YES

Injectors in working order Check operation and adjust them.


NO

YES

Injection pump timed Check correct timing as described in the relevant


NO paragraph.

YES

Automatic advance variator (in injection pump) in Check and bench--adjust the injection pump.
working order NO

YES

Distributing plunger (in injection pump) in work-- Check and bench--adjust the injection pump.
ing order NO

(to be continued)
EW--1--8

DIAGNOSTICS

Injection pump rate correct Check and bench--adjust the injection pump.
NO

YES

Speed governor (in injection pump) in working Check and bench--adjust the injection pump.
order at all speeds NO

YES

Circuit and L.D.A. device both in working order Check.


NO

YES

Injection pump with peak adjusting--screw fine-- Fine--tune the peak adjusting--screw.
tuned NO

YES

Correct play between the valves and rocker arms Adjust the play between the valves and rocker
NO arms.

YES

Prescribed compression ratio Check and bench--adjust the injection pump.


NO

YES

Turbocharger in working order Repair or replace the unit.


NO

YES

Correct tie rod length between the accelerator Adjust the tie rod length.
and injection pump NO
EW--1--9

DIAGNOSTICS

4 ENGINE EXHAUST SMOKE BLACK OR


DARK GREY

Air filter in working order Replace.


NO

YES

Thermal starter in working order Replace.


NO

YES

Automatic addition device comes into operation Check and replace (if necessary).
NO

YES

Injectors in working order Check operation and adjust them as described.


NO

YES

Injection pump timed Check correct timing as described in the relevant


NO paragraph.

YES

L.D.A. device in working order Ad just the L.D.A. device.


NO

YES

Injection pump adjusted as prescribed Check and bench--adjust the injection pump.
NO

(to be continued)
EW--1--10

DIAGNOSTICS

Injection pipes intact Check the condition of pipes and replace them (if
NO necessary).

YES

Prescribed compression ratio Check by means of a Motometer 75301430 tool


NO and carry out the necessary operations.

YES

High--quality diesel fuel Clean the tank and replace the diesel oil filter.
NO

5 ENGINE EXHAUST SMOKE GREY (VERG--


ING ON WHITE)

The thermostat comes into operation correctly Replace.


NO

YES

Injectors in working order Check operation and adjust as described in S.I.


NO 1094.

YES

Injection pump timed Check correct timing as described in the relevant


NO paragraph.

YES

Coolant level correct Possible flow of coolant into the combustion


NO
chamber; replace the cylinder head gasket or
overhaul the engine.

(to be continued)
EW--1--11

DIAGNOSTICS

High--quality diesel oil Clean the tank and replace the diesel oil filters.
NO

6 ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption Check the oil vapour vent and cylinder compres--
YES sion. Overhaul, if necessary, the cylinder head or
engine.

7 ENGINE KNOCKS IRREGULARLY

Knock detected in the injection pump Perform correct timing of injection pump on the
YES engine.

NO

Knock detected in the drive shaft Check the following items: journal play and out--
YES of--roundness; screw fastening for bed caps and
engine flywheel; oil pressure. Replace the parts
or overhaul the engine.

NO

Knock detected in the connecting rods Check the following items: crankpin play and
YES out--of--roundness; screw fastening for connect--
ing rod caps; connecting rod squaring. Replace
the parts or overhaul the engine.

NO

Knock detected in pistons Check the following items: play between the pis--
YES tons and the cylinder liners; integrity of piston
rings; play between the pins and the piston hubs.
Replace the parts or overhaul the engine.

(to be continued)
EW--1--12

DIAGNOSTICS

Knock detected in the cylinder head Check the following items: operation play be--
YES tween the rocker arms and the valves; injection
pump timing; valve timing. Adjust.

NO

Knock detected in the valve gear Check and replace (if necessary) the gears;
moreover, check for broken springs, for excess--
YES ive play between the stems and guides, the
tappets and seats. Adjust the play between the
valves and rocker arms.

NO

Knock detected in injectors Check and adjust as described in S.I. 1094, then
YES replace.

NO

Knock detected in the engine flywheel Replace loose screws and tighten all screws to
YES the specified torque and angles.

NO

Knock detected in the fuel piping Clean the pipes and replace the pipes that show
YES evident dents; clean (if necessary) the injection
pump.

8 ENGINE STOPS

Fuel tank filled Refuel and drain (if necessary).


NO

YES

Fuel filters in working order Replace.


NO

(to be continued)
EW--1--13

DIAGNOSTICS

Feeling circuit in working order Check the circuit and drain.


NO

YES

Regular idle speed Adjust.


NO

YES

Regular injection pump rates Bench--check the flow rates.


NO

YES

Injection pump controls in working order Replace worn parts and adjust.
NO

YES

Correct play between the valves and rocker arms Ad just the play between the valves and rocker
arms.
NO

YES

Intact valves Replace the valves.


NO

9 ENGINE EXCEEDS MAX. REVS NUMBER

Speed governor in working order Check and replace (if necessary) the worn parts.
NO
EW--1--14

DIAGNOSTICS

10 EXCESSIVE OR INSUFFICIENT OIL


PRESSURE

Pressure control valve in working order Check and replace (if necessary).
NO

YES

Oil pump and delivery pipes both in working or-- Check and replace (if necessary).
der NO

YES

Main bearings and connecting rod bearings both Replace the bearings and reface (if necessary)
in working order NO the drive shaft.

YES

Engine oil SAE viscosity conforming to stan-- Replace the engine oil with equivalent of ad--
dards NO equate viscosity.

11 EXCESSIVE FUEL CONSUMPTION

Fuel tank and pipes in working order Eliminate leaks (if any) and replace the worn
NO parts.

YES

Air filter in working order Replace.


NO

(to be continued)
EW--1--15

DIAGNOSTICS

Correct injector adjustment Check operation and adjust them.


NO

YES

Correct injection pump adjustment Check and bench--adjust.


NO

YES

L.D.A. device in working order Adjust the L.D.A. device.


NO

YES

Injection pump timed Check static force--fit of the injection pump.


NO

12 ENGINE WON’T STOP

Cut--off electromagnet in working order Replace the electromagnet.


NO

YES

Speed governor in working order at all speeds Overhaul the injection pump and bench--adjust it
NO according to the relevant adjustment table.
EW--1--16

DIAGNOSTICS

NOTES
SECTION 2 F4BE0454 -- F4BE0484

ENGINES F4BE0454B F4BE0484D


F4BE0484E OVERHAUL

INDEX
Engines F4BE0484 . . . . . . . . . . . . . . . . . EW--2--3 Checking the eccentric lift and the
Coding of source engines . . . . . . . . . . EW--2--4 pin alignment . . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Main engines features . . . . . . . . . . . . . . EW--2--5 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--60
Torque and rating features . . . . . . . . . . EW--2--7 Replacing the bushings . . . . . . . . . . . . . . EW--2--61
General engines features F4BE0454 . EW--2--8 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--61
Assembling engines play F4BE0454 -- Mounting the tappets – Distributing shaft EW--2--61
specifications . . . . . . . . . . . . . . . . . . . . . EW--2--10
General engines features F4BE0484 . EW--2--16 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Assembling engines play F4BE0484 -- Measuring the journals and crankpins . . EW--2--62
specifications . . . . . . . . . . . . . . . . . . . . . EW--2--18 Replacing the oil pump drive gears . . . . EW--2--65
Tightening torque . . . . . . . . . . . . . . . . . . EW--2--24 Mounting the main bearings . . . . . . . . . . EW--2--65
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--25 Measuring the journal assembling play . EW--2--65
Graphic indications and symbols . . . EW--2--26 Checking the drive shaft shoulder play . EW--2--66
General remarks . . . . . . . . . . . . . . . . . . . EW--2--27 Connecting rod--piston assembly . . . EW--2--67
Description of main mechanic
engine components . . . . . . . . . . . . . . . . EW--2--28 Measuring the piston diameter . . . . . . . . EW--2--68
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--28 Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--29 Conditions for correct pin/piston
Drive shaft seal rings . . . . . . . . . . . . . . . . EW--2--29 matching. . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--30 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--31 Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--70
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--32 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--71
Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--2--33 Checking the connecting rods . . . . . . . . . EW--2--71
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Checking the torsion . . . . . . . . . . . . . . . . . EW--2--71
Valves and valve seats . . . . . . . . . . . . . . . EW--2--35
Checking the flexion . . . . . . . . . . . . . . . . . EW--2--71
Valve guides . . . . . . . . . . . . . . . . . . . . . . . . EW--2--36
Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--2--37 Connecting rod--piston match . . . . . . . . . EW--2--72
Auxiliary component drive . . . . . . . . . . . . EW--2--38 Mounting the piston rings . . . . . . . . . . . . . EW--2--72
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--39 Mounting the connecting rod/piston
Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--2--40 assemblies in the cylinder liners . . . . . . . EW--2--73
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--41 Measuring the crankpin assembling play EW--2--73
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--42 Checking piston protrusion . . . . . . . . . . . EW--2--74
Oil vapour recirculation . . . . . . . . . . . . . . . EW--2--43 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--74
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--44 Distribution gearbox case . . . . . . . . . . . . EW--2--74
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--2--45 Valve timing . . . . . . . . . . . . . . . . . . . . . . . . EW--2--75
Mechanic injection feeding system . . . . EW--2--46
Injection pump – 1st phase . . . . . . . . . EW--2--76
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . EW--2--46
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--46 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--76
Mechanic fuel pump . . . . . . . . . . . . . . . . . EW--2--47 Flywheel cover case . . . . . . . . . . . . . . . . EW--2--76
Injection assembly . . . . . . . . . . . . . . . . . . . EW--2--48 Mounting the rear seal ring . . . . . . . . . . . EW--2--77
Engine bench--overhaul . . . . . . . . . . . . EW--2--49 Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--77
Disassembling the engine . . . . . . . . . . . . EW--2--49 Replacing the engine flywheel ring gear EW--2--77
Removing the front seal ring . . . . . . . . . . EW--2--51 Injection pump – 2nd phase . . . . . . . . . EW--2--78
Removing the injection pump . . . . . . . . . EW--2--52 Mounting the injection pump –
Removing the rear seal ring . . . . . . . . . . EW--2--53 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--78
Removing the rocker arm assembly Mounting the oil and water pumps . . EW--2--79
and cylinder head . . . . . . . . . . . . . . . . . . . EW--2--55
Monting the front seal ring . . . . . . . . . . . . EW--2--79
Repair work on cylinder cluster . . . . . EW--2--57
Checks and measurements . . . . . . . . . . . EW--2--57 Mounting the oil sump . . . . . . . . . . . . . . EW--2--80
Checking the surface supporting Mounting the water / oil heat
the head on the cylinder cluster . . . . . . . EW--2--58 exchanger . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--81
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--59 Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--81
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--59 Removing the valves . . . . . . . . . . . . . . . . EW--2--81
INDEX

Checking the cylinder head supporting Rocker arm assembly . . . . . . . . . . . . . . . . EW--2--87


surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--82 Mounting the injectors . . . . . . . . . . . . . . . EW--2--88
Checking the cylinder head water seal . EW--2--83 Intake manifold unit . . . . . . . . . . . . . . . . . . EW--2--89
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--83 Replacing the injectors . . . . . . . . . . . . . EW--2--91
Valve descaling, check and grinding . . . EW--2--83 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--91
Checking the play between the valve Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--92
stem, valve guide and valve centring . . . EW--2--84
Rocker arm removal/reassembling . . EW--2--92
Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--84 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--92
Valve seat reconditioning -- replacement EW--2--84 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--92
Valve springs . . . . . . . . . . . . . . . . . . . . . . . EW--2--86 Adjusting the tappets . . . . . . . . . . . . . . EW--2--93
Mounting the cylinder head . . . . . . . . . EW--2--86 Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--2--93
Reattaching the cylinder head . . . . . . . . . EW--2--87 Check priming of the injection pump . . . EW--2--94
EW--2--3

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

ENGINES F4BE0484E

Figure 1

84235
EW--2--4

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

CODING OF SOURCE ENGINES

F 4 B E 0 4 8 4 E * D +

Emission level

Approved rating

Use

Feeding / Injection
D = TIER 2
Cylinder no.

Cylinder pattern:
0 = 4 strokes, vertical

Engine

Type of crankcase:
B = non--structural 4 = 4--cylinder

Group
Engines

8 = Direct injection turbo


diesel with intercooler
5 = Direct injection turbo
diesel

4 = Earthmovers

X Y Y Y Y Y Y Y Y

X = 6 rotary, 2--valve injection pump Manufacturing sequence number


Y = Engine model
EW--2--5

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

MAIN ENGINES FEATURES

A MH2.6 E145 E195

B F4BE0454B F4BE0484D

C *D602 *D601 *D608

E 3922 cm3

74kW 88 kW
F 2100 min--1 2200 min--1

G Direct injection

H Rotary injection pump

T.C. T.A.A.
I
(Boosted) (Boosted by intercooler)

A Excavator initials
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--6

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

MAIN ENGINES FEATURES

A MH3.6 MH4.6 E175

B F4BE0484E

C *D605 *D601 *D607

E 3922 cm3

83 kW
F 2000 min--1

G Direct injection

H Rotary injection pump

T.A.A.
I (Boosted by intercooler)

A Excavator initials
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--7

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

TORQUE AND RATING FEATURES

Figure 2

Torque - Nm
Rating - kW

Torque Rating

84279
EW--2--8

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

GENERAL ENGINES FEATURES F4BE0454


F4BE0454B
Type
*D601 *D602

Cycle 4--stroke diesel engine


Feeding Boosted
Injection Direct

Number of cylinders 4 in--line

Bore mm 102

Stroke mm 120

Total displacement cm3 3922

Compression ratio 17.5 : 1

Max. rating kW 74
min --1 2100

Max. torque Nm 390


min --1 1400

No--load idle rpm min --1 800

No--load peak rpm min --1 2300

BOOSTING With intercooler


Type of turbocompressor: HOLSET HX25W

Forced by means of gear pump,


LUBRICATION
pressure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
EW--2--9

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0454B
Type
*D601 *D602
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81 ± 2

Ambra Master gold HSP REFUELLING


15W40
10W30 -- engine sump + filter litres 12.5

FEEDING
Bosch--type injection VE4 / 12 F 1100 L

Pump setting 0° ± 0°.5

Start of delivery mm 1

Type of nozzle DSLA 145 P603

Injection sequence 1 -- 3 -- 4 -- 2

Injection pressure (bar) 245 bar


EW--2--10

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

ASSEMBLING ENGINES PLAY F4BE0454 -- SPECIFICATIONS


F4BE0454B
Type
*D601 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Cylinder liners ∅1 102.01 to 102.03

Pistons: supplied with standard


spares
Measurement dimension X 61
Outer diameter ∅1 101.757 to 01.775
Pin seat ∅2 40.006 to 40.012
Piston -- cylinder liners 0.215 to 0.253

Piston diameter ∅1 0.5

Position of pistons from crankcase X 0.28 to 0.52

Gudgeon pin ∅3 39.9938 to 40.0002

Gudgeon pin -- Pin seat 0.0058 to 0.0182

Type of piston X1* 2.69


Piston ring slots X2 2.425 to 2.445
X3 4.040 to 4.060
* measured on ∅ of 99 mm
S1* 2.310 to 2.340
Piston rings S2 2.560 to 2.605
S3 3.975 to 4.000
* measured on ∅ of 99 mm
1 0.082 to 0.133
Piston rings – Slots 2 0.135 to 0.180
3 0.040 to 0.085

Piston rings 0.5


EW--2--11

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0454B
Type
*D601 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55

Connecting rod small--end


bushing seat ∅1 42.987 to 43.013
Connecting rod bearing seat ∅2 72.987 to 73.013

Connecting rod small--end bushing


diameter 43.279 to 43.553
Outer ∅4 40.019 to 40.033
Inner ∅3 1.63 to 1.76

Connecting rod small--end bushing –


seat 0.266 to 0.566
Gudgeon pin – Bushing 0.0158 to 0.0362

Measurement dimension X --

Max. error on connecting rod axis


parallelism = --

Journals ∅1 82.99 to 83.01


Crankpins ∅2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares

Bed supports no.:


no. 1--5 ∅3 87.982 to 88.008
no. 2--3--4 87.977 to 88.013
EW--2--12

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0454B
Type
*D601 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
no. 1--5 0.041 to 0.119
no. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings

Shoulder journal X1 37.475 to 37.545

Shoulder bed support X2 25.98 to 26.48

Shoulder half rings X3 37.28 to 37.38

Drive shaft shoulder 0.068 to 0.410


EW--2--13

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0454B
Type
*D601 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm

Valve guide seats on


cylinder head ∅1 8.019 to 8.039

Valves:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°

Valve stem and respective guide 0.052 to 0.092

Seat on head for valve seat:


∅1 46.987 to 47.013

∅1 43.637 to 43.663

Valve seat outer diameter;


inclination of valve seats on cylinder
head:
∅2 47.063 to 47.089
α 60°
∅2 43.713 to 43.739
α 45°
Hollow X 0.356 to 1.102

X 0.104 to 0.840

Between the valve 0.050 to 0.102


seat and the head
0.050 to 0.102

Valve seats --
EW--2--14

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0454B
Type
*D601 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20

Injector protrusion X not adjustable

Seats for distributing shaft bushings


--
no. 1--5
--
Distributing shaft seats no. 2--3--4

Distributing shaft support pins:


1⇒5 ∅ 53.995 to 54.045

Bushing outer diameter for


distributing shaft: ∅ --

Bushing inner diameter ∅ 54.083 to 54.147

Bushings and seats in crankcase --

Bushings and support pins 0.038 to 0.162


Eccentric working lift:
6.045

7.239
EW--2--15

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0454B
Type
*D601 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm

∅1 Seat for tappet


collar
in the crankcase ∅1 16.000 to 16.030

∅2
Outer diameter of tappet collar:
∅3 ∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980

Between the tappets and the seats 0.020 to 0.065

Tappets --

∅1

Rocker arm shaft ∅1 18.963 to 18.975

Rocker arms ∅2 19.000 to 19.026


∅2
Between the rocker arm and the
0.025 to 0.063
shaft
EW--2--16

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

GENERAL ENGINES FEATURES F4BE0484


F4BE0484
Type
E*D601 E*D605 E*D607 D*D608

Cyicle 4--stroke diesel engine


Feeding Boosted by intercooler
Injection Direct

Number of cylinders 4 in--line

Bore mm 102

Stroke mm 120

Total displacement cm3 3922

Compression ratio 17,5 : 1

Max. rating kW 83 88
min --1 2000 2200

Max. torque Nm 450 500


min --1 1400 1400

No--load idle rpm min --1 800 850

No--load peak rpm min --1 2200 2400

BOOSTING With intercooler


Type of turbocompressor: HOLSET HX35W

Forced by means of gear pump, pres-


LUBRIFICATION
sure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1,2
at peak rpm bar 3,8
EW--2--17

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81± 2
Ambra Master gold HSP REFUELLING
15W40
-- engine sump + filter litres 12 5
12.5
10W30

FEEDING
VE4 / 12 F 1100 L
Bosch--type injection

Pump setting 0° ± 0°≥5

Start of delivery mm 1

Type of nozzle DSLA 145 P603

Injection sequence 1 -- 3 -- 4 -- 2

Injection pressure (bar) 245 bar


EW--2--18

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

ASSEMBLING ENGINES PLAY F4BE0484 -- SPECIFICATIONS


F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Cylinder liners ∅1 102.01 to 102.03

Pistons: supplied with standard


spares
Measurement dimension X 61
Outer diameter ∅1 101.757 to 101.775
Pin seat ∅2 40.006 to 40.012
Piston -- cylinder liners 0.215 to 0.253

Piston diameter ∅1 0.4

Position of pistons
0.28 to 0.52
from crankcase X

Gudgeon pin ∅3 39.9938 to 40.0002

Gudgeon pin -- Pin seat 0.0058 to 0.0182

Type of piston X1* 2.69


Piston ring slots X2 2.74
X3 4.040 to 4.060
* measured on ∅ of 99 mm
S1* 2.567 to 2.618
Piston rings S2 2.560 to 2.605
S3 3.975 to 4.000
* measured on ∅ of 99 mm
1 0.082 to 0.133
Piston rings – Slots 2 0.135 to 0.180
3 0.040 to 0.085

Piston rings 0.4


EW--2--19

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55

Connecting rod small--end


bushing seat ∅1 42.987 to 43.013
Connecting rod bearing seat ∅2 72.987 to 7.013

Connecting rod small--end bushing


diameter
Outer ∅4 43.279 to 43.553
Inner ∅3 40.019 to 40.033

Connecting rod small--end bushing


– seat 0.266 to 0.566
Gudgeon pin – Bushing 0.0158 to 0.0362

Measurement dimension X --

Max. error on connecting rod axis


parallelism = --

Journals ∅1 82.99 to 83.01


Crankpins ∅2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares

Bed supports no.:


no. 1--5 ∅3 87.982 to 88.008
no. 2--3--4 87.977 to 88.013
EW--2--20

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
no. 1--5 0.041 to 0.119
no. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings

Shoulder journal X1 37.475 to 37.545

Shoulder bed support X2 25.98 to 26.48

Shoulder half rings X3 37.28 to 37.38

Drive shaft shoulder 0.068 to 0.410


EW--2--21

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
VALVE GEAR – CYLINDER ASSEMBLY mm

Valve guide seats on


cylinder head ∅1 8.019 to 8.039

Valvese:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°

Valve stem and respective guide 0.052 to 0.092

Seat on head for valve seat:


∅1 46.987 to 47.013

∅1 43.637 to 43.663

Valve seat outer diameter;


inclination of valve seats
on cylinder head:
∅2 47,063 ÷ 47,089
α 60°
∅2 43.713 to 43.739
α 45°
Hollow X 0.356 to 1.102

X 0.104 to 0.840

Between the valve 0.050 to 0.102


seat and the head
0.050 to 0.102

Valve seats --
EW--2--22

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20

Injector protrusion X not adjustable

Seats for distributing shaft


bushings no. 1--5 --
Distributing shaft seats no. 2--3--4 --

Distributing shaft support pins:


1⇒5 ∅ 53.995 to 54.045

Bushing outer diameter for


distributing shaft: ∅ --

Bushing inner diameter ∅ 54.083 to 54.147

Bushings and seats in crankcase --

Bushings and support pins Bushings and support pins


Eccentric working lift:
6.045

7.239
EW--2--23

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

F4BE0484
Type
E*D601 E*D605 E*D607 D*D608
VALVE GEAR – CYLINDER ASSEMBLY mm

∅1 Seat for tappet


collar
in the crankcase ∅1 16.000 to 16.030

∅2
Outer diameter of tappet collar:
∅3 ∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980

Between the tappets and the


seats 0.020 to 0.065

Tappets --

∅1

Rocker arm shaft ∅1 18.963 to 18.975

Rocker arms ∅2 19.000 to 19.026


∅2
Between the rocker arm and the
shaft 0.025 to 0.063
EW--2--24

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

TIGHTENING TORQUE

PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
2nd pphase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st phase
p 50 ± 6 (5 ± 0.6)
2nd p
phase 80 ± 6 (8 ± 0.6)
rd
3 phase 90°
Connecting g rod cap
p fastening
g screws 1st p
phase 30 ± 5 (3 ± 0.5)
nd
2 p phase 50 ± 5 (5 ± 0.5)
rd
3 phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)

-- Lubrication with oil


EW--2--25

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

TOOLS
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Joint for pressure control in the cylinders (use with 380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000998 Manual pump for pressure and depression measuring
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Diesel engine cylinder compression control device
380001084 Comparator holder tool for rotary injection pump timing (to be used with 380000228)
380002730 Engine PMS positioning tool
EW--2--26

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

GRAPHIC INDICATIONS AND SYMBOLS

Detachment
Intake
Disconnect

Reattachment
Exhaust
Connect

Removing
Operation
Disassembling

Mounting
Assembling
ρ Compression ratio

Tolerance
Torque--tighten
Weight difference

Torque--tighten + angular value Dragging torque


α

Countersink Rotation

Adjustment Angle
Setting Angular value

Warning
! Preload
Note

Visual check
Revs number
Mounting position check

Measurement
Dimension to be measured Temperature
Check

Equipment bar
Pressure

Increase
Surface to be machined
Greater than .....
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum
Selection
Thickness
Classes
Play
Increases
Lubricate Temperature < 0 °C
Moisten Cold
Grease Winter
Temperature < 0 °C
Sealant Hot
Summer

Air bleed
EW--2--27

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

GENERAL REMARKS

Figure 3

84236

1. Turbocompressor – 2. Fan pulley – 3. Fixed guide pulley – 4. Alternator – 5. Fan, alternator and water
pump drive belt – 6. Automatic belt stretcher – 7. Fixed guide pulley – 8. Fixed guide pulley – 9. Fan
pulley – 10. In--line injection pump – 11. Cold start air heater – 12. Blow--by

Figure 4

Aspiration manifold part for applications without


intercooler: F4BE0454.

88233
EW--2--28

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

DESCRIPTION OF MAIN MECHANIC


ENGINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the fol- It also incorporates the coolant circulation chambers
lowing items are realized: cylinder liners (1); bed and the engine member lubricating circuit ducts.
supports (5) and seats for: distributing shaft bush-
ings (3), tappets, water/oil heat exchanger (7), water Plate (6) is fitted to the lower part of the crankcase
pump (2) and oil pump (4). and ensures greater resistance to forces and stress.

Figure 5

2
7 3

86605
EW--2--29

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Drive shaft
It is made of steel and rests on five induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine fly-
wheel mounting hub.
Inside the drive shaft are the lubricating oil ducts.
The main half bearings are made of steel with anti--
The following items are force--fitted on the front friction alloy coating.
shank: oil pump drive gear, phonic wheel, damper
The second main half bearing is equipped with a
flywheel and auxiliary component drive pulley.
shoulder to restrain the drive shaft end play.
Parts (1) and (2) are mounted in an interfering
manner on the rear shank and cannot be replaced.

Figure 6

84207

1. Valve gear drive gear -- 2. Flywheel attachment hub -- 3. Oil pump drive gear

Drive shaft seal rings


The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000980 and 380000981, and mounted by means of tools 380000983 and 380000984.
EW--2--30

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
The connecting rod half bearings are made of steel, ing the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.

Figure 7

84038
EW--2--31

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Pistons

Figure 8

84039

The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1 and 2, trapezoidal in shape and with ce-
Three slots (piston ring seats) are provided: the first ramic chrome coating.
one and the second one are obtained from a cast-- Ring 3, with double scraper ring shoe with inner
iron insert with trapezoidal section. spring.
The identification number and manufacturing data
(1) are shown on the piston crown.

Figure 9

84040
EW--2--32

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
The supports (front and rear) are equipped with steel B. Exhaust valve control
bushings mounted in an interfering manner and
coated with anti--friction material; two control eccen- The distributing shaft is controlled directly by the
trics are provided for each cylinder. drive shaft by means of straight--tooth gears.

Figure 10

70164

84238
EW--2--33

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Valve control

Figure 11

84239

1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--2--34

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Cylinder head
The seats of the following parts are obtained from Moreover, the following components are inserted on
the cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injector (6); - intake manifold (2) with seat for cold start air
heater (3).
- thermostat (5);

Figure 12

84240

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS


EW--2--35

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Valves and valve seats

Figure 13

S 1

84241

1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side.

The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).

Figure 14

84242

Figure 14 shows the oil seals mounted on valve


stems.
EW--2--36

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Valve guides

Figure 15

INTAKE EXHAUST
84046

DETAIL OF VALVE GUIDES AND SEATS


EW--2--37

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-

Figure 16

84048
EW--2--38

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Auxiliary component drive


A Poly--V belt (4) transmits the motion of drive shaft The belt is stretched by means of automatic belt
(5) to water pump (1), alternator (2) and fan (6). stretcher (3).

Figure 17

84243

1. Water pump -- 2. Alternator -- 3. Belt stretcher -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan pulley
EW--2--39

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Lubrication
Forced circulation lubrication is performed by the fol- - water / oil heat exchanger housed in the crank-
lowing components: case, with oil filter adapter;
- rotor--equipped oil pump housed in the crank- - oil pressure control valve built into the oil filter
case front part, controlled by the straight--tooth adapter;
gear force--fitted on the drive shaft shank; - by--pass valve for clogged oil filter cut--off, built
into the oil filter adapter;
- cartridge--type oil filter.

Figure 18

84244

Oil return drop--type path Oil supply

Pressure oil path


EW--2--40

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Heat exchanger

Figure 19

84051

1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block – 5. Oil return to filter – 6. Oil inflow from filter
EW--2--41

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Oil pump

Figure 20

84052

Figure 21

70150

1. Drive shaft with oil pump drive gear


EW--2--42

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Oil sump
The oil sump (1) is secured elastically to the crank- The C--section rubber gasket (2) (fitted onto the oil
case by means of an aluminium plate (3), Figure 22. sump leading profile) enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.

Figure 22

84245

Figure 23

84246

The sumps mounted on the two engine models are the same as concerns their shape, yet they are rotated by
180° to each other.
EW--2--43

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Oil vapour recirculation


Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.

Figure 24

114063
EW--2--44

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Cooling
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the crank-
circuit circulation type and is made up of the follow- case front part;
ing components:
- heat exchanger, to cool the lubricating oil; - thermostat, to regulate coolant flow.

Figure 25

84247

Water flowing out of the thermostat Water flowing into the pump

Water recirculating in the engine


EW--2--45

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Water pump
The water pump is housed in a seat obtained from The engine temperature is controlled by a thermo-
the crankcase and is controlled by means of a stat.
poly--V belt.
The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.

Figure 26

84058

Figure 27

84059
EW--2--46

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Mechanic injection feeding system


Fuel prefilter

The filter support (1) incorporates manual priming


pump (4), screw (2) used to blow air off the system,
and cartridge (3).
Figure 28

84060

Fuel filter
The support (1) incorporates fuel temperature sen- Degree of filtration of cartridge: 6 micron.
sor (5), heater resistor (2), water drain screw (3), air Maximum working pressure: 5 bar.
bleeding screw (6) and filter (4). Working temperature: – 40 °C to + 90 °C.

Figure 29

84248
EW--2--47

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Mechanic fuel pump


Displacement pump mounted on the engine left
side; it is used to feed the injection pump and is con-
trolled by the distributing shaft.

Figure 30

84249

1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank

Figure 31

84250

1. Pump -- 2. Control lever -- 3. Distributing shaft


EW--2--48

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Injection assembly

Figure 32

84251

1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for
fuel discharge from injectors -- 6. Connector for pipe measuring the pressure inside the L.D.A. intake
manifold -- 7. Thermal bulb for KSB -- 8. Injection pump – 9. Solenoid valve -- 10. Injector
EW--2--49

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

ENGINE BENCH--OVERHAUL Figure 35


Disassembling the engine
Figure 33

84252 84254

Drain the engine oil by taking the cap off the sump - disconnect the engine oil vapour recovery pipe
and the oil filling cap off the head cover. from blow--by (1);
Remove the fan unit from the fan pulley. - take off tappet covers (4);
In order to be able to fit bracket 380000995 (which - disconnect electric wiring (8);
fastens the engine to the overhaul stand) to the - take off fuel filter (9);
crankcase, it is necessary to:
- take off intake manifold (3);
- remove electric wiring (1).
- take off container (2);
- take off container control unit (5);
- disconnect the piping from L.D.A. system (13);
Figure 34
- disconnect quick--coupling pipes (7), (10), (11)
and (13), by following the indications given in
Figure 36;
- take off fuel filter support (6).

Figure 36

84253
In order to be able to fit bracket 380000995 to the
crankcase on the right side, it is necessary to re-
move:
- the starter motor (3);
- the bracket (2) fastening the oil return pipe (1);
- the oil return piping (1) relative to turbine;
- oil pipes (4) and (5) from heat exchanger unit
(6). 70126

Secure the engine to rotary stand 380000978. Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid damaging the same,
- take off turbine lubrication delivery pipe (7);
bring fork (1) back to the locking position (detail B)
after the adapter has been removed.
EW--2--50

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 37 Figure 40

84255

- Remove injector (5) feed pipes (5) from injection 84082

pump (6); remove the rackets fastening the pipe


Take out injectors (2) by means of tool (1) 380000982.
unit (1), (2) and (3) on the cylinder head.
- Remove the priming pump (4).

Figure 38

Figure 41

84256

- Remove the feed pipe unit from injectors (1).


- Remove fuel drain pipe (2) from injectors by re-
moving the screw (4) and the seal (3).

Figure 39

84258

- Remove the belt tightener (4).


- Remove the auxiliary component belt (6) operat-
ing the alternator fastening bracket (1).
87005 - Remove the alternator (2), the water pump (5),
- Remove the screws (3) and then remove the tur- the fan pulley (8) and the guide pulleys (7).
bine (1).
- Remove the pulley support (9).
- Remove the exhaust manifold (2).
- Remove the engine cooling system connection
- Remove water temperature sensor (4). (3) from the cylinder block.
EW--2--51

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 42 Removing the front seal ring


Figure 44

84068

Apply tool 380000990 (1) to the flywheel housing to


78256
stop flywheel rotation.

Apply tool 380000980 (4) on drive shaft front shank


(2).
Drill inner seal ring (1), through tool 380000980 (4)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000980 (4) to ring (1) by screwing the
6 screws (5) provided.
Take off ring (1) by fastening screw (3).

Figure 43 Figure 45

84259 78257

Unscrew fastening screws (1) from pulley (2). Apply the proper tension rod (3) of tool 380000996 to
outer seal ring (2) as shown in the figure, then take the
same off front cover (1) by means of lever (4).
Remove the front cover.
EW--2--52

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 46 Figure 48

84260

84237 To correctly preset the injection pump prior to remov-


ing it, loosen screw (2) and remove L--shaped spacer
(1).
Remove gear oil pump (1).
Fasten again screw (2) to its abutting end.

IMPORTANT -- Oil pump (1) cannot be recondi- IMPORTANT -- Carefully store the L--shaped
tioned. spacer with the pump body.

Removing the injection pump Figure 49


Figure 47

84073

84071

Prior to removing the injection pump, take off the fly- - Remove cover (1) from gear covering case (2).
wheel locking tool described in Figure 42. - Lock the engine flywheel as described in
Rotate the drive shaft until it reaches the condition of Figure 42.
1° cylinder at top dead centre. - Loosen nut (3) securing the injection pump drive
Such condition is obtained when (after removing the gear (4).
closing plug), by pushing pin 380002730 (1) shown
by the arrow, it is housed in its own seat obtained on
distributing shaft drive gear (2).
EW--2--53

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 50 Figure 52

84261
84076
Loosen the three nuts (2) (4) (5) securing the injection Screw two pins (2) of adequate length into drive shaft
pump (1) to the flywheel covering case (3), then take holes (3).
the pump out of its housing by means of tool
380000979 through proper application to gear (4) in Remove tool 380000990 (2, Figure 51).
Figure 49.
Take out engine flywheel (1) so that it can be har-
nessed by means of a hoist and placed into its own
container.

Removing the rear seal ring

Figure 51 Figure 53

84075 78258

Remove screws (3) securing engine flywheel (4) to the Apply tool 380000981 (3) on drive shaft rear shank
drive shaft. (5).
Drill inner seal ring (1), through tool 380000981 (3)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by fastening the
6 screws (4) provided.
Take off ring (1) by fastening screw (2).
EW--2--54

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 54 Figure 57

78257

Apply the proper torsion bar (3) of tool 380000996 to


86601
outer seal ring (2) as shown in the figure, then take the
same off flywheel cover case (1) by means of lever APPLICATION WITH ROSE PIPE IN FRONT
(4). POSITION
Figure 58
Figure 55

84077
86470
Remove screws (2) and take off rear cover (1). APPLICATION WITH ROSE PIPE IN REAR
POSITION
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter. Remove screws (1) and (4) and take off oil suction
strainer (5).
Remove screws (2) and take off stiffening plate (3).
Figure 56 Figure 59

84278 70156
Turn the engine upside down, remove screws (2), Remove screws (1) and take off gear (3) from distrib-
take off both plate (3) and oil sump (1). uting shaft (2).
EW--2--55

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Removing the rocker arm assembly and Figure 63


cylinder head
Figure 60

84085

84081 Remove screws (2) and take off timing gear case (1).
For each cylinder, remove rocker arm assembly (1),
loosen adjusting nuts (3), unscrew registers (2) and
remove screws (4).
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter.
Figure 61

87006 Figure 64
Remove screws (1) securing the head to the crank-
case.

Figure 62

70158

Remove connecting rod cap (2) fastening screws (1),


then take off the caps.
Remove the pistons (complete with connecting rods)
from the crankcase upper part.

87007
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be used
Hook the wire ropes to brackets (1) and (2), then sep-
again, they must be mounted in the same position
arate the cylinder head from the crankcase by means
they had prior to being taken off.
of a hoist.
EW--2--56

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 65 Figure 68

70159

Remove screws (1) and take off bed caps (2). 70162

Take off main half bearings (1).


Figure 66
Remove screws (2) and take off oil nozzles (3).

Figure 69

70160

The penultimate bed cap (1) and its respective sup-


port have half bearing (2) provided with shoulder.
70163

Remove screws (1) and take off distributing shaft (3)


IMPORTANT -- Take note of the mounting position retaining plate (2).
of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in IMPORTANT -- Take note of plate (2) mounting
the same position they had prior to being taken off. position.

Figure 67
Figure 70

70161
70164
Remove drive shaft (2) from crankcase by means of Carefully remove the distributing shaft from the
tool 380000362(1) and a hoist. crankcase.
EW--2--57

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 71 Figure 72

70165 70166

Remove tappets (1) from the engine crankcase. The check of cylinder liner inner diameter (in order to
measure the amount of out--of--roundness, taper and
wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
ring gauge (2) of the cylinder liner diameter.

NOTE – If no ring gauge is available, use a micro-


meter to perform reset.

Repair work on cylinder cluster Figure 73


Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Check the condition of working caps. They must be
replaced if they are rusty or their sealing properties
are in doubt.
Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.

70167

Measurements must be taken for each single cylin-


der, at three different heights of the liner and on two
planes perpendicular to each other: one parallel to the
engine longitudinal axis (A), the other perpendicular
(B); the greatest amount of wear is usually found on
the latter plane and during the first measurement.
When detecting out--of--roundness, taper or wear, the
cylinder liners must be bored and refaced. Cylinder
liner reconditioning must be performed with regard to
the spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play.
EW--2--58

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 74 Checking the surface supporting the head on


the cylinder cluster
Figure 75

70170

Verify that the head supporting plane on the cylinder


cluster does not show deformations.
This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
70168 The flatness error must not be greater than 0.075 mm.

IMPORTANT -- In case of reconditioning, all the


liners must be machined to the same increase (0.5
mm).
NOTE -- Crankcase flattening may be carried out
Check the main bearing seats as follows: only after making sure, when the repair work has
- mount the bed caps on the supports without bear- been completed, that the protrusion of the piston
ings; from the cylinder liner is not greater than the speci-
fied value.
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com- Check the condition of cylinder cluster working caps
parator, that the seat diameter is the same as the (1); they must be replaced if they are rusty or their
specified value. sealing properties are in doubt.
If a greater value is found, replace the crankcase. After flattening, restore the cylinder liner countersink,
as shown in Figure 74.
EW--2--59

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Valve gear
Distributing shaft
Figure 76

70169

MAIN FEATURES OF DISTRIBUTING SHAFT


The features given below refer to the normal diameter of pins

The shaft support pin and eccentric surfaces must be Figure 77


perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.239 mm for ex-
haust eccentrics and 6.045 mm for intake eccentrics;
if different values are found, replace the shaft.

70171

Check the diameter of distributing shaft support pins


(2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
EW--2--60

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Bushings Figure 78
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
dicular to each other.

70172

Figure 79

sec. A-A

70173

MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS


* Dimension to be obtained after driving the bushings
EW--2--61

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Replacing the bushings Mounting the tappets – Distributing shaft


Figure 80 Figure 82

70174 70176

To replace front and rear bushings (1), use beater Lubricate tappets (1) and fit them to their respective
380000991 (2) and handle 380000999 (3) to remove seats of the crankcase.
and reassemble the bushings.

IMPORTANT -- Bushings (1) must, upon mount-


ing, be turned in such a way that the lubricating
holes match with the holes available on the crank-
case seats.

Tappets

Figure 81 Figure 83

84053 70164

MAIN FEATURES OF TAPPETS AND THEIR Lubricate the distributing shaft support bushings and
RESPECTIVE SEATS ON THE CRANKCASE mount distributing shaft taking care not to damage the
bushings or supporting seats during operation.
EW--2--62

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 84 Figure 86

70238 70180

Place distributing shaft (3) retaining plate (1) with Mount nozzles (2) and tighten fastening screws (1) to
the slotted hole facing the crankcase upper side and the specified torque.
the stamping facing the operator, then fasten
screws (2) to the specified torque.
Drive shaft
Measuring the journals and crankpins

Figure 87

Figure 85

70182

If traces of excessive seizing, scoring or out--of--


roundness are found on journals and crankpins, it is
necessary to reface the pins by grinding. Prior to
grinding pins (2), measure the journals by means of
a micrometer (1) so as to determine the amount (di-
ameter) by which the pins have to be reduced.

NOTE -- It is advisable to write down the measured


values on a table.
See Figure 88.

70179

Check the distributing shaft end play (1).


EW--2--63

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Reduction classes are 0.250 and 0.500 mm.


IMPORTANT -- Journals and crankpins must al-
ways be ground to the same reduction class.
The reduction carried out on journals and crank-
pins must be marked with a special stamping
made on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.

Figure 88

70181

DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--2--64

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 89

70183

MAIN TOLERANCES OF DRIVE SHAFT


TOLERANCES
TOLERANCE--RELATED FEATURE GRAPHIC SYMBOL
CONCERNING:
Roundness f
SHAPE
Cylindricality /f/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL


CRITICAL ©
IMPORTANT
SECONDARY

Figure 90

BEARINGS ON TIMING INTERMEDIATE FIRST


SIDE BEARINGS BEARING ON
UPPER SIDE

84275
EW--2--65

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Replacing the oil pump drive gears Measuring the journal assembling play
Figure 91 Figure 93

70184 70161

Verify that the teeth of gear (1) force--fitted on drive Mount the drive shaft (1) on which gears (2) and (3)
shaft (2) are not damaged or worn; otherwise, pro- are force--fitted.
ceed with removal by means of a suitable extractor
(3).
When fitting the new gear, the latter must be heated
for 10 minutes in a small furnace at a temperature
of 180 °C and force--fitted onto the drive shaft by put-
ting the key in between.

Mounting the main bearings


Figure 92 Figure 94

70185 70186

Check the play between the drive shaft journals and


IMPORTANT -- If main bearings do not need re- their respective bearings by following the procedure
placing, they must be fitted in the same order and below:
positions they had when removed. - clean thoroughly the parts and eliminate traces (if
any) of oil;
- place a piece of gauged wire (3) (parallel to the
Main bearings (1) are supplied as spares reduced on longitudinal axis) on drive shaft pins (4);
their inner diameter by 0.250 – 0.500 mm.
- mount caps (1), complete with half bearings (2),
on their respective supports.
IMPORTANT -- No matching operation must be
carried out on bearings.
Clean thoroughly the main half bearings (1) provided
with lubrication holes, then fit them to their seats.
The penultimate main half bearing (1) is provided with
shoulder half rings.
EW--2--66

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 95 Figure 97

70187 70189

Fasten pre--lubricated screws (1) by tightening them - Take the caps off the supports.
in three subsequent phases. The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 ± 6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 ± 6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.

Checking the drive shaft shoulder play


Figure 96 Figure 98

70188 70190

- 3rd phase with tool 380001001 (1) placed as The shoulder play is checked by placing a magnetic
shown in the figure: tighten screws (2) further to comparator (2) on drive shaft (3) as shown in the fig-
an angle of 60° ± 5°. ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
EW--2--67

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Connecting rod--piston assembly

Figure 99

70191

PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY


1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod --
8. Bushing

NOTE -- Pistons are supplied as spares increased by 0.5 mm.

Figure 100 Figure 101

84093 84094

Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000986 (3). moved by means of a mark scraper (3).
EW--2--68

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 102

84095
MAIN DATA ABOUT PISTON IN APPLICATION WITH INTERCOOLER

86471

MAIN DATA ABOUT PISTON IN APPLICATION WITHOUT INTERCOOLER

Measuring the piston diameter

Figure 103 Figure 104

84096 70192

Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.
NOTE -- The diameter must be measured 61 mm far
from the piston skirt base.
EW--2--69

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Gudgeon pins Figure 108


Figure 105

84097 84100

Measuring the gudgeon pin diameter (1) by means Use a thickness gauge (1) to check the play between
of a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching

Figure 106

Figure 109

84098

Lubricate pin (1) and its respective seat on piston


hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.
Piston rings
Figure 107

84101

SCHEME FOR MEASURING PLAY X FOR THE


TRAPEZOIDAL RING
Due to the peculiar shape of the first trapezoidal cross--
sectioned seal ring, the play between the slot and the
ring itself must be measured as follows; allow piston (1)
to protrude from the crankcase so that ring (2) at issue
comes out of about half from cylinder liner (3).
In this position, check, by means of a thickness
84099 gauge, the play (X) between the ring and the slot: it
must correspond to the specified value.
Check the thickness of seal rings (2) by means of a
micrometer (1).
EW--2--70

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 110 Figure 112

CONNECTING ROD BODY

CONNECT-
70194 ING ROD
WEIGHT
NO.

Measuring the play between the ends of piston rings


(2) inserted into cylinder liner (3), by means of a thick-
ness gauge (1).

Connecting rods

Figure 111

CONNECTING ROD CAP

CONNECTING ROD YEAR DAY


NO.

70196

IMPORTANT -- Each connecting rod is marked as


follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted. In case of replace-
86472 ment, it is therefore necessary to number the
MAIN DATA OF CONNECTING ROD, GUDGEON new connecting rod with the same number as
PIN BUSHING AND HALF BEARINGS the replaced one.

* Dimension of inner diameter to be obtained after - By a letter (on the connecting rod body) which
driving into the connecting rod small--end and refacing indicates the weight class of the factory--as-
by means of a reamer. sembled connecting rod:
-- V, 1820 to 1860 (marked in yellow);
** This dimension cannot be measured in a free state. -- W, 1861 to 1900 (marked in green);
-- X, 1901 to 1940 (marked in blue);
Replacement rods are supplied class W and
IMPORTANT -- The connecting rod--connecting marked in green *.
rod cap matching surfaces are knurled to ensure
better match. Material removal is not permitted.
Therefore, it is recommended not to remove
knurls.
EW--2--71

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Bushings Checking the torsion


Figure 114
Verify that the bushing in the connecting rod small--
end is not loosened and does not show traces of scor-
ing or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes al-
lowing oil to flow onto the bushing and the connecting
rod small--end correspond to each other. Use a re-
amer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods
Figure 113

61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ∼ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.

Checking the flexion


Figure 115

61696
Check parallelism of the axles of the connecting rods
(1) with a suitable device (5) as follows:
- mount connecting rod (1) on tool (5) spindle, then
secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).

61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--2--72

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Connecting rod--piston match Mounting the piston rings


Figure 119
Figure 116

84103 84093

The following reference data are engraved on the pis- Use pliers 380000986 (3) to fit piston rings (1) on pis-
ton crown: ton (2).
1. Spare part number and design modification The rings must be mounted with the writing “TOP”
number; facing upwards; moreover, the ring apertures must be
turned in such a way that they are offset to each other
2. Date of manufacture;
by 120°.
3. Inscription (facing the crankcase front side) indi-
cating the mounting sign of the piston in the cylin- IMPORTANT -- Spare piston rings are supplied in
der liner. the following dimensions:
Figure 117 -- standard, marked with yellow paint;
-- increased by 0.5 mm, marked with yellow/green
paint;

Figure 120

84104
Connect piston (2) to connecting rod (4) by means of
pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers (5)
stamped on connecting rod (4) can be seen as shown
in the figure.
Figure 118

70200
Mount half bearings (1) both on the connecting rod
and the cap.

IMPORTANT -- If connecting rod bearings do not


need replacing, they must be fitted in the same
order and positions they had prior to being taken
off.
No matching operation must be carried out on half
72705 bearings.
Insert pin (1) fastening piston rings (2).
EW--2--73

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 123
Figure 121

70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners; of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their re-
spective half bearings (4);
Figure 124

Figure 122

70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a
torque wrench (2).
Figure 125

84040

SCHEME FOR MOUNTING THE CONNECTING


ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
by 120°;
- all the connecting rod/piston assemblies weigh
the same;
- the writing stamped on the piston crown faces the 70205
crankcase front side, or the notch obtained on the - Apply tool 380001001 (1) on the compass
piston skirt corresponds to the position of oil nozz- wrench, then tighten screws (2) further in a criss--
les. cross sequence.
EW--2--74

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 126 Checking piston protrusion


Figure 128

70206 70208
- Take off the cap and calculate the existing play by After the connecting rod--piston assemblies have
comparing the width of gauged wire (1) with the been mounted, check, by means of comparator
scale graduation shown on the wire envelope (2). 380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane.
Said protrusion must be 0.28 to 0.52 mm.
Valve gear
Distribution gearbox case
Figure 127 Figure 129

70207

If the measured play is different from the specified 84105


one, replace half bearings and repeat the check.
SCHEME FOR SEALANT LOCTITE 5205
Once the specified play has been obtained, lubricate APPLICATION AREA
the connecting rod half bearings and mount them defi- Clean thoroughly distribution gearbox case (1) and
nitely by tightening the connecting rod cap fastening the engine crankcase.
screws as described. Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5205 on the case so as to
IMPORTANT -- Prior to mounting the connecting make a bead with a diameter of a few millimetres.
rod cap fastening screws definitely, verify that the The bead must be smooth (no lumps) and free from
diameter of the same (as measured at the middle air bubbles, thin areas or gaps.
of the thread length) is not smaller than 0.1 mm of Any defect must be corrected as soon as practicable.
the diameter measured at about 10 mm from the Avoid using excess material to seal the joint.
screw end. An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
Check manually that connecting rods (1) run axially After completing sealant application, the joints must
on the drive shaft pins, and that the end play of the be mounted immediately (within 10 -- 20 minutes).
same (as measured by means of a thickness gauge
(2) is 0.10 to 0.33 mm.
EW--2--75

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 130 Figure 132

84106 84107
SCHEME FOR REAR GEARBOX CASE FASTEN- Turn drive shaft (4) and distributing shaft (2) in such
ING SCREW TIGHTENING SEQUENCE a direction that when mounting driven gear (1) on the
Reassemble case to the crankcase. distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.
Tighten the fastening screws in the same positions
they had prior to being taken off, then fasten the
screws to the specified torque.

Valve timing
Figure 131 Figure 133

70211 70213

Mark, with a felt--tip pen, the tooth of drive gear (1) Tighten gear (2) fastening screws (1) to distributing
mounted on drive shaft (2), the side surface of which shaft (3), then fasten them to the specified torque.
bears a stamped notch (→) for timing.
EW--2--76

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Injection pump – 1st phase Figure 136


Timing
Figure 134

84108
Force--fit gear (1) transmitting the motion to the pump,
then fasten nut (2) by hand.
84071
Flywheel cover case
Bring cylinder 1 to the top dead centre. This condition
occurs when pin 380002730 (1) (shown by an arrow) Figure 137
is housed in the seat available on the distributing shaft
drive gear (2).

84109

SCHEME FOR SEALANT LOCTITE 5205


APPLICATION AREA
Clean thoroughly the attaching surfaces of flywheel
case (1) and distribution gearbox.
Figure 135
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5205 on the case (1) so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).
84273
Mount the injection pump body (1) in the gearbox seat
(2), then secure it by means of screws (3).
EW--2--77

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 138 Engine flywheel


Figure 140

84110 84111

SCHEME FOR FLYWHEEL COVER CASE Check the clutch disc supporting surface and turn it if
FASTENING SCREW TIGHTENING SEQUENCE scoring is detected.
Fit case (1) back to the crankcase, tighten the fasten-
ing screws in the positions they had prior to being
taken off, then fasten them to the specified torque. NOTE -- The rated thickness of the engine flywheel
is 51 mm.
Screws:
- M12 x 1.75 x 100 80 ± 10 Nm Replacing the engine flywheel ring gear
- M16 x 1.50 x 80 200 ± 20 Nm Check the condition of ring gear (2) teeth. If breaks or
- M16 x 1.50 x 100 200 ± 20 Nm excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, Figure 140) by using a
- M12 x 1.75 x 78 80 ± 10 Nm normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter
must face the engine flywheel.
Mounting the rear seal ring

Figure 139 Figure 141

70216 84076
Apply part (5) of tool 380000984 on drive shaft rear Screw down two pins (2) of adequate length into the
shank (6), secure it by means of screws (4) and force-- shaft holes (3), then remove the engine flywheel (1)
fit the new seal ring (3) on the same. by means of suitable harnesses and a hoist.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--2--78

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 142 Injection pump – 2nd phase


Mounting the injection pump – 2nd phase
Figure 144

84075 84115
Apply tool 380000990 (2) to the flywheel cover case Torque--tighten nut (1) by means of torque wrench (2).
(1) to stop engine flywheel (4) rotation.
Tighten screws (3) fastening engine flywheel (4) to the
Figure 145
drive shaft.

Figure 143

α 84116

Apply sealant (1) as shown in the figure, then put on


small cover (2).

Figure 146

84114

Tighten engine flywheel (2) fastening screws (1) in


two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
- 2nd phase: tighten to an angle of 60° ± 5°. 84260

Remove plug (1) from the distribution gear seat


Figure 47.
IMPORTANT -- Angle tightening is carried out by
means of tool 380001001. Remove presetting screw (2) and insert L--shaped
spacer (1). Fasten again the screw to its abutting end.
EW--2--79

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Mounting the oil and water pumps Figure 150

Figure 147

70223

Take seal ring (2) off front cover (1), clean thoroughly
the attaching surface and apply sealant LOCTITE
5205 onto the same.
70220
Figure 151
Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.

Figure 148

70224

Clean thoroughly the surface of front cover (2) attach-


ing base, then mount front cover (2).
Fasten screws (1) and tighten them to the specified
torque.
70221
Mounting the front seal ring
Apply a new seal ring (2) onto water pump (1).
Figure 152

Figure 149

70225

Apply part (5) of tool 380000983 on drive shaft front


70222
shank (6), secure it by means of screws (4) and force--
Mount water pump (1). fit the new seal ring (3) on the same.
Fasten screws (2) and tighten them to the specified Position part (1) on part (5), then screw nut (2) to fully
torque. mount seal ring (3) in front cover (7).
EW--2--80

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Mounting the oil sump Figure 156


Figure 153

84278
86601
Mount oil sump (1) and apply plate (3) on the same.
APPLICATION WITH ROSE PIPE IN FRONT
POSITION Fasten screws (2) and tighten them to the specified
torque.
Figure 154 Screws:
- M10 x 1.50 x 70 70 ± 5 Nm
- M10 x 1.50 x 45 50 ± 5 Nm
- M10 x 1.50 x 100 70 ± 5 Nm
- M10 x 1.50 x 90 70 ± 5 Nm

NOTE – On engines: F4BE0484E*607 --


F4BE484D*608, the oil sump is to be assembled on
a rotated position of 180° in relation to the one
shown on the figure.

86470

APPLICATION WITH ROSE PIPE IN REAR


POSITION
Mount plate (3) and strainer (5), then screw down
fastening screws (2, 4 and 1) and tighten them to the Figure 157
specified torque.
Figure 155

84280
70227
Force--fit pulley (1) complete with spacer (2) onto the
Place gasket (1) on oil sump (2). drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380001001.
IMPORTANT -- The gasket can be used again,
provided it is not damaged. Secure guide pulleys (4) to the front cover by means
of screws (3).
EW--2--81

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Mounting the water / oil heat exchanger Figure 161


Figure 158

84175 84281
Mount the following items on the crankcase: a new Fit alternator (1) back to alternator support (3).
gasket (1), heat exchanger (2), a new gasket (3), and
Fasten screws (2) without torque--tightening them.
oil filter support (4). Fasten screws (5) and tighten
them to the specified torque.
Figure 159

84176
Lubricate seal ring (1) with engine oil, then position it Cylinder head
on oil pipe coupling (2).
Removing the valves
Fit oil pipe coupling (2) to support (4).
Figure 162
Place a new seal ring (3) in the crankcase housing.

Figure 160

84179

Valves can be removed by means of tool 380000987


(1) by pressing slightly on collar (3) so that lock cones
84177
(2) can be removed by compressing springs (4). Then
Position alternator support (1) in such a way that pins
remove collar (3) and springs (4).
(3 and 4) are placed against the engine crankcase.
Fasten screws (2) and tighten them to the specified Repeat the procedure on all valves.
torque.
EW--2--82

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 163 Figure 165

84282 87008

Take off oil seals (1) fitted to the valve stems. Remove the thermostat unit (2) and brackets (1) and
(4).
To remove the valves, properly turn the head upside
down. Remove the cover (3) of the intake manifold.

IMPORTANT -- Mark the exhaust and intake


valves prior to removing them.

Checking the cylinder head supporting surface

Figure 164 Figure 166

INTAKE EXHAUST
84181 84183

In addition to the head dimensions, the exhaust The plane of the supporting surface of head (1) to cyl-
valves differ from intake valves in that they are inder cluster is checked by means of a ruler (2) and
equipped with a supplementary notch (1) obtained on a thickness gauge (3).
the stem for intake valves. The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
If greater values are found, reface the cylinder head
according to the values and instructions given in the
next figure.
EW--2--83

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Checking the cylinder head water seal Valves


Check the water seal by means of suitable equipment. Figure 168
Use a pump to feed water heated to ∼ 90 °C at a pres- EXHAUST INTAKE
sure of 2 to 3 bar. VALVE VALVE
If leaks are detected from the caps, the latter must be
replaced by using a suitable beater for disassembling/
assembling operations.

IMPORTANT -- Prior to mounting the caps, apply


water--repellent sealant on the sealing surface of
the same.

If leaks are detected from the cylinder head, the latter


must be replaced. 84185

MAIN DATA OF INTAKE AND EXHAUST VALVES

Valve descaling, check and grinding


Figure 167
Figure 169

84284

Nominal thickness A of the cylinder head is 95 ± 0.25


84186
mm, max. admitted metal removal shall not exceed
thickness B, i.e. 0.13 mm. Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
IMPORTANT -- After regrinding, check valve sink- crimping or burns.
ing and regrind valve seats if required, to obtain
the required value. Adjust, if required, the valve seats with the proper
grinder, removing the least amount of material pos-
sible.
EW--2--84

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 170 Valve guide


Figure 172

84187

Use a micrometer (2) to measure valve stem (1),


which must be equal to 7.96 to 7.98. INTAKE EXHAUST
84046

Use a bore gauge to measure the valve guide inner


diameter, which must be equal to the value shown in
the figure.

Checking the play between the valve stem, Valve seats


valve guide and valve centring
Valve seat reconditioning -- replacement
Figure 171 Figure 173

84188 84189

Check can be made by means of a magnetic com- Check valve seats (2). Check by reading the scorings
parator (1) placed as shown. Assembling play must and burns, use the tool (1) over it again according to
be equal to 0.039 to 0.079 mm. the tilting values indicated on the Figure 174.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
EW--2--85

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 174

EXHAUST INTAKE

87009

VALVE SEAT DIMENSIONS

Figure 175

EXHAUST INTAKE

87010

VALVE SEAT HOUSING DIMENSIONS

If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same proper tool (1, Figure 173) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of the proper tool, according to the values shown in Figure 174.
EW--2--86

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 176 MOUNTING THE CYLINDER HEAD


Figure 178

87008

84192
Apply sealant LOCTITE 5205 between cover (3) and
cylinder head, then tighten the screws to the specified
After the reconditioning operations, verify, by means torque.
of base 380001000 (2) and comparator 380001004 Mounting the thermostat unit (2) and brackets (1) and
(1), that valve hollow (3) corresponds to the specified (4), then tighten the screws to the specified torque.
value.
Figure 179

Valve springs

Figure 177

84282
Lubricate the valve stem and insert into the respective
valve guide according to the position marked upon
disassembling.
Mount seal rings (1) onto the valve guide.

84193
Figure 180
MAIN DATA FOR INTAKE AND EXHAUST VALVE
SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of the proper tool. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below.

Height Under a load of


mm N
84179
H(Free) 63.50 No load
Position spring (4) and upper collar (3) on the cylinder
H1 49.02 P1 329 head: use tool 380000987 (1) to compress spring (4)
H2 38.20 P2 641 and link the parts to the valve by means of lock cones
(2).
EW--2--87

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Reattaching the cylinder head Figure 183


Figure 181

84113 84209

Verify that the cylinder head attaching plane and the Prior to inserting the pushrods, verify their state of
crankcase attaching plane are both clean. preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must
Do not spoil the cylinder head gasket. not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in-
take and exhaust valves are identical and, therefore,
IMPORTANT -- Prior to reusing the cylinder head they are interchangeable.
fastening screws, verify that they do not show Rocker arm assembly
traces of wear or deformations; otherwise, replace
them. Figure 184

84195

PARTS MAKING UP THE ROCKER ARM


ASSEMBLY:
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws
Figure 182 Figure 185

87006 84196

Mount the cylinder head on the crankcase by fastening MAIN DATA OF ARBOUR--ROCKER ARM
screws (1) without torque--tightening them. Verify that the arbour/rocker arm matching sur-
faces do not show excessive wear or damages.
EW--2--88

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 186 Figure 189

84197

Verify that the tappet adjusters are unscrewed to pre- 87037


vent the latter from crawling on the rods when the Ad just the play between the rocker arms and the
rocker arm assembly (1) is mounted. valves by means of an Allen wrench (2), box wrench
Mount the rocker arm assembly made up of the ar- (3) and thickness gauge (1).
bours and rocker arm support, then secure them to
the head without torque--tightening screws (2) and The operation play is:
(3). -- intake valves: 0.25 ± 0.05 mm
Figure 187 -- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
FIRING ORDER 1--3--4--2
Adjusting cylinder
1 3 4 2
valve no.
Adjusting clearance
4 2 1 3
of cylinder valve no.

Mounting the injectors


Figure 190
87036

Fasten the head screws according to the instructions


given in Figure 188.
Figure 188

84285
Scheme of cylinder head fastening screw tightening
sequence:
- 1st phase: pre--fastening by means of a torque
wrench: 84201

screw M12 x 1.75 x 70 [ ]50 Nm ± 5 Nm;


screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm; Mount a new seal ring (2) lubricated with petrolatum
screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm; and a new seal washer (3) on injector (1).
- 2nd phase: angle tightening: 90° Mount the injectors on their seats on the cylinder
- 3rd phase: angle tightening only for screws 140 head, then tighten them by means of a torque wrench.
and 180 mm long: 90°.
EW--2--89

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Intake manifold unit Figure 193


Figure 191

87012
- Mount exhaust manifold (2).
- Mount turbine (1) by means of screws (3).
- Mount water temperature sensor (4).

86604
The intake manifold unit is made up of manifold (6) on
the cylinder head, cover (5), seal gaskets (2) and (4),
cold--start heater (3) and elbow (1).
Apply sealant LOCTITE 5205 between cover (5) and
manifold (6), then tighten the screws to the specified
torque.

Figure 192 Figure 194

87011

84255

Mount the injector feeding pipe assembly (1). Mount Mount the injection pump (6) injector feeding pipes
the pipes for fuel discharge (2) from injectors, by using (5), then secure brackets (1), (2) and (3) fastening the
gaskets (3) and by tightening screws (4). pipe assembly onto the cylinder head.
Mount priming pump (4).
EW--2--90

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 195 Figure 197

84253
87038
- Mount tappet covers (1).
- Mount the starter motor (3).
- Mount container control unit (2).
- Mount turbine lubricating oil return piping (1) with
- Mount fuel filter support (3). its respective fastening bracket (2).
- Mount fuel filter (7). - Mount turbine lubricating oil delivery pipe (7) and
- Attach quick coupling pipes (4), (8) and (10) by fol- engine oil pipes (4) and (5) to water / oil heat ex-
lowing the indications given in Figure 196. changer unit (6).
- Mount electric wiring (5) and (6).
- Mount L.D.A. system piping (9).
- Connect the engine oil vapour recovery pipe to
blow--by (11).

Figure 196 Figure 198

87013

- Mount fan pulley support (3) on head (1) by


torque--tightening screws (2).

70126

Press clip (1) in the direction of the arrow (detail B),


then connect the piping. Bring the clip back to the in-
itial locking position (detail A).
EW--2--91

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Figure 199 REPLACING THE INJECTORS


Removal
Figure 201

84288

Mount fan pulley (2) on support (1) by torque--tighten-


ing screws (3).
84289

Place the vehicle in safe conditions.


Lift the engine compartment cover, disconnect the
battery cables and proceed as follows:
- disconnect engine oil vapour recovery pipe (2)
from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors
(3).

Figure 200 Figure 202

84258
84082
Mount Poli--V belt (5) on pulley (7), drive shaft pulley,
guide pulleys (6), water pump (4) and on alternator
(2); then, stretch the belt by acting on automatic belt Remove injectors (2) by means of tool 380000982 (1)
stretcher (3). and take them off the cylinder head.
EW--2--92

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Reassembling Rocker arm removal/reassembling


Figure 203 Removal
Figure 205

84081
Loosen tappet adjuster fastening nuts (3), then un-
screw adjusters (2).
84201
Remove screws (4) and dismount rocker arm assem-
bly (1) made up of the rocker arm support and ar-
Mount a new seal ring (2) lubricated with petrolatum bours, then take off valves.
and a new seal washer (3) on injector (1). Reassembling
Mount the injectors on their seats on the cylinder Verify that the tappet adjusters are unscrewed to pre-
head, then tighten them by means of a torque wrench. vent the latter from crawling on the rods when the
rocker arm assembly is mounted.
Mount the rocker arm assemblies made up of rocker
arm support and arbours, then secure them to the cyl-
inder head by tightening the fastening screws to a
torque of 36 Nm.
Ad just the tappets as described above.
Figure 204

84290

Mount new seal rings (1) on fuel manifolds (2).


Connect the manifolds to the injectors, by tightening
the fastening nuts to a torque of 50 Nm.
Reassemble the tappet cover.
Re--connect the engine oil vapour recovery pipe to the
blow--by.
EW--2--93

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Adjusting the tappets


Figure 206

84200

Ad just the play between the rocker arms and the FIRING ORDER 1--3--4--2
valves by means of an Allen wrench (2), box wrench
(3) and thickness gauge (1).
Adjusting cylinder
1 3 4 2
The operation play is: valve no.
Adjusting clearance
-- ± 0.05 mm of cylinder valve no.
4 2 1 3
– intake valves: 0.25 ± 0.05 mm
-- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.

Valve timing
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.
Figure 207

84210
EW--2--94

ENGINES F4BE0454 -- F4BE0484 OVERHAUL

Check priming of the injection pump Turn the engine shaft counter clockwise of a few de-
grees and then turn again in the opposite direction un-
til the P.M.S. is determined.
Figure 208
In this position, on the comparator (2) you will read the
pumping element pre--lift value prescribed.
Turn the pump counter clockwise if the stroke is lower,
or clockwise if the stroke is higher until the stroke pre-
scribed is achieved.
Then lock the pump with the fixing nuts to the couple
prescribed.

88141

Turn the engine shaft unit the piston of the 1st cylinder
near the P.M.S. and close the relevant valves (com-
pression stage).
Assemble tool 380000977 (1) and with the compara-
tor (2) in the seat of the injector of the 1str cylinder,
preload the comparator (2).

Figure 209

87720

- With the injection pump inserted in the relevant


seat and the fixing screws loosened, assemble
the comparator 380001004 (2) and its holder
380001084 (1), preloading the rod of 2.5 mm.
Turn the engine shaft properly in order to determine
the exact PMS of the piston of the 1st cylinder and of
the injection pump pumping element, zero the
comparators (2, Figure 208 and 2, Figure 209).
SECTION 3 F4BE0684

ENGINES F4BE0684B -- F4BE0684M


OVERHAUL

INDEX
Engine F4BE0684 . . . . . . . . . . . . . . . . . . EW--3--3 Injection assembly with mechanical
Engine coding . . . . . . . . . . . . . . . . . . . . . EW--3--4 on line pump engine F4BE0684B . . . . . . EW--3--39
Main engine features . . . . . . . . . . . . . . . EW--3--5 Injection assembly with rotary pump
engines F4BE0684M . . . . . . . . . . . . . . . . EW--3--39
Torque and rating features . . . . . . . . . . EW--3--6
Engine bench--overhaul . . . . . . . . . . . . EW--3--40
Main engine features . . . . . . . . . . . . . . . EW--3--7
Disassembling the engine . . . . . . . . . . . . EW--3--40
Assembling play -- specifications . . . EW--3--9
Tightening torque . . . . . . . . . . . . . . . . . . EW--3--15 Removing the front seal ring . . . . . . . . . . EW--3--42
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--16 Removing the injection pump . . . . . . . . . EW--3--43
Graphic indications and symbols . . . EW--3--17 Removint the rear seal ring . . . . . . . . . . . EW--3--45
General remarks . . . . . . . . . . . . . . . . . . . EW--3--18 Removing the rocker arm assembly
and cylinder head . . . . . . . . . . . . . . . . . . . EW--3--46
Description of main mechanic
engine components . . . . . . . . . . . . . . . . EW--3--19 Repair work on cylinder cluster . . . . . EW--3--48
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--19 Checks and measurements . . . . . . . . . . . EW--3--48
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--20 Checking the surface supporting
the head on the cylinder cluster . . . . . . . EW--3--49
Drive shaft seal rings . . . . . . . . . . . . . . . . EW--3--20
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--50
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--21
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--3--50
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--22
Checking the eccentric lift and the
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--3--23
pin alignment . . . . . . . . . . . . . . . . . . . . . . . EW--3--50
Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--3--24
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--51
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . EW--3--25
Replacing the bushings . . . . . . . . . . . . . . EW--3--52
Valves and valve seats . . . . . . . . . . . . . . . EW--3--26
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--52
Valve guides . . . . . . . . . . . . . . . . . . . . . . . . EW--3--27
Mounting the tappets – Distributing shaft EW--3--52
Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--3--28
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--53
Auxiliary component drive . . . . . . . . . . . . EW--3--29
Measuring the journals and crankpins . . EW--3--53
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--30
Replacing the oil pump drive gears . . . . EW--3--56
Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--3--31
Mounting the main bearings . . . . . . . . . . EW--3--56
Oil pressure regulation valve . . . . . . . . . . EW--3--31
Measuring the journal assembling play . EW--3--56
By--pass valve . . . . . . . . . . . . . . . . . . . . . . EW--3--31
Checking the drive shaft shoulder play . EW--3--57
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--32
Connecting rod--piston assembly . . . EW--3--58
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--33
Measuring the piston diameter . . . . . . . . EW--3--59
Oil vapour recirculation . . . . . . . . . . . . . . . EW--3--34
Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . EW--3--60
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--35
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--3--36 Conditions for correct pin/piston
matching . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--60
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--36
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--60
Mechanic injection feeding system . . . . EW--3--37
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--61
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . EW--3--37
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--62
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--37
Checking the connecting rods . . . . . . . . . EW--3--62
Engine F4BE0684B mechanical
feed pump . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--38 Checking the torsion . . . . . . . . . . . . . . . . . EW--3--62
Engine F4BE0684M mechanical Checking the flexion . . . . . . . . . . . . . . . . . EW--3--62
feed pump . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--38 Connecting rod--piston match . . . . . . . . . EW--3--63
Characteristics . . . . . . . . . . . . . . . . . . . . . . EW--3--38 Mounting the piston rings . . . . . . . . . . . . . EW--3--63
INDEX

Mounting the connecting rod/piston Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--74


assemblies in the cylinder liners . . . . . . . EW--3--64 Valve descaling, check and grinding . . . EW--3--75
Measuring the crankpin assembling play EW--3--64 Checking the play between the
Checking piston protrusion . . . . . . . . . . . EW--3--65 valve stem, valve guide and valve
centring . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--75
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--66
Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--75
Distribution gearbox case . . . . . . . . . . . . EW--3--66
Valve seat reconditioning -- replacement EW--3--75
Valve timing . . . . . . . . . . . . . . . . . . . . . . . . EW--3--66
Valve springs . . . . . . . . . . . . . . . . . . . . . . . EW--3--77
Injection pump – 1st phase . . . . . . . . . EW--3--67
Mounting the cylinder head . . . . . . . . . EW--3--77
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--67
Mounting the injection pump – 1st phase EW--3--67 Reattaching the cylinder head . . . . . . . . . EW--3--78
Flywheel cover case . . . . . . . . . . . . . . . . EW--3--68 Rocker arm assembly . . . . . . . . . . . . . . . . EW--3--78
Mounting the rear seal ring . . . . . . . . . EW--3--68 Mounting the injectors . . . . . . . . . . . . . . . EW--3--80
Intake manifold unit . . . . . . . . . . . . . . . . . . EW--3--80
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--3--69
Replacing the injectors . . . . . . . . . . . . . EW--3--83
Replacing the engine flywheel ring gear EW--3--69
Injection pump – 2nd phase . . . . . . . . . EW--3--70 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--83
Mounting the injection pump – 2nd phase EW--3--70 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--3--83
Mounting the oil and water pumps . . EW--3--70 Adjusting the tappets . . . . . . . . . . . . . . EW--3--85
Mounting the front seal ring . . . . . . . . EW--3--71 Rocker arm removal/reassembling . . EW--3--85
Mounting the oil sump . . . . . . . . . . . . . EW--3--71 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--85
Mounting the water/oil heat exchanger EW--3--72 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--3--85
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--3--73 Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--3--85
Removing the valves . . . . . . . . . . . . . . . . EW--3--73 Check priming of the injection pump
Checking the cylinder head supporting (F4BE0684M engine only) . . . . . . . . . . . . EW--3--86
surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--74 Check priming of the injection pump
Checking the cylinder head water seal . EW--3--74 (F4BE0684B engine only) . . . . . . . . . . . . EW--3--86
EW--3--3

ENGINES F4BE0684 OVERHAUL

ENGINE F4BE0684

Figure 1

84034
EW--3--4

ENGINES F4BE0684 OVERHAUL

ENGINE CODING

F 4 B E 0 6 8 4 B * D +

Emission level

Approved rating

Use

Feeding / Injection
D = TIER 2
Cylinder no.

Cylinder pattern
0 = 4 strokes, vertical

Engine

Type of crankcase:
B = non--structural 6 = 6--cylinder

Engine
group

8 = Direct injection turbo


diesel with intercooler

4 = Earthmovers

X Y Y Y Y Y Y Y Y

X = 4 in--line, 2--valve injection pump Manufacturing sequence number


Y = Engine model
EW--3--5

ENGINES F4BE0684 OVERHAUL

MAIN ENGINE FEATURES

A E215 -- E245 * MH Plus C • E215 -- E245 ** MH Plus C ••

B F4BE0684B F4BE0684M

C *D402 *D401 *D600 *D602

E 5883 cm3

118 kW
F 2150 min--1
* up to frame Nr. 2831 -- ** from frame Nr. 2832
• up to frame Nr. 0978 -- •• from frame Nr. 0979

G Direct injection

H In--line injection pump

T.A.A.
I (Boosted by intercooler)

A Excavator initials
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--3--6

ENGINES F4BE0684 OVERHAUL

TORQUE AND RATING FEATURES

Figure 2

Torque - Nm
Rating - kW

Torque Rating

84277
EW--3--7

ENGINES F4BE0684 OVERHAUL

MAIN ENGINE FEATURES


F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602

Cycle 4--stroke diesel engine


Feeding Boosted by intercooler
Injection Direct

Number of cylinders 6 in--line

Bore mm 102

Stroke mm 120

Total displacement cm3 5883

Compression ratio 17.5 : 1

Max. rating kW 118


min --1 2150

Max. torque Nm 620


min --1 1400

No--load idle rpm min --1 700

No--load peak rpm min --1 2350

BOOSTING With intercooler


Type of turbocompressor: HOLSET HX35W/0

Forced by means of gear pump,


LUBRICATION
pressure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
EW--3--8

ENGINES F4BE0684 OVERHAUL

F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
start of opening: °C 81 ± 2
Ambra Master gold HSP REFUELLING
15W40
-- engine sump + filter litres 16.9
10W30

FEEDING VE6/12F
PES 6A
Bosch--type injection 1075 1046

Pump setting 0° ± 0°.5

Start of delivery mm 1

Type of nozzle DSLA 145 P603

Injection sequence 1 -- 5 -- 3 --6 --2 -- 4

Injection pressure bar 245 bar


EW--3--9

ENGINES F4BE0684 OVERHAUL

ASSEMBLING PLAY -- SPECIFICATIONS


F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Cylinder liners ∅1 102.01 to 102.03

Pistons: supplied with standard


spares
Measurement dimension X 61
Outer diameter ∅1 101.757 to 101.775
Pin seat ∅2 40.006 to 40.012
Piston -- cylinder liners 0.235 to 0.273

Piston diameter ∅1 0.5

Position of pistons --
from crankcase X
--

Gudgeon pin ∅3 39.9938 to 40.0002

Gudgeon pin--Pin seat 0.0058 to 0.0182

Type of piston X1* 2.70


Piston ring slots X2* 2.74
X3 4.04 to 4.06
* measured on ∅ of 99 mm
S1*
2.567 to 2.618
Piston rings S2*
2.560 to 2.605
S3
3.075 to 4.000
* measured 1.5 mm away from the
external ∅
1 0.082 to 0.133
Piston rings– Slots 2 0.135 to 0.180
3 0.040 to 0.985

Piston rings 0.5


EW--3--10

ENGINES F4BE0684 OVERHAUL

F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cylinder
liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55

Connecting rod small--end


bushing seat ∅1 42.987 to 43.013
Connecting rod bearing seat ∅2 72.987 to 73.013

Connecting rod small--end bushing


diameter
Outer ∅4 43.279 to 43.553
Inner ∅3 40.019 to 40.033

Connecting rod small--end bushing –


0.266 to 0.566
seat
Gudgeon pin – Bushing 0.0158 to 0.0362

Measurement dimension X --

Max. error on connecting rod axis


parallelism = --

Journals ∅1 82.99 to 83.01


Crankpins ∅2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares

Bed supports no.:


n. 1--7 ∅3 87.982 to 88.008
n. 2--3--4--5--6 87.977 to 88.013
EW--3--11

ENGINES F4BE0684 OVERHAUL

F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
n. 1--7 0.044 to 0.106
n. 2--3--4--5--6 0.039 to 0.111
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings

Shoulder journal X1 37.475 to 37.545

Shoulder bed support X2 25.98 to 26.48

Shoulder half rings X3 37.28 to 37.38

Drive shaft shoulder 0.095 to 0.265


EW--3--12

ENGINES F4BE0684 OVERHAUL

F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm

Valve guide seats on


cylinder head ∅1 8.019 to 8.039

Valves:
∅4 7.96 to 7.98
α 60°
∅4 7.96 to 7.98
α 45°

Valve stem and respective guide 0.039 to 0.079

Seat on head for valve seat:


∅1 46.987 to 47.013

∅1 43.637 to 43.663

Valve seat outer diameter; inclination


of valve seats on cylinder head:

∅2 47.063 to 47.089
α 60°
∅2 43.713 to 43.739
α 45°
Hollow X 1.00 to 1.52

X 1.00 to 1.52

Between the valve 0.050 to 0.102


seat and the head
0.050 to 0.102

Valve seats --
EW--3--13

ENGINES F4BE0684 OVERHAUL

F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20

Injector protrusion X not adjustable

Seats for distributing shaft bushings


no. n. 7
59.222 to 59.248
Distributing shaft seats no.
54.089 to 54.139
1--2--3--4--5--6

Distributing shaft support pins:

1⇒7 ∅ 53.995 to 54.045

External diameter of the bushing


for the camshaft with a load
of 3.3 kN ∅ 59.222 to 59.248

Bushing inner diameter ∅ 54.083 to 54.147

Bushing and seat in crankcase 0.113 to 0.165

Bushing and support pin 0.038 to 0.162


Eccentric working lift:
6.045

7.239
EW--3--14

ENGINES F4BE0684 OVERHAUL

F4BE0684B F4BE0684M
Type
*D401 *D402 *D600 *D602
VALVE GEAR – CYLINDER ASSEMBLY mm

∅1 Seat for tappet


collar
in the crankcase ∅1 16.000 to 16.030

∅2
Outer diameter of
tappet collar:
∅3
∅2 15.929 to 15.959
∅2 ∅3 15.965 to 15.980

Between the tappets and the seats 0.020 to 0.065

Tappets --

∅1

Rocker arm shaft ∅1 18.963 to 18.975

Rocker arms ∅2 19.000 to 19.026


∅2
Between the rocker arm and the
0.025 to 0.063
shaft
EW--3--15

ENGINES F4BE0684 OVERHAUL

TIGHTENING TORQUE

PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
nd
2 p phase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st pphase 50 ± 6 (5 ± 0.6)
2nd pphase 80 ± 6 (8 ± 0.6)
rd
3 phase 90° ± 5°
Connecting g rod cap g 1st p
p fastening phase 30 ± 5 (3 ± 0.5)
nd
2 p phase 50 ± 5 (5 ± 0.5)
rd
3 phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Sump oil drain plug 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90° ± 5°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)

-- Lubrication with oil


EW--3--16

ENGINES F4BE0684 OVERHAUL

TOOLS
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Joint for pressure control in the cylinders (use with 380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000997 Comparator holding tool for in line injection pump timing, engine F4BE0684B (use with
380001005)
380000998 Manual pump for pressure and depression measuring
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Diesel engine cylinder compression control device
380001084 Comparator holding tool for rotary injection pump timing, engine F4BE0684M (use with
380001005)
380002730 Engine PMS positioning tool
EW--3--17

ENGINES F4BE0684 OVERHAUL

GRAPHIC INDICATIONS AND SYMBOLS

Detachment
Intake
Disconnect

Reattachment
Exhaust
Connect

Removing
Operation
Disassembling

Mounting
Assembling
ρ Compression ratio

Tolerance
Torque--tighten
Weight difference

Torque--tighten + angular value Dragging torque


α

Countersink Rotation

Adjustment Angle
Setting Angular value

Warning
! Preload
Note

Visual check
Revs number
Mounting position check

Measurement
Dimension to be measured Temperature
Check

Equipment bar
Pressure

Increase
Surface to be machined
Greater than .....
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum
Selection
Thickness
Classes
Play
Increases
Lubricate Temperature < 0 °C
Moisten Cold
Grease Winter
Temperature < 0 °C
Sealant Hot
Summer

Air bleed
EW--3--18

ENGINES F4BE0684 OVERHAUL

GENERAL REMARKS

Figure 3

84035

1. Turbocompressor – 2. Fan pulley – 3. Fixed guide pulley – 4. Alternator – 5. Fan, alternator and water
pump Poly--V drive belt – 6. Automatic belt stretcher – 7. Fixed guide pulley – 8. Damper flywheel –
9. Fixed guide pulley – 10. Diesel oil filters – 11. In--line injection pump (F4BE0684B engine) –
12. Blow--by -- 13. Cold start air heater
EW--3--19

ENGINES F4BE0684 OVERHAUL

DESCRIPTION OF MAIN MECHANIC EN-


GINE COMPONENTS
Crankcase
The block is a cast iron structure in which the cylinder It also incorporates the coolant circulation chambers
linings (1) bench supports (5) and the seat for: the and the engine member lubricating circuit ducts.
timing shaft bushing (3) and the tappets, for the wa-
ter/oil heat exchanger (7), for the water pump (2) and Plate (6) is fitted to the lower part of the crankcase
for the oil pump (4) are made. and ensures greater resistance to forces and stress.

Figure 4

2
7 3

86605
EW--3--20

ENGINES F4BE0684 OVERHAUL

Drive shaft
It is made of steel and rests on seven induction--har- The following items are force--fitted on the rear
dened supports. shank: distributing shaft drive gear and engine fly-
Inside the drive shaft are the lubricating oil ducts. wheel mounting hub.
The main half bearings are made of steel with anti--
The following items are force--fitted on the front friction alloy coating.
shank: oil pump drive gear, phonic wheel, damper
flywheel and auxiliary component drive pulley. The penultimate main half bearings are equipped
with a shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering
manner on the rear shank and cannot be replaced.

Figure 5

84037

1. Oil pump drive gear -- 2. Drive shaft -- 3. Valve gear drive gear --
4. Flywheel attachment hub

Drive shaft seal rings


The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000980 and 380000981, and mounted by means of tools 380000983 and 380000984.
EW--3--21

ENGINES F4BE0684 OVERHAUL

Connecting rods
They are steel--stamped, of the oblique cut type, Each connecting rod is marked:
with separation of the cap obtained by an advanced - By a number (on the connecting rod body and
technology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
The connecting rod half bearings are made of steel, ing the weight class of the factory--assembled
with anti--friction alloy coating. connecting rod.

Figure 6

84038
EW--3--22

ENGINES F4BE0684 OVERHAUL

Pistons

Figure 7

84039

The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1° and 2°, trapezoidal in shape and with
Three slots (piston ring seats) are provided: the first ceramic chrome coating.
one and the second one are obtained from a cast-- Piston ring 3°, with double scraper ring shoe with
iron insert with trapezoidal section. inner spring.
The identification number and manufacturing data
(1) are shown on the piston crown.

Figure 8

84040
EW--3--23

ENGINES F4BE0684 OVERHAUL

Distributing shaft
The distributing shaft rests on seven supports in the A. Intake valve control
crankcase.
B. Exhaust valve control
The rear support has a steel bushing lined with anti--
friction material, assembled with interference: there The distributing shaft is controlled directly by the
are 2 control eccentrics for each cylinder. drive shaft by means of straight--tooth gears.

Figure 9

70164

84041
EW--3--24

ENGINES F4BE0684 OVERHAUL

Valve control

Figure 10

84042

1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--3--25

ENGINES F4BE0684 OVERHAUL

Cylinder head
The seats of the following parts are obtained on the Moreover, the following components are inserted on
cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injectors (6); - intake manifold (2) with seat for cold start air
- thermostat (5); heater (3).
Figure 11

84043

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS


EW--3--26

ENGINES F4BE0684 OVERHAUL

Valves and valve seats


Figure 12

84044

1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side

The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).

Figure 13

84045

Figure 13, shows the oil seals mounted on valve


stems.
EW--3--27

ENGINES F4BE0684 OVERHAUL

Valve guides

Figure 14

INTAKE EXHAUST

84046

DETAIL OF VALVE GUIDES AND SEATS


EW--3--28

ENGINES F4BE0684 OVERHAUL

Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-

Figure 15

84047

ENGINES: F4BE0684B*402 -- F4BE0684M*D600

Figure 16

84048

ENGINES: F4BE0684B*401 -- F4BE0684M*D602


EW--3--29

ENGINES F4BE0684 OVERHAUL

Auxiliary component drive


A Poly--V belt (4) transmits the motion of drive shaft
(5) to water pump (1), alternator (2) and fan (6).
The belt is stretched by means of automatic belt
stretcher (3).

Figure 17

84049

1. Water pump -- 2. Alternator -- 3. Automatic belt stretcher -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan
pulley
EW--3--30

ENGINES F4BE0684 OVERHAUL

Lubrication
Forced circulation lubrication is performed by the fol- - water / oil heat exchanger housed in the engine
lowing components: crankcase, with oil filter adapter;
- rotor--equipped oil pump housed in the crank- - oil pressure control valve built into the oil filter
case front part, controlled by the straight--tooth adapter;
gear force--fitted on the drive shaft shank; - by--pass valve for clogged oil filter cut--off, built
into the oil filter adapter;
- cartridge--type oil filter.

Figure 18

84050

Oil return drop--type path

Pressure oil path


EW--3--31

ENGINES F4BE0684 OVERHAUL

Heat exchanger
Figure 19

84051

1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block – 5. Oil return to filter – 6. Oil inflow from filter

Oil pressure regulation valve By--pass valve


Figure 20 Figure 21

107419 70482

PRINCIPAL DATA FOR OIL PRESSURE Blow--by max:


REGULATION VALVE SPRING CHECKING 20 cm3/l’ with 0.83 bar pressure and 26.7 _C oil
Pressure regulating calibration at 100_C oil temper- temperature.
ature
-- minimum speed 1.2 bar;
-- maximum speed 3.8 bar.
EW--3--32

ENGINES F4BE0684 OVERHAUL

Oil pump

Figure 22

84052

Figure 23

70150

1. Drive shaft with oil pump drive gear


EW--3--33

ENGINES F4BE0684 OVERHAUL

Oil sump
The oil sump (1) is secured elastically to the crank- The C--section rubber gasket (2), fitted onto the oil
case by means of an aluminium plate (3), Figure 25. sump leading profile, enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.

Figure 24

84054

Figure 25

84055

The sumps mounted on the two engine models are the same as concerns their shape, yet they are rotated by
180° to each other.
EW--3--34

ENGINES F4BE0684 OVERHAUL

Oil vapour recirculation


Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.

Figure 26

114063
EW--3--35

ENGINES F4BE0684 OVERHAUL

Cooling
The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the engine
circuit circulation type and is made up of the following crankcase front part;
components:
- heat exchanger, used to cool the lubricating oil; - thermostat, used to regulate coolant flow.

Figure 27

84057

Water flowing out Water flowing in

Water recirculating
EW--3--36

ENGINES F4BE0684 OVERHAUL

Water pump Thermostat


The water pump is housed in a seat obtained from the
crankcase and is controlled by means of a poly--V Figure 30
belt.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
The engine temperature is controlled by a thermostat.
The coolant flows also in the oil heat exchanger.

Figure 28

79458

A = stroke start at 79.0 ÷ 83.0 _C;


B = stroke at 96 _C ≥ 7.5 mm.

84058

Figure 29

84059
EW--3--37

ENGINES F4BE0684 OVERHAUL

Mechanic injection feeding system


Fuel prefilter

The filter support (1) incorporates: manual priming


pump (4), screw (2) used to blow air off the system,
and cartridge (3).
Figure 31

84060

Fuel filters
The support (2) incorporates: fuel temperature sen- Maximum working pressure: 5 bar.
sor (1), heater resistors (4), air bleeding screws (3) Working temperature: --25 °C to + 90 °C.
and filter (5).
Degree of filtration of cartridge: 10 micron.
Figure 32

84061
EW--3--38

ENGINES F4BE0684 OVERHAUL

Engine F4BE0684B mechanical feed


pump
Displacement pump mounted on the injection
pump left side; it is used to feed the injection
pump.

Figure 33

84062

1. Injection pump -- 2. Fuel outflow to the filter -- 3. Fuel pump -- 4. Fuel inflow from the tank --
5. Manual control lever

Engine F4BE0684M mechanical feed pump Characteristics

Volumetric pump, assembled on the left side of the Priming at 60 rpm : max 28 cycles
engine, supplies the injection pump. It is controlled Unitary displacement 60 rpm: ∼10 cm3
by the camshaft. Static pressure at 1800 rpm: 0,47÷0.61 bar
Minimum capacity at 600 rpm: 111.3 L/h
Minimum capacity at rpm: 127.3 L/h

Figure 34

84250

1. Pump -- 2. Control lever -- 3. Distributing shaft


EW--3--39

ENGINES F4BE0684 OVERHAUL

Injection assembly with mechanical on line pump engine F4BE0684B


Figure 35

84063

1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Injector 5
fuel pipe -- 6. Injector 6 fuel pipe -- 7. Pipe for fuel discharge from injectors -- 8. Connector for pipe
measuring the pressure inside the L.D.A. intake manifold -- 9. Injection pump -- 10. Injector

Injection assembly with rotary pump engines F4BE0684M


Figure 36

86495

1. Injector fuel pipe 1 -- 2. Injector fuel pipe 2 -- 3. Injector fuel pipe 3 --


4. Injector fuel pipe 4 -- 5. Fuel discharge pipe from injectors -- 6. Injector fuel pipe 5 --
7. Injector fuel pipe 6 -- 8. Injection pump -- 9. Injector
EW--3--40

ENGINES F4BE0684 OVERHAUL

ENGINE BENCH--OVERHAUL
Disassembling the engine
- Disconnect electric wiring; - for engine F4BE0684B
- drain the engine oil by taking the cap off the sump disconnect injector feed pipes (7) from injection
and the oil filling cap off the head cover; pump (9); remove the brackets fastening pipe (2),
(5) and (15) unit on the cylinder head;
- fit bracket 380000995 (which fastens the engine
to the overhaul stand) to the crankcase; - for engine F4BE0684B
take off injection pump (10) lubrication pipes;
- disconnect the engine oil vapour recovery pipe
from blow--by (4); - disconnect quick--coupling pipes (8) and (14) by
following the indications given in Figure 39;
- take off tappet covers (6);
- take off fuel filters (12);
- take off intake manifold unit (1);
- for engine F4BE0684B - take off fuel filter support (13).
disconnect the piping from L.D.A. system (3); - take off oil level check piping (11).

Figure 37

84064

NOTE – The figure represents engine F4BE0684B.


EW--3--41

ENGINES F4BE0684 OVERHAUL

Figure 38 Figure 40

88142 84065

For engine F4BE0684M In order to be able to fit bracket 380000995 to the en-
- Disconnect the pipes (1) of the LDA from the gine crankcase on the right side, it is necessary to re-
head and from the supply pump; move:
put the plugs on the pipe ends, on the supply - the starter motor (3);
pump and on the engine block. - the bracket (2) fastening the oil return pipe (1);
- Disassemble the pipes (2) that constitute the - the oil return piping (1) relative to turbine;
supply and recover fuel between the pump and
the injectors. - oil pipes (4) and (5) from heat exchanger unit (6).
- take off turbine lubrication delivery pipe (7);
Secure the engine to rotary stand 380000978.

Figure 39 Figure 41

84066

70126

- Take off the feed pipe assembly from injectors (1).


Act on fork (1) as shown in the figure (detail A), then - Take off the pipe (2) for discharging fuel from the
remove the adapter. To avoid deformations, bring injectors by removing screw (4) and gasket (3).
fork (1) back to the locking position (detail B) after the
adapter has been removed.
EW--3--42

ENGINES F4BE0684 OVERHAUL

Figure 42 - Remove Poly--V belt (10).


- Remove alternator fastening bracket (3).
- Remove alternator (5), water pump (7), fan pulley
(2) and guide pulleys (4), (9) and (13).
- Remove the support from pulley (1).
- Remove engine cooling system adapter (6) from
the crankcase.
- Remove damper flywheel (12) with underlying
pulley (11).

Figure 45
87039

- Remove screws (2) and take off turbine (1).


- Remove the exhaust manifold (3).

Figure 43

84070

Take off water / oil heat exchanger unit (2) with oil
pipe adapter (1).

Removing the front seal ring


Figure 46
84068

Apply tool 380000990 (1) to the flywheel cover case


to stop flywheel rotation.

Figure 44

78256

Apply tool 380000980 (4) on drive shaft front shank


(2). Drill inner seal ring (1), through tool 380000980
(4) guide holes, with an inset (∅ 3.5 mm) down to a
depth of 5 mm. Secure tool 380000980 (4) to ring (1)
by screwing the six screws (5) provided. Take off ring
(1) by fastening screw (3).
84069

- Remove fan (14).


- Remove automatic belt stretcher (8).
EW--3--43

ENGINES F4BE0684 OVERHAUL

Figure 47 Figure 49

78257
Apply the proper tension rod (3) of tool 380000996 to 84071
outer seal ring (2) as shown in the figure, then take the Such condition is obtained when (after removing the
same off front cover (1) by means of lever (4). closing plug), by pushing pin 380002730 (1) shown by
Remove the front cover. the arrow, it is housed in its own seat obtained on dis-
tributing shaft drive gear (2).
Figure 50
Figure 48

84072
Only F4BE0684B engines
To correctly preset the injection pump prior to remov-
84237 ing it, loosen screw (2), take out the timing pin (1),
Remove screws (1) and take off gear oil pump. turn it upside down and insert it again until the pump
shaft is locked.
Fasten again screw (2).
Figure 51
IMPORTANT -- Oil pump (1) cannot be recondi-
tioned.

Removing the injection pump


Prior to removing the injection pump, take off the fly-
wheel locking tool described in Figure 43.
Rotate the drive shaft until it reaches the condition of
1° cylinder at top dead centre.
If required, for engine shaft rotation apply tool
380000988 in the starting engine seat.

84073

Remove cover (1) from gear covering case (2).


Lock the engine flywheel as described in Figure 43.
Loosen nut (3) securing the injection pump drive
gear (4).
Apply extractor 380000979 in the threaded holes of
the gears (4).
EW--3--44

ENGINES F4BE0684 OVERHAUL

Figure 52 Figure 54

84072

Only F4BE0684B engines 88149


Loosen the four symmetrically arranged nuts (two of
which – (2) and (4) – within sight) which secure injec- Remove the fixing nuts (1) and disassemble the in-
tion pump (1) to flywheel cover case (3). jection pump as shown on the figure.
With tool 380000979 positioned as described in the
Figure 51, take out the gear (4, Figure 51) from the Figure 55
shaft of the injection pump and disassemble the
pump from its seat.

Only F4BE0684M engines


Instead if the pump needs to be disassembled and re-
assembled afterwards without repairs, you must pre-
set it while it is still assembled on the engine, as de-
scribed in chapter “Injection pump priming check” on
page EW--3--86 and only after disassemble it as fol-
lows.

84075
Figure 53 Apply tool 380000990 (2) to unlock screws (3).
Remove tool 380000990 (2).
Remove screws (3) fastening engine flywheel (4) to
the drive shaft.

Figure 56

2 1

88148

- Loosen the side screw (1) that locks rotation of


the pump shaft partially and insert spacer (2). It
must be kept aside (we suggest to fix it on the
pump with a strap or a metal wire). 84076
- Loosen the side screw (1) blocking the rotation of Screw two pins (2) of adequate length into drive shaft
the pump shaft. holes (3).
Take out engine flywheel (1) so that it can be har-
nessed by means of a hoist and placed into its own
container.
EW--3--45

ENGINES F4BE0684 OVERHAUL

Removing the rear seal ring Figure 59

Figure 57

84077

Remove screws (2) and take off rear cover (1).

78258
IMPORTANT -- Take note of the mounting position
Apply tool 380000981 (3) on drive shaft rear shank of screws (2), due to the different size of the latter.
(5).
Drill inner seal ring (1), through tool 380000981 (3) Figure 60
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by screwing the
six screws (4) provided.
Take off ring (1) by fastening screw (2).

84078

Turn the engine upside down, remove screws (2),


take off both plate (3) and oil sump (1).
Figure 61

Figure 58

86517

Engines: F4BE0684B*402 -- F4BE0684M*D600


78257
Apply the proper tension rod (3) of tool 380000996 to Remove screws (1) and (4) and dismantle oil suction
outer seal ring (2) as shown in the figure, then take the strainer (5).
same off flywheel cover case (1) by means of lever Remove screws (2) and dismantle stiffening plate (3).
(4).
EW--3--46

ENGINES F4BE0684 OVERHAUL

Figure 62 Figure 65

84081
86516
For each cylinder, remove rocker arm assembly (1),
Engines: F4BE0684B*401 -- F4BE0684M*D602 loosen adjusting nuts (3), unscrew registers (2) and
Remove screws (1) and (4) and dismantle oil suction remove screws (4).
strainer (5).
Remove screws (2) and dismantle stiffening plate (3).

Figure 63 Figure 66

70156 87040
Remove screws (1) and take gear (3) off distributing Remove screws (1) securing the head to the crank-
shaft (2). case.
Removing the rocker arm assembly and cylin-
der head Figure 67
Figure 64

87041

84082
Hook the wire ropes to brackets (1) and (2), then sep-
arate the cylinder head from the crankcase by means
Take out injectors (2) by means of tool (1) 380000982. of a hoist.
EW--3--47

ENGINES F4BE0684 OVERHAUL

Figure 68 Figure 71

84085 70160

Remove screws (2) and take off timing gear case (1). The penultimate bed cap (1) and its respective sup-
port have half bearing (2) provided with shoulder.

IMPORTANT -- Take note of the mounting position IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter. of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in the
Figure 69 same position they had prior to being taken off.

Figure 72

70158
Remove connecting rod cap (2) fastening screws
(1), then take off the caps.
Remove the pistons (complete with connecting 84086
rods) from the crankcase upper part.
Remove drive shaft (2) from crankcase by means of
tool 380000992 (1) and a hoist.
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be
used again, they must be mounted in the same
position they had prior to being taken off. Figure 73
Figure 70

70162
70159
Remove screws (1) and take off bed caps (2). Take off main half bearings (1).
Remove screws (2) and take off oil nozzles (3).
EW--3--48

ENGINES F4BE0684 OVERHAUL

Figure 74 Repair work on cylinder cluster


Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Check the condition of working caps. They must be
replaced if they are rusty or their sealing properties
are in doubt.
Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.

70163

Remove screws (1) and take off distributing shaft (3)


retaining plate (2). Figure 77

IMPORTANT -- Take note of plate (2) mounting


position.

Figure 75

84087

The check of cylinder liner inner diameter (in order to


measure the amount of out--of--roundness, taper and
70164 wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
Carefully remove distributing shaft (1) from the engine ring gauge (2) of the cylinder liner diameter.
crankcase.
Figure 76 NOTE -- If no ring gauge is available, use a micro-
meter to perform reset.

70165

Remove tappets (1) from the engine crankcase.


EW--3--49

ENGINES F4BE0684 OVERHAUL

Figure 78 Check the main bearing seats as follows:


- mount the bed caps on the supports without bear-
ings;
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com-
parator, that the seat diameter is the same as the
specified value.
If a greater value is found, replace the crankcase.

70167

Measurements must be taken for each single cylinder,


at three different heights of the liner and on two planes
perpendicular to each other: one parallel to the engine
longitudinal axis (A), the other perpendicular (B); the
greatest amount of wear is usually found on the latter
plane and during the first measurement. When detect- Checking the surface supporting the head on
ing out--of--roundness, taper or wear, the cylinder the cylinder cluster
liners must be bored and refaced. Cylinder liner re- Figure 80
conditioning must be performed with regard to the
spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play.

Figure 79

84088

Verify that the head supporting plane on the cylinder


cluster does not show deformations.
This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
The flatness error must not be greater than 0.075 mm.

NOTE -- Crankcase flattening may be carried out


only after making sure, when the repair work has
been completed, that the protrusion of the piston
from the cylinder liner is not greater than the speci-
fied value.
70168
Check the condition of cylinder cluster working caps
(1); they must be replaced if they are rusty or their
sealing properties are in doubt.
IMPORTANT -- In case of reconditioning, all the
liners must be machined to the same increase (0.5 After flattening, restore the cylinder liner countersink,
as shown in Figure 79.
mm).
EW--3--50

ENGINES F4BE0684 OVERHAUL

Valve gear
Distributing shaft
Figure 81

84089

MAIN FEATURES OF DISTRIBUTING SHAFT


The features described given below refer to the normal diameter of pins.

The shaft support pin and eccentric surfaces must be Figure 82


perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.239 mm (for ex-
haust eccentrics) and 6.045 mm (for intake eccen-
trics). If different values are found, replace the shaft.

70171

Check the diameter of distributing shaft support pins


(2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
EW--3--51

ENGINES F4BE0684 OVERHAUL

Bushings Figure 83
The distributing shaft bushing (2) must be force--fitted
into the respective seat.
The inner surface must show no traces of seizing or
wear.
With the borer (3) measure the diameter of the rear
bushing (2) and the seat (1) of the camshaft.
Measurements must be taken on two axes perpen-
dicular to each other.

70172

Figure 84

sec. A-A

107268

MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS


* Dimension to be obtained after driving the bushings
EW--3--52

ENGINES F4BE0684 OVERHAUL

Replacing the bushings Figure 88


Figure 85

70174 70164
To disassemble and reassemble the rear bushing Rubricate the camshaft support bushing and as-
(1) when it needs to be replaces use beater semble the camshaft avoiding to damage the bushing
380000991 (2) with the handgrip 380000999 (3). and the seats of the support while operating.

IMPORTANT – Assembly of bushing (1) must be


positioned so that the holes for lubrication coincide
with the ones on the seat of the block.

Tappets
Figure 86

84053
MAIN FEATURES OF TAPPETS AND THEIR RE-
SPECTIVE SEATS ON THE CRANKCASE Figure 89
Mounting the tappets – Distributing shaft
Figure 87

70238

Place distributing shaft (3) retaining plate (1) with


70176 the slotted hole facing the crankcase upper side and
Lubricate tappets (1) and fit them to their respective the stamping facing the operator, then fasten
seats of the crankcase. screws (2) to the specified torque.
EW--3--53

ENGINES F4BE0684 OVERHAUL

Figure 90 Drive shaft


Measuring the journals and crankpins

Figure 92

70179

Check the distributing shaft end play (1).

70182

Figure 91 If traces of excessive seizing, scoring or out--of--


roundness are found on journals and crankpins, it is
necessary to reface the pins by grinding. Prior to
grinding pins (2), measure the journals by means of
a micrometer (1) so as to determine the amount (di-
ameter) by which the pins have to be reduced.

NOTE -- It is advisable to write down the measured


values on a table.
See Figure 93.

Reduction classes are 0.250 and 0.500 mm.

70180
IMPORTANT -- Journals and crankpins must al-
Mount nozzles (2) and tighten fastening screws (1) to ways be ground to the same reduction class.
the specified torque. The reduction carried out on journals and crank-
pins must be marked with a special stamping made
on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.
EW--3--54

ENGINES F4BE0684 OVERHAUL

Figure 93

84090

DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--3--55

ENGINES F4BE0684 OVERHAUL

Figure 94

84091

MAIN TOLERANCES OF DRIVE SHAFT


TOLERANCES GRAPHIC SYMBOL
TOLERANCE--RELATED FEATURE
CONCERNING:
Roundness f
SHAPE
Cylindricality /f/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL


CRITICAL ©
IMPORTANT
SECONDARY

Figure 95

BEARINGS ON TIMING INTERMEDIATE FIRST


SIDE BEARINGS BEARING ON
UPPER SIDE

84275
EW--3--56

ENGINES F4BE0684 OVERHAUL

Replacing the oil pump drive gears Measuring the journal assembling play
Figure 96 Figure 98

70184 84092
Verify that the teeth of gear (1) are not damaged or Mount drive shaft (1).
worn; otherwise, proceed with removal by means of Check the play between the drive shaft journals and
a suitable extractor (3) foce--fitted on drive shaft (2). their respective bearings by following the procedure
When fitting the new gear, the latter must be heated below:
for 10 minutes in a small furnace at a temperature of
180 °C and force--fitted onto the drive shaft by putting
the key in between.

Mounting the main bearings


Figure 97

Figure 99

70185

IMPORTANT -- If main bearings do not need re-


placing, they must be fitted in the same order and
positions they had prior to being taken off.

Main bearings (1) are supplied as spares reduced on


their inner diameter by 0.250 – 0.500 mm. 70186

Check the play between the drive shaft journals and


their respective bearings by following the procedure
IMPORTANT -- No matching operation must be
below:
carried out on bearings.
- clean thoroughly the parts and eliminate traces (if
Clean thoroughly the main half bearings (1) provided any) of oil;
with lubrication holes, then fit them to their seats. - place a piece of gauged wire (3) (parallel to the
The penultimate main half bearing (1) is provided with longitudinal axis) on drive shaft pins (4);
shoulder half rings. - mount caps (1), complete with half bearings (2),
on their respective supports.
EW--3--57

ENGINES F4BE0684 OVERHAUL

Figure 100 Figure 102

70187 70189

Fasten pre--lubricated screws (1) by tightening them - take the caps off the supports.
in three subsequent phases. The play between the main bearings and their re-
- 1st phase with a torque wrench at 50 ± 6 Nm. spective pins can be measured by comparing the
- 2nd phase with a torque wrench at 80 ± 6 Nm. width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.

Checking the drive shaft shoulder play


Figure 103

Figure 101

70190

The shoulder play is checked by placing a magnetic


comparator (2) on drive shaft (3) as shown in the fig-
ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
70188 again the play between the drive shaft pins and the
- 3rd phase with tool 380001001 (1) placed as main half bearings.
shown in the figure: tighten screws (2) further to
an angle of 60° ± 5°.
EW--3--58

ENGINES F4BE0684 OVERHAUL

Connecting rod--piston assembly

Figure 104

70191

PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY


1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod --
8. Bushing

NOTE -- Pistons are supplied as spares increased


by 0.5 mm.

Figure 105 Figure 106

84093 84094

Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000221 (3). moved by means of a mark scraper (3).
EW--3--59

ENGINES F4BE0684 OVERHAUL

Figure 107

84095

MAIN DATA OF PISTON

Measuring the piston diameter

Figure 108 Figure 109

84096 70192

Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.

NOTE -- The diameter must be measured 61 mm far


from the piston skirt base.
EW--3--60

ENGINES F4BE0684 OVERHAUL

Gudgeon pins Figure 113


Figure 110

84097 84100

Measuring the gudgeon pin diameter (1) by means of Use a thickness gauge (1) to check the play between
a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching
Figure 111

Figure 114
84098

Lubricate pin (1) and its respective seat on piston


hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.

Piston rings
Figure 112

84101

SCHEME FOR MEASURING PLAY X FOR THE


TRAPEZOIDAL RING
Due to the peculiar shape of the two trapezoidal
cross--sectioned seal ring, the play between the slot
and the ring itself must be measured as follows; allow
piston (1) to protrude from the crankcase so that ring
(2) at issue comes out of about half from cylinder liner
(3).
84099 In this position, check, by means of a thickness
Check the thickness of seal rings (2) by means of a gauge, the play (X) between the ring and the slot: it
micrometer (1). must correspond to the specified value.
EW--3--61

ENGINES F4BE0684 OVERHAUL

Figure 115 Figure 117

CONNECTING ROD BODY

70194
CONNECT- WEIGHT

Measuring the play between the ends of piston rings


ING ROD
NO.

(2) inserted into cylinder liner (3), by means of a thick-


ness gauge (1).

Connecting rods
Figure 116

CONNECTING ROD CAP

CONNECTING ROD YEAR DAY


NO.

70196

IMPORTANT -- Each connecting rod is marked as


follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted.
86472 In case of replacement, it is therefore necess-
ary to number the new connecting rod with the
MAIN DATA OF CONNECTING ROD, GUDGEON
same number as the replaced one.
PIN BUSHING AND HALF BEARINGS
- By a letter (on the connecting rod body) which
* Dimension of inner diameter to be obtained after
indicates the weight class of the factory--as-
driving into the connecting rod small--end and refacing
sembled connecting rod:
by means of a reamer.
-- V, 1820 to 1860 (marked in yellow);
** This dimension cannot be measured in a free state. -- W, 1861 to 1900 (marked in green);
-- X, 1901 to 1940 (marked in blue);
Replacement rods are supplied class W and
IMPORTANT -- The connecting rod--connecting marked in green *.
rod cap matching surfaces are knurled to ensure Material removal is not permitted.
better match.
Therefore, it is recommended not to remove
knurls.
EW--3--62

ENGINES F4BE0684 OVERHAUL

Bushings Checking the torsion


Verify that the bushing in the connecting rod small-- Figure 119
end is not loosened and does not show traces of scor-
ing or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes al-
lowing oil to flow onto the bushing and the connecting
rod small--end correspond to each other. Use a re-
amer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods

Figure 118

61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ~ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.

Checking the flexion


Figure 120

61696

Check the parallelism of connecting rod axes (1) by


means of the proper device (5). Proceed as follows:
- mount connecting rod (1) on tool (5) spindle, then
secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).

61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--3--63

ENGINES F4BE0684 OVERHAUL

Connecting rod--piston match Figure 123

Figure 121

72705

Insert pin (1) fastening piston rings (2).


84103

The following reference data are engraved on the pis-


ton crown:
1. Spare part number and design modification
number;
2. Date of manufacture;
3. Inscription (facing the crankcase front side) indi-
cating the mounting sign of the piston in the cylin-
der liner.
Mounting the piston rings
Figure 124

Figure 122

84093

Use pliers 380000986 (3) to fit piston rings (1) on pis-


ton (2).
The rings must be mounted with the writing “TOP”
facing upwards; moreover, the ring apertures must be
turned in such a way that they are offset to each other
by 120°.

IMPORTANT -- Spare piston rings are supplied in


84104 the following dimensions:
Connect piston (2) to connecting rod (4) by means of
-- standard, marked with yellow paint;
pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers (5) -- increased by 0.5 mm, marked with yellow/green
stamped on connecting rod (4) can be seen as shown paint;
in the figure.
EW--3--64

ENGINES F4BE0684 OVERHAUL

Figure 125 Figure 127

70200 84040

Mount half bearings (1) both on the connecting rod SCHEME FOR MOUNTING THE CONNECTING
and the cap. ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
IMPORTANT -- If connecting rod bearings do not by 120°;
need replacing, they must be fitted in the same - all the connecting rod/piston assemblies weigh
order and positions they had prior to being taken the same;
off. - the writing stamped on the piston crown faces the
No matching operation must be carried out on half crankcase front side, or the notch obtained on the
bearings. piston skirt corresponds to the position of oil nozz-
les.

Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 128
Figure 126

70201 70203

Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners; of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their re-
spective half bearings (4).
EW--3--65

ENGINES F4BE0684 OVERHAUL

Figure 129 Figure 132

70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a 70207
torque wrench (2); If the measured play is different from the specified
one, replace half bearings and repeat the check.
Once the specified play has been obtained, lubricate
the connecting rod half bearings and mount them defi-
nitely by tightening the connecting rod cap fastening
Figure 130 screws as described.
IMPORTANT -- Prior to mounting the connecting
α rod cap fastening screws definitely, verify that the
diameter of the same (as measured at the middle
of the thread length) is not smaller than 0.1 mm of
the diameter measured at about 10 mm from the
screw end.

Check manually that connecting rods (1) run axially


on the drive shaft pins, and that the end play of the
same (as measured by means of a thickness gauge
(2)) is 0.10 to 0.33 mm.

70205

- Apply tool 380001001 (1) on the compass


wrench, then tighten screws (2) further in a criss--
cross sequence.
Checking piston protrusion
Figure 131 Figure 133

70206 70208

- take off the cap and calculate the existing play by After the connecting rod--piston assemblies have
comparing the width of gauged wire (1) with the been mounted, check, by means of comparator
scale graduation shown on the wire envelope (2). 380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane. Said protrusion
must be 0.28 to 0.52 mm.
EW--3--66

ENGINES F4BE0684 OVERHAUL

Valve gear Valve timing


Distribution gearbox case Figure 136
Figure 134

70211

Mark, with a felt--tip pen, the tooth of drive gear (1)


mounted on drive shaft (2), the side surface of which
bears a stamped notch (→) for timing.
84105

SCHEME FOR SEALANT LOCTITE 5205


APPLICATION AREA Figure 137
Clean thoroughly distribution gearbox case (1) and
the engine crankcase.
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5205 on the case so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes). 84107

Turn drive shaft (4) and distributing shaft (2) in such


a direction that when mounting driven gear (1) on the
Figure 135 distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.

Figure 138

84106

SCHEME FOR REAR GEARBOX CASE FASTEN-


70213
ING SCREW TIGHTENING SEQUENCE
Reassemble case to the crankcase. Tighten gear (2) fastening screws (1) to distributing
Tighten the fastening screws in the same positions shaft (3), then fasten them to the specified torque.
they had prior to being taken off, then fasten the
screws to the specified torque.
EW--3--67

ENGINES F4BE0684 OVERHAUL

Injection pump – 1st phase Figure 141


Timing
Figure 139

2 1

88148

84071 Only F4BE0684M engines


Bring cylinder 1 to the top dead centre. This condition Assemble the new seal ring, the preset pump in the
occurs when pin 380002730 (1) (shown by an arrow) seat on the engine and insert the shaft in the gear hole
is housed in the seat available on distributing shaft (without the key).
drive gear (2). Screw on the fixing nut and lock the flange of the
pump at the middle of the slot.
If required, turn the engine shaft by applying tool
380000988 in the starting motor seat.

Mounting the injection pump – 1st phase


Figure 140

Figure 142

84112

Only F4BE0684B engines


Mount the injection pump body (1) in the gearbox case 84108
seat (4), then secure it by means of the four symmetri-
cally arranged screws (two of which – (2) and (3) –
within sight). Force--fit gear (1) transmitting the motion to the
pump, then fasten nut (2) by hand.

Only F4BE0684M engines (see Figure 141)


Unscrew the screw (1) that locks rotation of the pump
shaft partially and insert spacer (2). Tighten the screw
locking the above--mentioned spacer: in this way the
shaft of the supply pump can rotate.
EW--3--68

ENGINES F4BE0684 OVERHAUL

Flywheel cover case Figure 144


Figure 143

84110

SCHEME FOR FLYWHEEL COVER CASE


84109
FASTENING SCREW TIGHTENING SEQUENCE
Fit case (1) back to the crankcase, tighten the fasten-
ing screws in the positions they had prior to being
SCHEME FOR SEALANT LOCTITE 5205 taken off, then fasten them to the specified torque:
APPLICATION AREA
- M12 x 1.75 x 100 80 ± 10 Nm
Clean thoroughly the attaching surfaces of flywheel
case (1) and distribution gearbox case. - M16 x 1.50 x 80 200 ± 20 Nm
Cleaning the surface to be sealed is necessary and - M12 x 1.75 x 78 80 ± 10 Nm
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5205 on the case (1) so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
Mounting the rear seal ring
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes). Figure 145

70216

Apply part (5) of tool 380000983 on drive shaft rear


shank (6), secure it by means of screws (4) and
force--fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--3--69

ENGINES F4BE0684 OVERHAUL

Engine flywheel Figure 148


Figure 146

84111 84075

Replacing the engine flywheel ring gear Apply tool 380000990 (2) to the flywheel cover case
(1) to stop engine flywheel (3) rotation.
Check the condition of ring gear (2) teeth. If breaks or
excessive tooth wear is found, remove the ring gear Tighten screws (4) fastening engine flywheel (3) to
from the engine flywheel (1, Figure 146) by using a the drive shaft.
normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter
must face the engine flywheel.

Figure 149

Figure 147

84114

Tighten engine flywheel (2) fastening screws (1) in


two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
- 2nd phase: angle--tighten to 60° ± 5°.
84076

Screw down two pins (2) of adequate length into the


IMPORTANT -- Angle tightening is carried out by
shaft holes (3), then remove the engine flywheel (1)
means of tool 380001001.
by means of suitable harnesses and a hoist.
EW--3--70

ENGINES F4BE0684 OVERHAUL

Injection pump – 2nd phase Mounting the oil and water pumps
Mounting the injection pump – 2nd phase Figure 153
Figure 150

84115 70220

Torque--tighten nut (1) by means of torque wrench (2). Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.
Figure 151
Figure 154

84116
Apply sealant (1) as shown in the figure, then put on
small cover (2), then tighten screws to the specified 70221
torque.
Apply a new seal ring (2) onto water pump (1).
Figure 152

Figure 155

84072

Only F4BE0684B engines


Unscrew cover (2), take out timing pin (1), turn it up-
side down, insert it again in such a way that the pump
shaft is not locked, then screw cover (2) again.
70222

IMPORTANT -- Always check the direction of in- Mount water pump (1). Fasten screws (2) and tighten
sertion of the timing pin. them to the specified torque.
EW--3--71

ENGINES F4BE0684 OVERHAUL

Figure 156 Mounting the front seal ring


Figure 158

70223
70225
Take seal ring (2) off front cover (1), clean thoroughly Apply part (5) of tool 380000983 on drive shaft front
the attaching surface and apply sealant LOCTITE shank (6), secure it by means of screws (4) and force--
5205 onto the same. fit the new seal ring (3) onto the same. Position part
(1) on part (5), then screw nut (2) to fully mount seal
ring (3) in front cover (7).
Mounting the oil sump

Figure 159

Figure 157
86517

Engines: F4BE0684B*D402 -- F4BE0684M*D600


Figure 160

70224
86516
Clean thoroughly the surface of front cover (2) attach- Engines: F4BE0684B*D401 -- F4BE0684M*D602
ing base, then mount front cover.
Mount plate (3) and strainer (5), then screw down
Fasten screws (1) and tighten them to the specified fastening screws (2) and (4) and tighten them to the
torque. specified torque.
EW--3--72

ENGINES F4BE0684 OVERHAUL

Figure 161 Figure 163

84117 84174

Place gasket (1) on oil sump (2). Force--fit pulley (3) with damper flywheel (4) onto the
drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380001001.
IMPORTANT -- The gasket can be used again,
provided it is not damaged. Secure guide pulleys (1) and (5) to the front cover by
means of screws (2) and (6) and tighten them to the
specified torque.

Figure 162

Mounting the water / oil heat exchanger


Figure 164

84118

Mount oil sump (1) and apply plate (3) on the same.
Fasten screws (2) and tighten them to the specified
torque.
Screws:
- M10 x 1.50 x 90 70 ± 5 Nm
- M10 x 1.50 x 45 50 ± 5 Nm
- M10 x 1.50 x 190 70 ± 5 Nm
- M10 x 1.50 x 125 70 ± 5 Nm
84175

NOTE – On engines:, F4BE0684B*D402 -- Mount the following items on the crankcase: a new
F4BE0684M*D600 the oil sump is to be assembled gasket (1), heat exchanger (2), a new gasket (3), and
on a rotated position of 180° in relation to the one oil filter support (4). Fasten screws (5) and tighten
shown on the figure. them to the specified torque.
EW--3--73

ENGINES F4BE0684 OVERHAUL

Figure 165 Cylinder head


Removing the valves

Figure 168

84176

Lubricate seal ring (1) with engine oil, then position it


on oil pipe coupling (2).
Fit oil pipe coupling (2) to support (4). 84179

Place a new seal ring (3) in the crankcase housing. Valves can be removed by means of tool 380000987
(1) by pressing slightly on collar (3) so that lock cones
Figure 166 (2) can be removed by compressing springs (4). Then
remove collar (3) and springs (4).
Repeat the operation on all valves.

84177
Position alternator support (1) in such a way that pins
(3 and 4) are placed against the engine crankcase. Figure 169
Fasten screws (2) and tighten them to the specified
torque.
Figure 167

87042

Take off oil seals (1) fitted to the valve stems.


84178 To remove the valves, properly turn the head upside
Fit alternator (1) back to alternator support (3). down.
Fasten screws (2) without torque--tightening them.
Fit automatic belt stretcher (4) back to alternator sup-
IMPORTANT -- Mark the exhaust and intake
port (3).
valves prior to removing them.
EW--3--74

ENGINES F4BE0684 OVERHAUL

Figure 170 Checking the cylinder head water seal


Check the water seal by means of suitable equipment.
Use a pump to feed water heated to ∼ 90 °C at a pres-
sure of 2 to 3 bar.
If leaks are detected from the caps, the latter must be
replaced by using a suitable beater for disassembling/
assembling operations.

IMPORTANT -- Prior to mounting the caps, apply


water--repellent sealant on the sealing surface of
the same.

INTAKE EXHAUST If leaks are detected from the cylinder head, the latter
84181
must be replaced.
In addition to the head dimensions, the exhaust
valves differ from intake valves in that they are Figure 173
equipped with a supplementary notch (1) obtained on
the stem for intake valves.

Figure 171

87044

The rated thickness A of the cylinder head is 95 ± 0,25


mm; maximum allowed metal removal must not ex-
87043 ceed thickness B by 0.13 mm.
Remove the thermostat unit (2) and brackets (1) and
(4). IMPORTANT -- After reconditioning, check valve
Remove the cover on intake manifold (3). hollow and recondition, if necessary, the valve
Checking the cylinder head supporting surface seats to obtain the prescribed hollow.
Figure 172
Valves
Figure 174
EXHAUST INTAKE
VALVE VALVE

84183

The plane of the supporting surface of head (1) to cyl-


inder cluster is checked by means of a ruler (2) and
a thickness gauge (3).
The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
84185
If greater values are found, reface the cylinder head
according to the values and instructions given in the MAIN DATA OF INTAKE AND EXHAUST VALVES
next figure.
EW--3--75

ENGINES F4BE0684 OVERHAUL

Valve descaling, check and grinding Valve guide


Figure 175 Figure 178

84186
Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
crimping or burns. INTAKE EXHAUST
Reface, if necessary, the valve seats by means of
grinder, by removing as less material as possible. 84046

Use a bore gauge to measure the valve guide inner


Figure 176 diameter, which must be equal to the value shown in
the figure.

84187

Use a micrometer (2) to measure valve stem (1),


which must be equal to 7.96 to 7.98. Valve seat reconditioning -- replacement
Checking the play between the valve stem,
Figure 179
valve guide and valve centring
Figure 177

84188 84189
Check can be made by means of a magnetic com- Check valve seats (2). If slight burns or scoring are
parator (1) placed as shown. Assembling play must found, proceed with reconditioning by means of the
be equal to 0.039 to 0.079 mm. proper tool (1) according to the inclination values
Check, by making valve (2) rotate, that the centring shown in Figure 180.
error is not greater than 0.03 mm.
EW--3--76

ENGINES F4BE0684 OVERHAUL

Figure 180

EXHAUST INTAKE

87009

VALVE SEAT DIMENSIONS

Figure 181

EXHAUST INTAKE

87010

VALVE SEAT HOUSING DIMENSIONS

If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool (1, Figure 179) and taking care not to indent the cylinder head, remove as much material
as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of the proper tool, according to the values shown in Figure 180.
EW--3--77

ENGINES F4BE0684 OVERHAUL

Figure 182 Mounting the cylinder head


Figure 184

84192

After the reconditioning operations, verify, by means 87043

of base 380001000 (2) and comparator 380001004 Apply sealant LOCTITE 5205 between cover (3) and
(1), that valve hollow (3) corresponds to the specified cylinder head, mounting the cover, then tighten the
value. screws to the specified torque.
Mounting the thermostat unit (2) and brackets (1) and
(4), then tighten the screws to the specified torque.

Valve springs

Figure 183 Figure 185

87042

Lubricate the valve stem and insert into the respective


valve guide according to the position marked upon
84193
disassembling.
MAIN DATA FOR INTAKE AND EXHAUST VALVE Mount seal rings (1) onto the valve guide.
SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of the proper tool. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below.

Height Under a load of


mm N
H (free) 63.50 No load
H1 49.02 P1 329
H2 38.20 P2 641
EW--3--78

ENGINES F4BE0684 OVERHAUL

Figure 186 Figure 188

87040
84179

Position spring (4) and upper collar (3) on the cylinder Mount the cylinder head on the crankcase by fasten-
head: use tool 380000987 (1) to compress spring (4) ing screws (1) without torque--tightening them.
and link the parts to the valve by means of lock cones
(2). Figure 189

84209

Prior to inserting the pushrods, verify their state of


preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must
Reattaching the cylinder head not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in-
Figure 187 take and exhaust valves are identical and, therefore,
they are interchangeable.
Rocker arm assembly
Figure 190

84113

Verify that the cylinder head attaching plane and the


crankcase attaching plane are both clean.
Do not spoil the cylinder head gasket.
84195
IMPORTANT -- Prior to reusing the cylinder head
fastening screws, verify that they do not show
PARTS MAKING UP THE ROCKER ARM
traces of wear or deformations; otherwise, replace
ASSEMBLY:
them.
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws
EW--3--79

ENGINES F4BE0684 OVERHAUL

Figure 191 Figure 194

84196
84199
MAIN DATA OF ARBOUR--ROCKER ARM
Scheme of cylinder head fastening screw tightening
Verify that the arbour/rocker arm matching surfaces sequence:
do not show excessive wear or damages.
- 1st phase: pre--fastening by means of a torque
wrench:
Figure 192 screw M12 x 1.75 x 70 [ ] 50 Nm ± 5 Nm;
s

screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm;


screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm;
- 2nd phase: angle tightening: 90°
- 3rd phase: angle tightening only for screws 140
and 180 mm long: 90°.

Figure 195

84197

Verify that the tappet adjusters are unscrewed to pre-


vent the latter from crawling on the rods when the
rocker arm assembly (1) is mounted. Mount the
rocker arm assembly made up of the arbours and
rocker arm support, then secure them to the head
without torque--tightening screws (2).

Figure 193
87037
Ad just the play between the rocker arms and the
valves by means of an Allen wrench (2), box wrench
(3) and thickness gauge (1).
The operation play is:
-- intake valves: 0,25 ± 0,05 mm
-- exhaust valves: 0,50 ± 0,05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--6, 2--5 and 3--4.
FIRING ORDER 1--5--3--6--2--4
Adjuting cylinder
1 5 3 6 2 4
87036 valve no.
Fasten the head screws (1) according to the instruc- Adjusting clearance
6 2 4 1 5 3
tions given Figure 194. of cylinder valve no.
EW--3--80

ENGINES F4BE0684 OVERHAUL

Mounting the injectors Figure 198


Figure 196

87046

Mount the injector feeding pipe assembly (1).


84201 Mount the pipes for fuel discharge (2) from injectors,
by using gaskets (3) and by tightening screws (4).
Mount a new seal ring (2) lubricated with petrolatum
and a new seal washer (3) on injector (1).
Mount the injectors on their seats on the cylinder
head, then tighten them by means of a torque wrench.

Intake manifold unit


Figure 197 Figure 199

87047
- Mount exhaust manifold (3).
- Mount turbine (1) by means of screws (2).
- Mounting water temperature sensor (4).
87045
The intake manifold unit is made up of manifold (6) on
the cylinder head, cover (5), seal gaskets (2) and (4),
cold--start heater (3) and elbow (1).
Apply sealant LOCTITE 5205 between cover (5) and
manifold (6), then tighten the screws to the specified
torque.
EW--3--81

ENGINES F4BE0684 OVERHAUL

- Only engine F4BE0684B - mount fuel filters (11);


Mount the injector feed pipes (6) to injection pump - Only engine F4BE0684B
(8), then secure brackets (1), (4) and (14) fasten- mount injection pump lubricating pipes (9);
ing the pipe assembly onto the cylinder head; - mount oil level check pipe (10);
- mount tappet covers (5); - Only engine F4BE0684B
- connect the engine oil vapour recovery pipe to mount L.D.A. system piping (2);
blow--by (3); - mount quick coupling pipes (7) and (13) by follow-
- mount fuel filter support (12); ing the indications given in Figure 202.

Figure 200

87048
EW--3--82

ENGINES F4BE0684 OVERHAUL

Figure 201 Figure 203

84065
- Mount starter motor (3).
88142
- Mount turbine lubricating oil (1) return pipe with its
respective fastening bracket (2).
For engine F4BE0684M
- Mount turbine lubricating oil (7) delivery pipe and
- Connect pipes (1) for the LDA from the head and engine oil pipes (4) and (5) to water/oil heat ex-
from the feed pump. changer (6).
- Assemble the pipes (2) that constituted feed and
recovery of fuel between the pump and the injec- Figure 204
tors.

87049

- Mount fan pulley support (3) on head (1) by


Figure 202 torque--tightening screws (2).

Figure 205

70126
84204
Act on fork (1) as shown in the figure (detail A), then Mount fan pulley (2) with spacer (5) on support (1) by
remove the adapter. To avoid deformations, bring fork torque--tightening screws (3).
(1) back to the locking position (detail B) after the Mount fan (4) on spacer and torque--tighten the
adapter has been removed. screws.
EW--3--83

ENGINES F4BE0684 OVERHAUL

Figure 206 Figure 208

84205 84082

Mount Poli--V belt (1) on fan pulley, drive shaft pulley, Remove injectors (2) by means of tool 380000982 (1)
guide pulleys, water pump and on alternator; then, and take them off the cylinder head.
stretch the belt by acting on automatic belt stretcher
(2).

Reassembling
Replacing the injectors Figure 209

Removal
Figure 207

84206 84201

Place the vehicle in safe conditions. Mount a new seal ring (2) lubricated with petrolatum
Lift the engine compartment cover, disconnect the and a new seal washer (3) on injector (1).
battery cables and proceed as follows: Mount the injectors on their seats on the cylinder
- disconnect engine oil vapour recovery pipe (2) head, then tighten them by means of a torque wrench.
from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors
(3).
EW--3--84

ENGINES F4BE0684 OVERHAUL

Mount new seal rings (1) on fuel manifolds (2). Reassemble the tappet cover.
Connect the manifolds to the injectors, by tightening Re--connect the engine oil vapour recovery pipe to the
the fastening nuts to a torque of 50 Nm. blow--by.

Figure 210

84208
EW--3--85

ENGINES F4BE0684 OVERHAUL

Adjusting the tappets Rocker arm removal/reassembling


Figure 211 Removal
Figure 212

84200
84081
Ad just the play between the rocker arms and the Loosen tappet adjuster fastening nuts (3), then un-
valves by means of an Allen wrench (2), box wrench screw adjusters (2).
(3) and thickness gauge (1).
Remove screws (4) and dismount rocker arm assem-
The operation play is: bly (1) made up of the rocker arm support and ar-
-- ± 0,05 mm bours, then take off valves.
– intake valves: 0,25 ± 0,05 mm Reassembling
-- exhaust valves: 0,50 ± 0,05 mm. Verify that the tappet adjusters are unscrewed to pre-
Take the cylinder where clearance must be adjusted vent the latter from crawling on the rods when the
to the bursting phase; its valves are closed while bal- rocker arm assembly is mounted.
ancing the symmetric cylinder valves. Mount the rocker arm assemblies made up of rocker
Symmetric cylinders are 1--6, 2--5 and 3--4. arm support and arbours, then secure them to the cyl-
inder head by tightening the fastening screws to a
FIRING ORDER 1--5--3--6--2--4 torque of 36 Nm.
Adjuting cylinder Ad just the tappets as described above.
1 5 3 6 2 4
valve no.
Adjusting clearance
6 2 4 1 5 3
of cylinder valve no.

Valve timing
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.
Figure 213

84210
EW--3--86

ENGINES F4BE0684 OVERHAUL

Check priming of the injection pump Check priming of the injection pump
(F4BE0684M engine only) (F4BE0684B engine only)
Figure 214 Figure 216

88141 88141

Turn the engine shaft unit the piston of the 1st cylinder Turn the engine shaft unit the piston of the 1st cylinder
near the P.M.S. and close the relevant valves (com- near the P.M.S. and close the relevant valves (com-
pression stage). pression stage).
Assemble tool 380000977 (1) and with the compara- Assemble tool 380000977 (1) and with the compara-
tor 380001005 in the seat of the injector of the 1str cyl- tor 380001005 in the seat of the injector of the 1str cyl-
inder, preload the comparator (2). inder, preload the comparator (2).
Figure 215 Figure 217

87720 90636

With the injection pump inserted in the relevant seat Once the injection pump is correctly positioned and
and the fixing screws loosened, assemble the the locking screws are loose, remove the side cover.
comparator holding tool 380001003 (1), supplied with Mount the gauge 380001005 (2) on the No. 6 pumping
comparator 380001005 (2), preloading the rod of 2.5 element and the No. 380000997 gauge tool (1) and
mm. pre--load the 2.5--mm rod.
Turn the engine shaft properly in order to determine Turn the engine shaft properly in order to determine
the exact PMS of the piston of the 1st cylinder and of the exact PMS of the piston of the 6th cylinder and of
the injection pump pumping element, zero the the injection pump pumping element, zero the
comparators (2, Figure 214 e 2, Figure 215). comparators (2, Figure 216 e 2, Figure 217).
Turn the engine shaft counter clockwise of a few de- Turn the engine shaft counter clockwise of a few de-
grees and then turn again in the opposite direction un- grees and then turn again in the opposite direction un-
til the P.M.S. is determined. In this position, on the til the P.M.S. is determined. In this position, on the
comparator (2) you will read the pumping element comparator (2) you will read the pumping element
pre--lift value prescribed. Turn the pump counter pre--lift value prescribed. Turn the pump counter
clockwise if the stroke is lower, or clockwise if the clockwise if the stroke is lower, or clockwise if the
stroke is higher until the stroke prescribed is stroke is higher until the stroke prescribed is
achieved. achieved.
Then lock the pump with the fixing nuts to the couple Then lock the pump with the fixing nuts to the couple
prescribed. prescribed.
SECTION 4

RECHARGE AND START--UP

INDEX
Starter motor . . . . . . . . . . . . . . . . . . . . . . EW--4--3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--4--5

Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--4--3 Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--4--5

Bosch 24 V -- 4 kW . . . . . . . . . . . . . . . . . . EW--4--4 Bosch NCBI 28 V 35--70 A . . . . . . . . . . EW--4--6


INDEX
EW--4--3

RECHARGE AND START--UP

STARTER MOTOR

BOSCH -- 24 V -- 4 kW

Quick diagnosis

Fault Possible causes Remedy

Dragging torque insufficient 1. Batteries run down Restore


2. Circuit connections oxidized or Replace the component
loose
3. Brushes not in working order Replace the component
4. Short--circuited field windings Replace the component
5. Interruptedor short circuited ar-- Replace the component
mature
6. Out--of--round collector Replace the component
Dragging torque sufficient, but 1. Free wheel or faulty electro--ma-- Replace the component
the engine won’t start. gnet
Pinion won’t engage. 1. Bevelled ring gear Restore
EW--4--4

RECHARGE AND START--UP

Bosch 24 V -- 4 kW
6--pole type with series excitation and engagement by means of a fork controlled by an electromagnet.
Clockwise direction of rotation
Rated voltage 24 V
Power 4 kW

84262 84267

WIRING DIAGRAM 3/4 VIEW

84268 84269

CHARACTERISTIC CURVES PINION ADJUSTER


EW--4--5

RECHARGE AND START--UP

ALTERNATOR

BOSCH NCBI 28 V 35--70 A

Quick diagnosis

Fault Possible causes Remedy

No recharge 1. Interruption of recharge circuit Check the recharge circuit con--


(warning light, fuse, connector, nections, clean and tighten the
etc.) cable terminals on the alterna--
tor and battery
2. Voltage regulator not in wor-- Replace the component
king order
3. Interrupted rotor winding Replace the component
4. Worn brushes Replace the component

Poor recharge 1. Loose belt Apply correct tension


2. Faulty voltage regulator Replace the component
3. Excessive wear of rotor rings Replace the component
or brushes
4. Short--circuited diodes Replace the component
5. Short--circuited rotor winding(s) Replace the component

Excessive recharge 1. Loose circuit connections Check the connections to ter--


minals and cable terminals of
batteries, starter motor and al--
ternator
2. Voltage regulator not in wor-- Replace the component
king order
3. Earth fault Check earth connections
EW--4--6

RECHARGE AND START--UP

Bosch NCBI 28 V 35--70 A


Thrre--phase type, claw--type rotor, 11--diode rectifier and electronic voltage regulator.
Direction of rotation (control side) clockwise
Current delivered at 6.000 min--1 ≥ 55A
Rated voltage 28,5V

84270 84271

WIRING DIAGRAM 3/4 VIEW

84272 84274

CHARACTERISTIC CURVES OF CURRENT CHARACTERISTIC CURVES OF VOLTAGE


DELIVERY REGULATOR