New Holland F4CE9484 / F4CE9487A / F4CE9487N / F4CE9684 / F4DE9484 NEF Tier 3Engine. SERVICE MANUAL (2013)

Mechanical fuel injection / Structural engine block

F4CE9454H*J601

F4CE9484J*J602

F4CE9484M*J603

F4CE9487M*J605

F4CE9684J*J601

F4CE9454H*J605

F4CE9484J*J604

F4CE9484M*J606

F4CE9487N*J601

F4CE9684J*J606

F4CE9484A*J600

F4CE9484L*J600

F4CE9484M*J607

F4CE9487N*J602

F4CE9684J*J607

F4CE9484A*J602

F4CE9484L*J602

F4CE9484M*J608

F4CE9487N*J603

F4CE9684J*J609

F4CE9484C*J600

F4CE9484L*J603

F4CE9484N*J601

F4CE9487N*J605

F4CE9684K*J601

F4CE9484C*J601

F4CE9484L*J604

F4CE9484N*J604

F4CE9487N*J606

F4CE9684K*J606

F4CE9484G*J600

F4CE9484L*J605

F4CE9487A*J600

F4CE9684B*J600

F4CE9684K*J607

F4CE9484G*J604

F4CE9484L*J606

F4CE9487A*J601

F4CE9684C*J600

F4CE9684K*J608

F4CE9484G*J607

F4CE9484M*J601

F4CE9487M*J602

F4CE9684H*J603

F4CE9684L*J600

F4CE9484G*J608

F4CE9484M*J602

F4CE9487M*J603

F4CE9684H*J604

F4CE9684L*J605

Mechanical fuel injection / Non-structural engine block

F4GE9454C*J601

F4GE9484C*J603

F4GE9484F*J615

F4GE9684C*J602

F4GE9684F*J604

F4GE9454C*J602

F4GE9484C*J605

F4GE9484H*J600

F4GE9684D*J600

F4GE9684G*J600

F4GE9454C*J607

F4GE9484C*J606

F4GE9484J*J600

F4GE9684D*J603

F4GE9684G*J601

F4GE9454C*J608

F4GE9484C*J607

F4GE9484J*J601

F4GE9684D*J604

F4GE9684G*J602

F4GE9454J*J605

F4GE9484D*J600

F4GE9484J*J603

F4GE9684E*J600

F4GE9684G*J603

F4GE9454J*J607

F4GE9484D*J603

F4GE9484J*J604

F4GE9684E*J601

F4GE9684G*J605

F4GE9454K*J602

F4GE9484D*J606

F4GE9484J*J605

F4GE9684E*J603

F4GE9684G*J606

F4GE9454K*J604

F4GE9484D*J607

F4GE9484P*J600

F4GE9684E*J604

F4GE9684H*J600

F4GE9454K*J605

F4GE9484D*J617

F4GE9484P*J601

F4GE9684E*J605

F4GE9684H*J601

F4GE9484A*J602

F4GE9484D*J618

F4GE9684A*J603

F4GE9684E*J606

F4GE9684R*J600

F4GE9484A*J605

F4GE9484D*J619

F4GE9684A*J605

F4GE9684E*J607

F4GE9684R*J601

F4GE9484A*J607

F4GE9484D*J620

F4GE9684B*J601

F4GE9684E*J610

F4GE9684R*J602

F4GE9484A*J608

F4GE9484E*J600

F4GE9684B*J602

F4GE9684E*J611

F4GE9684R*J603

F4GE9484A*J610

F4GE9484E*J601

F4GE9684B*J604

F4GE9684E*J612

F4GE9684R*J605

F4GE9484A*J611

F4GE9484E*J602

F4GE9684B*J605

F4GE9684E*J613

F4GE9684R*J606

F4GE9484A*J612

F4GE9484E*J603

F4GE9684B*J606

F4GE9684E*J615

F4GE9484C*J600

F4GE9484F*J600

F4GE9684B*J607

F4GE9684F*J600

F4GE9484C*J601

F4GE9484F*J610

F4GE9684C*J600

F4GE9684F*J602

F4GE9484C*J602

F4GE9484F*J614

F4GE9684C*J601

F4GE9684F*J603

Electronic fuel injection / Structural engine block

F4DE0484B*J100

F4DE9684B*J100

F4DE9684J*J101

F4DE9684R*J103

F4DE9687J*J104

F4DE0484C*J100

F4DE9684B*J101

F4DE9684J*J102

F4DE9684R*J104

F4DE9687R*J101

F4DE9484A*J100

F4DE9684B*J102

F4DE9684J*J104

F4DE9684R*J105

F4DE9687U*J100

F4DE9484A*J103

F4DE9684B*J104

F4DE9684J*J105

F4DE9684S*J100

F4DE9687U*J102

F4DE9484A*J104

F4DE9684B*J106

F4DE9684L*J100

F4DE9684S*J103

F4DE9687V*J100

F4DE9484B*J101

F4DE9684B*J107

F4DE9684L*J103

F4DE9684S*J106

F4DE9687V*J101

F4DE9484D*J101

F4DE9684B*J108

F4DE9684L*J106

F4DE9684S*J107

F4DE9687V*J104

F4DE9484E*J100

F4DE9684B*J109

F4DE9684L*J107

F4DE9684U*J100

F4DE9687X*J100

F4DE9484F*J100

F4DE9684B*J110

F4DE9684L*J108

F4DE9684Y*J100

F4DE9687X*J101

F4DE9484F*J101

F4DE9684B*J111

F4DE9684L*J109

F4DE9684Y*J101

F4DE9687X*J102

F4DE9484G*J100

F4DE9684C*J100

F4DE9684M*J100

F4DE9684Y*J102

F4DE9687X*J103

F4DE9484H*J100

F4DE9684D*J100

F4DE9684M*J101

F4DE9684Z*J102

F4DE9687X*J104

F4DE9487A*J103

F4DE9684E*J100

F4DE9684M*J103

F4DE9687A*J100

F4DE9687X*J105

F4DE9487A*J104

F4DE9684F*J100

F4DE9684N*J100

F4DE9687A*J103

F4DE9687X*J106

F4DE9487B*J100

F4DE9684F*J102

F4DE9684N*J104

F4DE9687A*J104

F4DE9687Y*J100

F4DE9487B*J101

F4DE9684G*J100

F4DE9684N*J107

F4DE9687C*J100

F4DE9687Y*J101

F4DE9487C*J100

F4DE9684G*J101

F4DE9684N*J108

F4DE9687J*J100

F4DE9687Y*J102

F4DE9487D*J101

F4DE9684H*J100

F4DE9684R*J100

F4DE9687J*J101

F4DE9487L*J100

F4DE9684J*J100

F4DE9684R*J102

F4DE9687J*J102

Electronic fuel injection / Non-structural engine block

F4HE0454D*J102

F4HE9484F*J105

F4HE9684E*J104

F4HE9684S*J102

F4HE9687L*J100

F4HE0454D*J104

F4HE9484F*J106

F4HE9684E*J106

F4HE9684S*J103

F4HE9687L*J101

F4HE0484A*J101

F4HE9484M*J100

F4HE9684E*J107

F4HE9684T*J100

F4HE9687M*J101

F4HE0484A*J103

F4HE9484M*J101

F4HE9684F*J100

F4HE9684T*J101

F4HE9687M*J103

F4HE0484G*J100

F4HE9684B*J100

F4HE9684F*J102

F4HE9684U*J101

F4HE9687M*J104

F4HE0484G*J101

F4HE9684B*J101

F4HE9684F*J103

F4HE9684U*J103

F4HE9687M*J105

F4HE0484G*J102

F4HE9684B*J103

F4HE9684F*J104

F4HE9684V*J102

F4HE9687N*J101

F4HE0484G*J103

F4HE9684B*J104

F4HE9684F*J105

F4HE9684V*J103

F4HE9687N*J103

F4HE0484G*J105

F4HE9684C*J100

F4HE9684F*J107

F4HE9687C*J100

F4HE9687N*J104

F4HE0484G*J106

F4HE9684C*J101

F4HE9684F*J108

F4HE9687C*J101

F4HE9687P*J101

F4HE0484G*J108

F4HE9684C*J102

F4HE9684F*J109

F4HE9687C*J103

F4HE9687Q*J101

F4HE0484G*J109

F4HE9684C*J104

F4HE9684J*J100

F4HE9687F*J100

F4HE9687Q*J103

F4HE0484G*J110

F4HE9684C*J105

F4HE9684J*J101

F4HE9687F*J101

F4HE9687S*J101

F4HE0684T*J100

F4HE9684C*J106

F4HE9684J*J102

F4HE9687G*J100

F4HE9687S*J103

F4HE0684T*J101

F4HE9684D*J100

F4HE9684J*J104

F4HE9687G*J101

F4HE9687S*J104

F4HE0684T*J103

F4HE9684D*J101

F4HE9684J*J106

F4HE9687G*J102

F4HE9687S*J105

F4HE9484C*J100

F4HE9684D*J102

F4HE9684K*J100

F4HE9687G*J104

F4HE9687T*J101

F4HE9484C*J102

F4HE9684D*J103

F4HE9684K*J102

F4HE9687H*J100

F4HE9687T*J103

F4HE9484C*J103

F4HE9684D*J105

F4HE9684L*J101

F4HE9687H*J101

F4HE9687T*J104

F4HE9484C*J104

F4HE9684D*J106

F4HE9684L*J102

F4HE9687H*J102

F4HE9687W*J100

F4HE9484C*J105

F4HE9684D*J107

F4HE9684M*J100

F4HE9687H*J103

F4HE9687W*J101

F4HE9484C*J106

F4HE9684D*J109

F4HE9684M*J101

F4HE9687K*J100

F4HE9687W*J102

F4HE9484C*J107

F4HE9684E*J100

F4HE9684P*J102

F4HE9687K*J101

F4HE9687Z*J100

F4HE9484C*J108

F4HE9684E*J101

F4HE9684P*J103

F4HE9687K*J102

F4HE9687Z*J101

F4HE9484F*J103

F4HE9684E*J102

F4HE9684S*J100

F4HE9687K*J103

F4HE9484F*J104

F4HE9684E*J103

F4HE9684S*J101

F4HE9687K*J105

Contents

INTRODUCTION

Engine

[10.001] Engine and crankcase

10.1

[10.102] Pan and covers

10.2

[10.106] Valve drive and gears

10.3

[10.101] Cylinder heads

10.4

[10.105] Connecting rods and pistons

10.5

[10.103] Crankshaft and flywheel

10.6

[10.110] Balancer and damper

10.7

[10.114] Pump drives

10.8

[10.210] Lift pump and lines

10.9

[10.206] Fuel filters

10.10

[10.218] Fuel injection system

10.11

[10.250] Turbocharger and lines

10.12

[10.254] Intake and exhaust manifolds and muffler

10.13

[10.400] Engine cooling system

10.14

[10.414] Fan and drive

10.15

[10.304] Engine lubrication system

10.16

[10.408] Oil cooler and lines

10.17

Electrical systems

[55.015] Engine control system

55.1

[55.201] Engine starting system

55.2

[55.301] Alternator

55.3

[55.202] Cold start aid

55.4

[55.010] Fuel injection system

55.5

[55.014] Engine intake and exhaust system

55.6

[55.012] Engine cooling system

55.7

4759767527/09/2013

INTRODUCTION

Foreword

Engine Overhaul

Part of the operations illustrated within this manual can be partially executed while the engine is assembled on the

vehicle, depending on the room available for access to the engine and on the equipment application as well.

NOTE: With regard to the engine disassembly operations, please apply for information consulting the specific manual.

The following information relates to the engine overhaul operations only for what concerns the different components

customizing the engine, according to its specific duties.

In section "General Overhaul", all the operations of engine block overhaul have been contemplated. Therefore the

above mentioned section is to be considered as following the part hereby described.

47597675 27/09/2013

INTRODUCTION

Safety rules

Standard safety prescriptions

Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working

area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the

personnel in charge of maintenance.

Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation

available for consultation.

• Keep working areas as clean as possible, ensuring adequate aeration.

• Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided

with adequate sanitary equipment.

• Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency

must be checked on a regular basis and the personnel must be trained on interventon methods and priorities.

• Organize and identify specific exit points to evacuate the areas in case of an emergency, providing for adequate

indications of the emergency indications of the emergency exit lines.

• Smoking in working areas subject to fire danger must be strictly prohibited.

• Provide warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy com-

prehension of the instructions even in case of an emergency.

Prevention of injury

• Do not wear unsuitable clothes for work, with fluttering ends, nor jewels such as and chains when working close to

engines and equipment in motion.

• Wear safety gloves and goggles when performing the following operations:

•

• filling inhibitors or anti-frost

• lubrication oil topping or replacement

• utilization of compressed air or liquids under pressure (pressure allowed < 2 bar (29 psi)).

• Wear safety helmet when working close to hanging loads or equipment working at head height level.

• Always wear safety shoes and clothes adhering to the body, better if provided with elastics at the ends.

• Use protection cream for hands.

• Change wet clothes as soon as possible.

• In presence of electrical current exceeding 48 - 60 V verify efficiency of earth and mass electrical connections.

Ensure that hands and feet are dry and execute working operations utilizing isolating foot boards. Do not carry out

working operations if not trained for.

• Do not smoke nor light up flames close to batteries and to any fuel material.

• Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.

• Do not execute any intervention if not provided with necessary instructions.

• Do not use any tool or equipment for any different operation from the ones they've been designed and provided for.

Serious injury may occur.

• In case of test or calibration operations requiring engine running, ensure that the area is sufficiently ventilated or

utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning or death.

During maintenance

• Never open filler cap of cooling system when the engine is hot. Operating pressure would provoke high temperature

with serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F).

• Never top up an overheated engine with cooler and utilize only appropriate liquids.

• Always operate when the engine is tuned off; when particular circumstances require maintenance intervention on

running engine, be aware of all risks involved with such operation.

• Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil.

47597675 27/09/2013

INTRODUCTION

•

Keep the engine clean from oil spills, diesel fuel and or chemical solvents.

•

Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas venti-

lated. Whenever necessary wear safety mask.

•

Do not leave rags impregnated with flammable substances close to the engine.

•

Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of a runaway

speed rate.

•

Do not utilize fast screw tightening tools.

•

Never disconnect batteries when the engine is running.

•

Disconnect batteries before any intervention on the electrical system.

•

Disconnect batteries from system before applying a load to them with the battery loader.

•

After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from

accidental short circuit and oxidation.

•

Do not disconnect and connect electrical connections in presence of electrical feed.

•

Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air

under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves.

Always wear adequate safety mask or goggles. Non fulfillment of these precautions may cause serious injury and

poisoning.

•

Avoid incorrect tightening or out of sequence. Danger: incorrect tightening may seriously damage engine's com-

ponents, affecting engine's duration.

•

Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters.

•

Do not modify cable wires: their lengths shall not be changed.

•

Do not connect to the engine electrical equipment unless specifically approved by Iveco.

•

Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized

modification will compromise warranty assistance and furthermore may affect engine correct working and duration.

For engines equipped with electronic controller:

• Do not execute electric arc welding without having previously removed electronic controller.

• Remove electronic controller in case of any intervention requiring heating over 80 °C (176 °F) temperature.

• Do not paint the components and the electronic connections.

• Do not vary or alter any data filed in the electronic controller driving the engine. Any manipulation or alteration

of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine

correct working and duration.

Respect of the Environment

• Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel's safety

and health shall be adopted.

• Be informed and inform personnel as well of the laws in force regulating use and exhaust of liquids and engine

drain oil. Provide for adequate board indications and organic specific training courses to ensure that personnel is

fully aware of such law prescriptions and of basic preventative safety measures.

• Collect drain oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in

specific, properly identified areas that shall be ventilated far from heat sources and not exposed to fire danger,

• Handle the batteries with care, storing them in ventilated environment and within anti-acid containers. Warning:

Battery exhalation represent serious danger of intoxication and environment contamination.

47597675 27/09/2013

INTRODUCTION

Torque

F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687,

F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Component

Size

Specification

Cylinder Head and Components

Plug

¼"

- 14 Nm (7.4 - 10.3 lb ft)

½"

- 28 Nm (14.8 - 20.7 lb ft)

¾"

- 41 Nm (22.9 - 30.2 lb ft)

Grid Heater

M6 Nut

10 Nm (4.4 - 7.4 lb ft)

Intake Manifold

M8 Screw

- 28 Nm (14.8 - 20.7 lb ft)

Engine Lifting Bracket

Rear

M12

- 89 Nm (47.9 - 65.6 lb ft)

Front

- 28 Nm (14.8 - 20.7 lb ft)

Cylinder Head

M12x1.75x130 mm

First Phase

- 40 Nm (22.1 - 29.5 lb ft)

Second Phase

- 95 °

Third Phase

- 95 °

Cylinder Head

M12x1.75x150 mm

First Phase

- 60 Nm (36.9 - 44.3 lb ft)

Second Phase

- 95 °

Third Phase

- 95 °

Rocker Bracket

- 41 Nm (22.9 - 30.2 lb ft)

Rocker Arm Jam Nuts

- 28 Nm (14.8 - 20.7 lb ft)

Exhaust Manifold

- 58 Nm (35.4 - 42.8 lb ft)

Valve Cover

M8 Nut

- 28 Nm (14.8 - 20.7 lb ft)

Turbocharger

6 Cylinder

M8 Screw

8 Nm (4.4 - 5.9 lb ft)

M8 Nut

- 49 Nm (27.3 - 36.1 lb ft)

4 Cylinder

M8 Screw

8 Nm (4.4 - 5.9 lb ft)

M8 Nut

- 28 Nm (14.8 - 20.7 lb ft)

Front Case

Front Cover

M8 Screw

- 28 Nm (14.8 - 20.7 lb ft)

Rear Case

Gear Case

M12 Screw

- 89 Nm (47.9 - 65.6 lb ft)

M10 Screw

- 52 Nm (31.0 - 38.4 lb ft)

M8 Screw

- 28 Nm (14.8 - 20.7 lb ft)

Flywheel Housing

M10

- 95 Nm (55.3 - 70.1 lb ft)

M12

- 54 Nm (32.5 - 39.8 lb ft)

Cylinder Block and Crankshaft Components

47597675 27/09/2013

INTRODUCTION

Component

Size

Specification

Camshaft Retaining Plate

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

Camshaft Gear

M8 Screw

32 - 40 Nm (23.6 - 29.5 lb ft)

Crankcase Plate

M10 Screw

38 - 48 Nm (28.0 - 35.4 lb ft)

Vibration Damper and Adapter

M12

First Phase

45 - 55 Nm (33.2 - 40.6 lb ft)

Second Phase

90 °

Drive Pulley

M10

61 - 75 Nm (45.0 - 55.3 lb ft)

Engine Flywheel

M12

First Phase

26 - 34 Nm (19.2 - 25.1 lb ft)

Second Phase

55 - 65 °

Main Caps

M12

First Phase

44 - 56 Nm (32.5 - 41.3 lb ft)

Second Phase

74 - 86 Nm (54.6 - 63.4 lb ft)

Third Phase

85 - 95 °

Connecting Rod Caps

First Phase

55 - 65 Nm (40.6 - 47.9 lb ft)

Second Phase

55 - 65 °

Lubrication System and Components

Oil Pump

First Phase

7 - 9 Nm (5.2 - 6.6 lb ft)

Second Phase

20 - 28 Nm (14.8 - 20.7 lb ft)

Oil Pressure Relief Valve

M22

72 - 88 Nm (53.1 - 64.9 lb ft)

Oil Cooler and Oil Filter Base

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

Oil Filter

Contact + ¾ Turn

Connection on Filter Base for Turbo Oil

1 ⅛"

20 - 28 Nm (14.8 - 20.7 lb ft)

Supply

Turbo Lubrication Pipe

M12 Nut

8 - 12 Nm (5.9 - 8.9 lb ft)

Turbo Lubrication Pipe Adapter

M12

30 - 40 Nm (22.1 - 29.5 lb ft)

Oil Pan

20 - 28 Nm (14.8 - 20.7 lb ft)

Piston Spray Nozzles

12 - 18 Nm (8.9 - 13.3 lb ft)

Electrical Components

Camshaft Sensor

M6 Studs

6 - 10 Nm (4.4 - 7.4 lb ft)

M6 Nut

8 - 12 Nm (5.9 - 8.9 lb ft)

M6 Screw

6 - 10 Nm (4.4 - 7.4 lb ft)

Wiring Bulkhead

M6 Screw

8 - 12 Nm (5.9 - 8.9 lb ft)

Support Bracket for Injector Wiring

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

Injector Wiring

1.25 - 1.75 Nm (0.92 - 1.29 lb ft)

ECU Cooling Plate

M6 Screw

8 - 12 Nm (5.9 - 8.9 lb ft)

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

Fuel Outlet

M12

10 - 14 Nm (7.4 - 10.3 lb ft)

Fuel Inlet

M12

10 - 14 Nm (7.4 - 10.3 lb ft)

Crankshaft Speed Sensor

M6 Screw

6 - 10 Nm (4.4 - 7.4 lb ft)

Coolant Temperature Sensor

M14 Screw

17 - 23 Nm (12.5 - 17.0 lb ft)

Oil Pressure / Temperature Sensor

M5 Screw

5 - 7 Nm (3.7 - 5.2 lb ft)

Fuel Pressure Sensor

30 - 40 Nm (22.1 - 29.5 lb ft)

Fuel Temperature Sensor

M14

17 - 23 Nm (12.5 - 17.0 lb ft)

Air Pressure / Temperature Sensor

5 - 7 Nm (3.7 - 5.2 lb ft)

Engine Oil Level Sensor

M12

10 - 14 Nm (7.4 - 10.3 lb ft)

Alternator Support Bracket

M10 Screw

37 - 49 Nm (27.3 - 36.1 lb ft)

Alternator Tension Bracket

M10 Screw

37 - 49 Nm (27.3 - 36.1 lb ft)

Starter

37 - 49 Nm (27.3 - 36.1 lb ft)

Fuel System and Components

47597675 27/09/2013

INTRODUCTION

Component

Size

Specification

Feed Pump

M8 Studs

10 - 14 Nm (7.4 - 10.3 lb ft)

High Pressure Pump Gear

M18 Nut

100 - 110 Nm (73.8 - 81.1 lb ft)

Fuel Pump

M8 Nut

20 - 28 Nm (14.8 - 20.7 lb ft)

Injector

First Phase

M6 Screw

8.15 - 8.85 Nm (6.0 - 6.5 lb ft)

Second Phase

M6 Screw

70 - 80 °

Injector Feed Connector

45 - 55 Nm (33.2 - 40.6 lb ft)

Common Rail

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

High Pressure Fuel Line

M14 Fitting

18 - 22 Nm (13.3 - 16.2 lb ft)

High Pressure Pipe Connector

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

Fuel Filter Bracket

M12 Screw

71 - 85 Nm (52.4 - 62.7 lb ft)

Fuel Filter Holder

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

Fuel Filter

Contact + ¾ Turn

Cooling System and Components

Engine Coolant Inlet

M10 Screw

37 - 49 Nm (27.3 - 36.1 lb ft)

Fitting on Coolant Inlet

90 ° Elbow

20 - 28 Nm (14.8 - 20.7 lb ft)

Compressor Cooling Pipe

20 - 24 Nm (14.8 - 17.7 lb ft)

Engine Coolant Drain Collector

M6 Screw

8 - 12 Nm (5.9 - 8.9 lb ft)

Water Pump

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

Belt Tensioner

M10

37 - 49 Nm (27.3 - 36.1 lb ft)

Idler Pulleys

M10

37 - 49 Nm (27.3 - 36.1 lb ft)

47597675 27/09/2013

INTRODUCTION

Torque

F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Component

Size

Specification

Cylinder Head and Components

Rocker Assembly

20 - 28 Nm (14.8 -

20.7 lb ft)

Cylinder Head

M12x70

Phase 1

50 Nm (36.9 lb ft)

Phase 2

90 °

Cylinder Head

M12x140

Phase 1

40 Nm (29.5 lb ft)

Phase 2

180 °

Cylinder Head

M12x180

Phase 1

70 Nm (51.6 lb ft)

Phase 2

180 °

Valve Cover

M8x1.25x25

20 -

28 Nm (14.8

20.7 lb ft)

Intake manifold

M8x1.25

20 -

28 Nm (14.8

20.7 lb ft)

Air intake elbow

M8x1.25

20 -

28 Nm (14.8

20.7 lb ft)

Exhaust manifold

M10x1.5x65

37 -

49 Nm (27.3

36.1 lb ft)

Rear lifting bracket

M12x1.75x30

65 -

89 Nm (47.9

65.6 lb ft)

Turbocharger

M10

37 -

49 Nm (27.3

36.1 lb ft)

Front Case

Front cover assembly

M8x1.25x45

20 -

28 Nm (14.8

20.7 lb ft)

M8x1.25x30

20 -

28 Nm (14.8

20.7 lb ft)

Rear Case

Gear Case

M8x1.25x40

20 -

28 Nm (14.8

20.7 lb ft)

M8x1.25x25

20 -

28 Nm (14.8

20.7 lb ft)

M10x1.5

44 -

54 Nm (32.5

39.8 lb ft)

Flywheel housing

M12x120

75 -

95 Nm (55.3

70.1 lb ft)

M12x80

75 -

95 Nm (55.3

70.1 lb ft)

M10x80

44 -

54 Nm (32.5

39.8 lb ft)

M10x40

44 -

54 Nm (32.5

39.8 lb ft)

Phase 1

M12x1.25

26 -

34 Nm (19.2

25.1 lb ft)

Phase 2

M12x1.25

55 -

65 °

Cylinder Block and Crankshaft Components

Main bearing cap

Phase 1

44 -

56 Nm (32.5

41.3 lb ft)

Phase 2

74 -

86 Nm (54.6

63.4 lb ft)

Phase 3

85 -

95 °

Connecting rod

M11x1.25

Phase 1

27 -

33 Nm (19.9

24.3 lb ft)

Phase 2

55 -

65 Nm (40.6

47.9 lb ft)

Phase 3

55 -

65 °

Timing Pin

4 - 6 Nm (3.0 - 4.4 lb ft)

Crankshaft pulley

M12x1.75

105 - 115 Nm (77.4 - 84.8 lb ft)

Camshaft retaining plate

20 - 28 Nm (14.8 - 20.7 lb ft)

Camshaft gear

32 - 40 Nm (23.6 - 29.5 lb ft)

Lubrication System and Components

47597675 27/09/2013

INTRODUCTION

Component

Size

Specification

Piston Cooling Nozzles

M8x1.25x10

- 18 Nm (8.9 - 13.3 lb ft)

Oil pump

M8x1.25x30

9 Nm (5.2 - 6.6 lb ft)

Stiffening Plate

M10x1.25x25

- 48 Nm (28.0 - 35.4 lb ft)

Oil plug

M10x1

7 Nm (3.7 - 5.2 lb ft)

M14x1.5

13 Nm (6.6 - 9.6 lb ft)

Oil Pick up tube

M8x1.25x20

- 28 Nm (14.8 - 20.7 lb ft)

Oil Pan

M8x1.25x25

- 28 Nm (14.8 - 20.7 lb ft)

M18x1.50

- 69 Nm (37.6 - 50.9 lb ft)

Oil Bypass Valve

M22x1.5x10

- 88 Nm (53.1 - 64.9 lb ft)

Turbo Lubrication Lines

Turbo end

M12x1.5

- 28 Nm (14.8 - 20.7 lb ft)

Filter base end

- 28 Nm (14.8 - 20.7 lb ft)

Drain

M8x1.25x16

- 28 Nm (14.8 - 20.7 lb ft)

Electrical Components

Alternator

M8x1.25x30

- 28 Nm (14.8 - 20.7 lb ft)

M10x1.25x25

- 28 Nm (14.8 - 20.7 lb ft)

M10

- 54 Nm (32.5 - 39.8 lb ft)

M12x1.75x120

- 49 Nm (27.3 - 36.1 lb ft)

Alternator wiring

M6x1.0 nut

11 Nm (5.9 - 8.1 lb ft)

Starter

M10

- 44 Nm (39.8 - 32.5 lb ft)

Fuel System and Components

Fuel pump

M8 screw

- 28 Nm (14.8 - 20.7 lb ft)

M6 screw

11 Nm (6.6 - 8.1 lb ft)

M6 nut

11 Nm (6.6 - 8.1 lb ft)

Fuel Pump Drive Gear

Phase 1

- 20 Nm (11.1 - 14.8 lb ft)

Phase 2

- 90 Nm (62.7 - 66.4 lb ft)

Timing Pin Cap

- 35 Nm (22.1 - 25.8 lb ft)

Fuel injectors

- 65 Nm (40.6 - 47.9 lb ft)

Fuel lift pump

- 28 Nm (14.8 - 20.7 lb ft)

Cooling System and Components

Water Pump

M8x1.25x25

- 28 Nm (14.8 - 20.7 lb ft)

Water outlet connection

M8x1.25x35

- 28 Nm (14.8 - 20.7 lb ft)

M8x1.25x70

- 28 Nm (14.8 - 20.7 lb ft)

Fan support

M10x1.5x20

- 38 Nm (20.7 - 28.0 lb ft)

Fan pulley

12 Nm (5.9 - 8.9 lb ft)

M10

- 49 Nm (19.9 - 36.1 lb ft)

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Contents

Engine - 10

Engine and crankcase - 001

TECHNICAL DATA

Engine

General specification

F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687,

F4HE9687G*J100

General specification

F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

General specification

F4GE9484, F4GE9484C*J601, F4GE9684

General specification

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

FUNCTIONAL DATA

Engine

Component localisation

F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687,

F4HE9687G*J100

Component localisation

F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Component localisation

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Component localisation

F4GE9484, F4GE9484C*J601, F4GE9684

SERVICE

Engine

Compression test

F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Place on stand

F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687,

F4HE9687G*J100

Place on stand

F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Place on stand

F4GE9484, F4GE9484C*J601, F4GE9684

Place on stand

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Service instruction Maintenance Procedures

F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687,

F4HE9687G*J100

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Engine - Engine and crankcase

Engine - General specification

F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0290FA

The NEF F4HE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves

per cylinder.

They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the

working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.

NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions

provided by FPT.

Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for

which the engine has been designed.

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Engine - Engine and crankcase

General Specifications

Engine Type

4 Cylinders

6 Cylinders

Cycle

Four-Stroke diesel engine

Power

Turbocharged with intercooler

Injection

Direct

Number of cylinders

Bore

104 mm (4 in)

Stroke

132 mm (5 in)

Total Displacement

4485 cm³

6728 cm³

Timing

Start before T.D.C.

18.5 °

End after B.D.C.

29.5 °

Start before B.D.C.

67 °

End after T.D.C.

35 °

Valve Clearance

Intake

0.20 - 0.30 mm (0.008 - 0.012 in)

Exhaust

0.45 - 0.55 mm (0.018 - 0.022 in)

Fuel Feed

Injection Type

Bosch high pressure common rail

Control

EDC7 ECU

Injector

CRIU 2

Nozzle Type

DSLA and DLLA

Injection Sequence

1-3-4-2

1-5-3-6-2-4

Injection pressure

250 - 1600 bar (3625 - 23200 psi)

Aspiration

Turbocharging

Intercooled

Turbocharger Type

Holset HX35

Lubrication

Oil Pressure @ Low Idle

0.7 bar (10 psi)

Oil Pressure @ Fast Idle

3.5 bar (51 psi)

Oil Pan Capacity

15 l (15.85 US qt)

Oil Filter Capacity

1 l (1.06 US qt)

Cooling

Water Pump

Belt Driven

Thermostat

79 - 83 °C (174 - 181 °F)

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Engine - Engine and crankcase

Clearance Data

Cylinder Block and Crankshaft Components

Cylinder Barrels

104.000 - 104.024 mm (4.094 - 4.095 in)

Oversize

0.4 mm (0.016 in)

103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -

Pistons

4.086 in) (*)

Skirt Height

55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*)

Pin housing

38.010 - 38.016 mm (1.496 - 1.497 in)

Piston (oversize)

0.4 mm (0.016 in)

Protrusion

0.28 - 0.52 mm (0.011 - 0.020 in)

37.994 - 38.000 mm (1.496 - 1.496 in)

Piston Pin - Pin Housing

0.01 - 0.022 mm (0.0004 - 0.001 in)

Piston ring landings

Combustion

2.705 - 2.735 mm (0.106 - 0.108 in)

Intermediate

2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 -

0.096 in) (*)

Oil Control

4.030 - 4.050 mm (0.159 - 0.159 in)

Piston Rings

Combustion

2.560 - 2.605 mm (0.101 - 0.103 in)

Intermediate

2.350 - 2.380 mm (0.093 - 0.094 in)

Oil Control

3.970 - 3.990 mm (0.156 - 0.157 in)

Piston Ring and Ring Landing Clearance

Combustion

0.100 - 0.175 mm (0.004 - 0.007 in)

Intermediate

0.060

0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 -

0.004 in) (*)

Oil Control

0.040 - 0.080 mm (0.002 - 0.003 in)

Piston Ring End Gap

Combustion

0.30 - 0.40 mm (0.012 - 0.016 in)

Intermediate

0.60 - 0.80 mm (0.024 - 0.031 in)

Oil Control

0.30 - 0.55 mm (0.012 - 0.022 in)

Connecting Rod

Small end housing

40.987 - 41.013 mm (1.614 - 1.615 in)

Big end housing

72.987 - 73.013 mm (2.874 - 2.875 in)

Small end bushing Inside

38.019 - 38.033 mm (1.497 - 1.497 in)

Diameter

Big end bearing shell

1.955 - 1.968 mm (0.077 - 0.077 in)

thickness

Piston Pin and Bushing

0.019 - 0.039 mm (0.001 - 0.002 in)

Clearance

Oversize Big end bearing

0.250 mm (0.010 in) ; 0.500 mm (0.020 in)

Shells

Crankshaft

Main Journals

82.99 - 83.01 mm (3.267 - 3.268 in)

Crankpins

68.987 - 69.013 mm (2.716 - 2.717 in)

Main Bearing Shell Thickness

2.456 - 2.464 mm (0.097 - 0.098 in)

Big end Bearing Shell

1.955 - 1.968 mm (0.077 - 0.078 in)

Thickness

Main Bearing Bore

No. 1,5 / 1,7

87.982 - 88.008 mm (3.464 - 3.465 in)

No. 2,3,4 / 2,3,4,5,6

87.977 - 88.013 mm (3.464 - 3.465 in)

Bearing Shell and Journal Clearance

No. 1,5 / 1,7

0.041 - 0.119 mm (0.002 - 0.005 in)

No. 2,3,4 / 2,3,4,5,6

0.041 - 0.103 mm (0.002 - 0.004 in)

Bearing Shell and Crankpin

0.033 - 0.041 mm (0.001 - 0.002 in)

Clearance

Thrust Journal

37.475 - 37.545 mm (1.475 - 1.478 in)

Thrust Bearing Bore

32.180 - 32.280 mm (1.267 - 1.271 in)

(*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A

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