New Holland F4DE9684B J111 Series User manual

Part number 47597675
1st edition English
October 2013
SERVICE MANUAL
F4CE9484 / F4CE9487A / F4CE9487N /
F4CE9684 / F4DE9484 / F4DE9684B*J111 /
F4DE9684M*J101 / F4DE9684M*J103 /
F4DE9684 / F4DE9687 / F4GE9484C*J601 /
F4GE9484 / F4GE9684 / F4HE0484G*J102 /
F4HE0484G*J109 / F4HE9484C*J102 /
F4HE9484C*J103 / F4HE9484 / F4HE9684 /
F4HE9687G*J100 / F4HE9687
NEF Tier 3
Engine
PrintedinU.S.A.
Copyright © 2013 CNH America LLC. All Rights Reserved. NewHollandisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.

Mechanical fuel injection / Structural engine bloc
k
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 bloc
k
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
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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
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.102]Panandcovers....................................................................10.2
[10.106]Valvedriveandgears..............................................................10.3
[10.101]Cylinderheads.....................................................................10.4
[10.105]Connectingrodsandpistons.......................................................10.5
[10.103]Crankshaftandywheel............................................................10.6
[10.110]Balanceranddamper..............................................................10.7
[10.114]Pumpdrives........................................................................10.8
[10.210]Liftpumpandlines.................................................................10.9
[10.206]Fuellters........................................................................10.10
[10.218]Fuelinjectionsystem.............................................................10.11
[10.250]Turbochargerandlines...........................................................10.12
[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.13
[10.400]Enginecoolingsystem...........................................................10.14
[10.414]Fananddrive....................................................................10.15
[10.304]Enginelubricationsystem........................................................10.16
[10.408]Oilcoolerandlines...............................................................10.17
Electricalsystems.......................................................................55
[55.015]Enginecontrolsystem..............................................................55.1
[55.201]Enginestartingsystem.............................................................55.2
[55.301]Alternator...........................................................................55.3
[55.202]Coldstartaid.......................................................................55.4
[55.010]Fuelinjectionsystem...............................................................55.5
[55.014]Engineintakeandexhaustsystem.................................................55.6
[55.012]Enginecoolingsystem.............................................................55.7
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[55.013]Engineoilsystem..................................................................55.8
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INTRODUCTION
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Contents
INTRODUCTION
Foreword........................................................................................3
Safetyrules.....................................................................................4
Torque..........................................................................................6
F4DE9484,F4HE9484,F4HE0484G*J109,F4HE0484G*J102,F4HE9484C*J102,F4HE9484C*J103,F4DE9684,F4DE9687,
F4HE9684,F4HE9687,F4HE9687G*J100,F4DE9684M*J101,F4DE9684M*J103,F4DE9684B*J111
Torque..........................................................................................9
F4CE9484,F4GE9484,F4CE9487N,F4CE9487A,F4GE9484C*J601,F4CE9684,F4GE9684
Specialtools..................................................................................11
F4DE9484,F4HE9484,F4HE0484G*J109,F4HE0484G*J102,F4HE9484C*J102,F4HE9484C*J103,F4DE9684,F4DE9687,
F4HE9684,F4HE9687,F4HE9687G*J100,F4DE9684M*J101,F4DE9684M*J103,F4DE9684B*J111
Specialtools..................................................................................17
F4CE9484,F4GE9484,F4CE9487N,F4CE9487A,F4GE9484C*J601,F4CE9684,F4GE9684
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INTRODUCTION
Foreword
EngineOverhaul
Partoftheoperationsillustratedwithinthismanualcanbepartiallyexecutedwhiletheengineisassembledonthe
vehicle,dependingontheroomavailableforaccesstotheengineandontheequipmentapplicationaswell.
NOTE:Withregardtotheenginedisassemblyoperations,pleaseapplyforinformationconsultingthespecicmanual.
Thefollowinginformationrelatestotheengineoverhauloperationsonlyforwhatconcernsthedifferentcomponents
customizingtheengine,accordingtoitsspecicduties.
Insection"GeneralOverhaul",alltheoperationsofengineblockoverhaulhavebeencontemplated.Thereforethe
abovementionedsectionistobeconsideredasfollowingthepartherebydescribed.
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INTRODUCTION
Safetyrules
Standardsafetyprescriptions
Particularattentionshallbedrawnonsomeprecautionsthatmustbefollowedabsolutelyinastandardworking
areaandwhosenonfulllmentwillmakeanyothermeasureuselessornotsufcienttoensuresafetytothe
personnelinchargeofmaintenance.
Beinformedandinformpersonnelaswellofthelawsinforceregulatingsafety,providinginformationdocumentation
availableforconsultation.
•Keepworkingareasascleanaspossible,ensuringadequateaeration.
•Ensurethatworkingareasareprovidedwithemergencyboxes,thatmustbeclearlyvisibleandalwaysprovided
withadequatesanitaryequipment.
•Provideforadequatereextinguishingmeans,properlyindicatedandalwayshavingfreeaccess.Theirefciency
mustbecheckedonaregularbasisandthepersonnelmustbetrainedoninterventonmethodsandpriorities.
•Organizeandidentifyspecicexitpointstoevacuatetheareasincaseofanemergency,providingforadequate
indicationsoftheemergencyindicationsoftheemergencyexitlines.
•Smokinginworkingareassubjecttoredangermustbestrictlyprohibited.
•Providewarningsthroughoutadequateboardssignalingdanger,prohibitionsandindicationstoensureeasycom-
prehensionoftheinstructionsevenincaseofanemergency.
Preventionofinjury
•Donotwearunsuitableclothesforwork,withutteringends,norjewelssuchasandchainswhenworkingcloseto
enginesandequipmentinmotion.
•Wearsafetyglovesandgoggleswhenperformingthefollowingoperations:
••llinginhibitorsoranti-frost
•lubricationoiltoppingorreplacement
•utilizationofcompressedairorliquidsunderpressure(pressureallowed<2
bar(29 psi)).
•Wearsafetyhelmetwhenworkingclosetohangingloadsorequipmentworkingatheadheightlevel.
•Alwayswearsafetyshoesandclothesadheringtothebody,betterifprovidedwithelasticsattheends.
•Useprotectioncreamforhands.
•Changewetclothesassoonaspossible.
•Inpresenceofelectricalcurrentexceeding48-60
Vverifyefciencyofearthandmasselectricalconnections.
Ensurethathandsandfeetaredryandexecuteworkingoperationsutilizingisolatingfootboards.Donotcarryout
workingoperationsifnottrainedfor.
•Donotsmokenorlightupamesclosetobatteriesandtoanyfuelmaterial.
•Putthedirtyragswithoil,dieselfuelorsolventsinanti-respeciallyprovidedcontainers.
•Donotexecuteanyinterventionifnotprovidedwithnecessaryinstructions.
•Donotuseanytoolorequipmentforanydifferentoperationfromtheonesthey'vebeendesignedandprovidedfor.
Seriousinjurymayoccur.
•Incaseoftestorcalibrationoperationsrequiringenginerunning,ensurethattheareaissufcientlyventilatedor
utilizespecicvacuumequipmenttoeliminateexhaustgas.Danger:poisoningordeath.
Duringmaintenance
•Neveropenllercapofcoolingsystemwhentheengineishot.Operatingpressurewouldprovokehightemperature
withseriousdangerandriskofburn.Waituntilthetemperaturedecreasesunder50
°C(122 °F).
•Nevertopupanoverheatedenginewithcoolerandutilizeonlyappropriateliquids.
•Alwaysoperatewhentheengineistunedoff;whenparticularcircumstancesrequiremaintenanceinterventionon
runningengine,beawareofallrisksinvolvedwithsuchoperation.
•Beequippedwithadequateandsafecontainersfordrainageoperationofengineliquidsandexhaustoil.
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INTRODUCTION
•Keeptheenginecleanfromoilspills,dieselfuelandorchemicalsolvents.
•Useofsolventsordetergentsduringmaintenancemayoriginatetoxicvapors.Alwayskeepworkingareasventi-
lated.Whenevernecessarywearsafetymask.
•Donotleaveragsimpregnatedwithammablesubstancesclosetotheengine.
•Uponenginestartaftermaintenance,undertakeproperpreventingactionstostopairsuctionincaseofarunaway
speedrate.
•Donotutilizefastscrewtighteningtools.
•Neverdisconnectbatterieswhentheengineisrunning.
•Disconnectbatteriesbeforeanyinterventionontheelectricalsystem.
•Disconnectbatteriesfromsystembeforeapplyingaloadtothemwiththebatteryloader.
•Aftereveryintervention,verifythatbatteryclamppolarityiscorrectandthattheclampsaretightandsafefrom
accidentalshortcircuitandoxidation.
•Donotdisconnectandconnectelectricalconnectionsinpresenceofelectricalfeed.
•Beforeproceedingwithpipelinesdisassembly(pneumatic,hydraulic,fuelpipes)verifypresenceofliquidorair
underpressure.T akeallnecessaryprecautionsbleedinganddrainingresidualpressureorclosingdumpvalves.
Alwayswearadequatesafetymaskorgoggles.Nonfulllmentoftheseprecautionsmaycauseseriousinjuryand
poisoning.
•Avoidincorrecttighteningoroutofsequence.Danger:incorrecttighteningmayseriouslydamageengine'scom-
ponents,affectingengine'sduration.
•Avoidprimingfromfueltanksmadeoutofcopperalloysand/orwithductsnotbeingprovidedwithlters.
•Donotmodifycablewires:theirlengthsshallnotbechanged.
•DonotconnecttotheengineelectricalequipmentunlessspecicallyapprovedbyIveco.
•DonotmodifyfuelsystemsorhydraulicsystemunlessIvecospecicapprovalhasbeenreleased.Anyunauthorized
modicationwillcompromisewarrantyassistanceandfurthermoremayaffectenginecorrectworkingandduration.
Forenginesequippedwithelectroniccontroller:
•Donotexecuteelectricarcweldingwithouthavingpreviouslyremovedelectroniccontroller.
•Removeelectroniccontrollerincaseofanyinterventionrequiringheatingover80
°C(176 °F)temperature.
•Donotpaintthecomponentsandtheelectronicconnections.
•Donotvaryoralteranydataledintheelectroniccontrollerdrivingtheengine.Anymanipulationoralteration
ofelectroniccomponentsshalltotallycompromiseengineassistancewarrantyandfurthermoremayaffectengine
correctworkingandduration.
RespectoftheEnvironment
•RespectoftheEnvironmentshallbeofprimaryimportance:allnecessaryprecautionstoensurepersonnel'ssafety
andhealthshallbeadopted.
•Beinformedandinformpersonnelaswellofthelawsinforceregulatinguseandexhaustofliquidsandengine
drainoil.Provideforadequateboardindicationsandorganicspecictrainingcoursestoensurethatpersonnelis
fullyawareofsuchlawprescriptionsandofbasicpreventativesafetymeasures.
•Collectdrainoilsinadequatespeciallyprovidedcontainerswithhermeticsealingensuringthatstorageismadein
specic,properlyidentiedareasthatshallbeventilatedfarfromheatsourcesandnotexposedtoredanger,
•Handlethebatterieswithcare,storingtheminventilatedenvironmentandwithinanti-acidcontainers.Warning:
Batteryexhalationrepresentseriousdangerofintoxicationandenvironmentcontamination.
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INTRODUCTION
Torque
F4DE9484,F4HE9484,F4HE0484G*J109,F4HE0484G*J102,F4HE9484C*J102,F4HE9484C*J103,F4DE9684,F4DE9687,F4HE9684,F4HE9687,
F4HE9687G*J100,F4DE9684M*J101,F4DE9684M*J103,F4DE9684B*J111
ComponentSizeSpecication
CylinderHeadandComponents
Plug¼"10-14
Nm(7.4-10.3 lbft)
½"20-28
Nm(14.8-20.7 lbft)
¾"31-41
Nm(22.9-30.2 lbft)
GridHeaterM6Nut6-10
Nm(4.4-7.4 lbft)
IntakeManifoldM8Screw20-28
Nm(14.8-20.7 lbft)
EngineLiftingBracket
RearM1265-89
Nm(47.9-65.6 lbft)
FrontM820-28
Nm(14.8-20.7 lbft)
CylinderHeadM12x1.75x130
mm
FirstPhase30-40
Nm(22.1-29.5 lbft)
SecondPhase85-95
°
ThirdPhase85-95
°
CylinderHeadM12x1.75x150
mm
FirstPhase50-60
Nm(36.9-44.3 lbft)
SecondPhase85-95
°
ThirdPhase85-95
°
RockerBracket31-41
Nm(22.9-30.2 lbft)
RockerArmJamNuts20-28
Nm(14.8-20.7 lbft)
ExhaustManifold48-58
Nm(35.4-42.8 lbft)
ValveCoverM8Nut20-28
Nm(14.8-20.7 lbft)
Turbocharger
6CylinderM8Screw6-8
Nm(4.4-5.9 lbft)
M8Nut37-49
Nm(27.3-36.1 lbft)
4CylinderM8Screw6-8
Nm(4.4-5.9 lbft)
M8Nut20-28
Nm(14.8-20.7 lbft)
FrontCase
FrontCoverM8Screw20-28
Nm(14.8-20.7 lbft)
RearCase
GearCaseM12Screw65-89
Nm(47.9-65.6 lbft)
M10Screw42-52
Nm(31.0-38.4 lbft)
M8Screw20-28
Nm(14.8-20.7 lbft)
FlywheelHousingM1075-95
Nm(55.3-70.1 lbft)
M1244-54
Nm(32.5-39.8 lbft)
CylinderBlockandCrankshaftComponents
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INTRODUCTION
ComponentSizeSpecication
CamshaftRetainingPlateM8Screw20-28
Nm(14.8-20.7 lbft)
CamshaftGearM8Screw32-40
Nm(23.6-29.5 lbft)
CrankcasePlateM10Screw38-48
Nm(28.0-35.4 lbft)
VibrationDamperandAdapterM12
FirstPhase45-55
Nm(33.2-40.6 lbft)
SecondPhase90
°
DrivePulleyM1061-75
Nm(45.0-55.3 lbft)
EngineFlywheelM12
FirstPhase26-34
Nm(19.2-25.1 lbft)
SecondPhase55-65
°
MainCapsM12
FirstPhase44-56
Nm(32.5-41.3 lbft)
SecondPhase74-86
Nm(54.6-63.4 lbft)
ThirdPhase85-95
°
ConnectingRodCaps
FirstPhase55-65
Nm(40.6-47.9 lbft)
SecondPhase55-65
°
LubricationSystemandComponents
OilPump
FirstPhaseM87-9
Nm(5.2-6.6 lbft)
SecondPhaseM820-28
Nm(14.8-20.7 lbft)
OilPressureReliefValveM2272-88
Nm(53.1-64.9 lbft)
OilCoolerandOilFilterBaseM8Screw20-28
Nm(14.8-20.7 lbft)
OilFilterContact+¾Turn
ConnectiononFilterBaseforTurboOil
Supply
1⅛"20-28
Nm(14.8-20.7 lbft)
TurboLubricationPipeM12Nut8-12
Nm(5.9-8.9 lbft)
TurboLubricationPipeAdapterM1230-40
Nm(22.1-29.5 lbft)
OilPan20-28
Nm(14.8-20.7 lbft)
PistonSprayNozzlesM812-18
Nm(8.9-13.3 lbft)
ElectricalComponents
CamshaftSensorM6Studs6-10
Nm(4.4-7.4 lbft)
M6Nut8-12
Nm(5.9-8.9 lbft)
M6Screw6-10
Nm(4.4-7.4 lbft)
WiringBulkheadM6Screw8-12
Nm(5.9-8.9 lbft)
SupportBracketforInjectorWiringM8Screw20-28
Nm(14.8-20.7 lbft)
InjectorWiring1.25-1.75
Nm(0.92-1.29 lbft)
ECUCoolingPlateM6Screw8-12
Nm(5.9-8.9 lbft)
M8Screw20-28
Nm(14.8-20.7 lbft)
FuelOutletM1210-14
Nm(7.4-10.3 lbft)
FuelInletM1210-14
Nm(7.4-10.3 lbft)
CrankshaftSpeedSensorM6Screw6-10
Nm(4.4-7.4 lbft)
CoolantTemperatureSensorM14Screw17-23
Nm(12.5-17.0 lbft)
OilPressure/T emperatureSensorM5Screw5-7
Nm(3.7-5.2 lbft)
FuelPressureSensor30-40
Nm(22.1-29.5 lbft)
FuelTemperatureSensorM1417-23
Nm(12.5-17.0 lbft)
AirPressure/T emperatureSensor5-7
Nm(3.7-5.2 lbft)
EngineOilLevelSensorM1210-14
Nm(7.4-10.3 lbft)
AlternatorSupportBracketM10Screw37-49
Nm(27.3-36.1 lbft)
AlternatorTensionBracketM10Screw37-49
Nm(27.3-36.1 lbft)
Starter37-49
Nm(27.3-36.1 lbft)
FuelSystemandComponents
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7

INTRODUCTION
ComponentSizeSpecication
FeedPumpM8Studs10-14
Nm(7.4-10.3 lbft)
HighPressurePumpGearM18Nut100-110
Nm(73.8-81.1 lbft)
FuelPumpM8Nut20-28
Nm(14.8-20.7 lbft)
Injector
FirstPhaseM6Screw8.15-8.85
Nm(6.0-6.5 lbft)
SecondPhaseM6Screw70-80
°
InjectorFeedConnector45-55
Nm(33.2-40.6 lbft)
CommonRailM8Screw20-28
Nm(14.8-20.7 lbft)
HighPressureFuelLineM14Fitting18-22
Nm(13.3-16.2 lbft)
HighPressurePipeConnectorM8Screw20-28
Nm(14.8-20.7 lbft)
FuelFilterBracketM12Screw71-85
Nm(52.4-62.7 lbft)
FuelFilterHolderM8Screw20-28
Nm(14.8-20.7 lbft)
FuelFilterContact+¾Turn
CoolingSystemandComponents
EngineCoolantInletM10Screw37-49
Nm(27.3-36.1 lbft)
FittingonCoolantInlet90
°Elbow20-28 Nm(14.8-20.7 lbft)
CompressorCoolingPipe20-24
Nm(14.8-17.7 lbft)
EngineCoolantDrainCollectorM6Screw8-12
Nm(5.9-8.9 lbft)
WaterPumpM8Screw20-28
Nm(14.8-20.7 lbft)
BeltT ensionerM1037-49
Nm(27.3-36.1 lbft)
IdlerPulleysM1037-49
Nm(27.3-36.1 lbft)
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INTRODUCTION
Torque
F4CE9484,F4GE9484,F4CE9487N,F4CE9487A,F4GE9484C*J601,F4CE9684,F4GE9684
ComponentSizeSpecication
CylinderHeadandComponents
RockerAssemblyM820-28
Nm(14.8-20.7 lbft)
CylinderHeadM12x70
Phase150
Nm(36.9 lbft)
Phase290
°
CylinderHeadM12x140
Phase140
Nm(29.5 lbft)
Phase2180
°
CylinderHeadM12x180
Phase170
Nm(51.6 lbft)
Phase2180
°
ValveCoverM8x1.25x2520-28
Nm(14.8-20.7 lbft)
IntakemanifoldM8x1.2520-28
Nm(14.8-20.7 lbft)
AirintakeelbowM8x1.2520-28
Nm(14.8-20.7 lbft)
ExhaustmanifoldM10x1.5x6537-49
Nm(27.3-36.1 lbft)
RearliftingbracketM12x1.75x3065-89
Nm(47.9-65.6 lbft)
TurbochargerM1037-49
Nm(27.3-36.1 lbft)
FrontCase
FrontcoverassemblyM8x1.25x4520-28
Nm(14.8-20.7 lbft)
M8x1.25x3020-28
Nm(14.8-20.7 lbft)
RearCase
GearCaseM8x1.25x4020-28
Nm(14.8-20.7 lbft)
M8x1.25x2520-28
Nm(14.8-20.7 lbft)
M10x1.544-54
Nm(32.5-39.8 lbft)
FlywheelhousingM12x12075-95
Nm(55.3-70.1 lbft)
M12x8075-95
Nm(55.3-70.1 lbft)
M10x8044-54
Nm(32.5-39.8 lbft)
M10x4044-54
Nm(32.5-39.8 lbft)
Phase1M12x1.2526-34
Nm(19.2-25.1 lbft)
Phase2M12x1.2555-65
°
CylinderBlockandCrankshaftComponents
Mainbearingcap
Phase144-56
Nm(32.5-41.3 lbft)
Phase274-86
Nm(54.6-63.4 lbft)
Phase385-95
°
ConnectingrodM11x1.25
Phase127-33
Nm(19.9-24.3 lbft)
Phase255-65
Nm(40.6-47.9 lbft)
Phase355-65
°
TimingPin4-6
Nm(3.0-4.4 lbft)
CrankshaftpulleyM12x1.75105-115
Nm(77.4-84.8 lbft)
CamshaftretainingplateM820-28
Nm(14.8-20.7 lbft)
CamshaftgearM832-40
Nm(23.6-29.5 lbft)
LubricationSystemandComponents
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INTRODUCTION
ComponentSizeSpecication
PistonCoolingNozzlesM8x1.25x1012-18
Nm(8.9-13.3 lbft)
OilpumpM8x1.25x307-9
Nm(5.2-6.6 lbft)
StiffeningPlateM10x1.25x2538-48
Nm(28.0-35.4 lbft)
OilplugM10x15-7
Nm(3.7-5.2 lbft)
M14x1.59-13
Nm(6.6-9.6 lbft)
OilPickuptubeM8x1.25x2020-28
Nm(14.8-20.7 lbft)
OilPanM8x1.25x2520-28
Nm(14.8-20.7 lbft)
M18x1.5051-69
Nm(37.6-50.9 lbft)
OilBypassValveM22x1.5x1072-88
Nm(53.1-64.9 lbft)
TurboLubricationLines
TurboendM12x1.520-28
Nm(14.8-20.7 lbft)
Filterbaseend20-28
Nm(14.8-20.7 lbft)
DrainM8x1.25x1620-28
Nm(14.8-20.7 lbft)
ElectricalComponents
Alternator
M8x1.25x3020-28
Nm(14.8-20.7 lbft)
M10x1.25x2520-28
Nm(14.8-20.7 lbft)
M1044-54
Nm(32.5-39.8 lbft)
M12x1.75x12037-49
Nm(27.3-36.1 lbft)
AlternatorwiringM6x1.0nut8-11
Nm(5.9-8.1 lbft)
StarterM1054-44
Nm(39.8-32.5 lbft)
FuelSystemandComponents
FuelpumpM8screw20-28
Nm(14.8-20.7 lbft)
M6screw9-11
Nm(6.6-8.1 lbft)
M6nut9-11
Nm(6.6-8.1 lbft)
FuelPumpDriveGear
Phase115-20
Nm(11.1-14.8 lbft)
Phase285-90
Nm(62.7-66.4 lbft)
TimingPinCap30-35
Nm(22.1-25.8 lbft)
Fuelinjectors55-65
Nm(40.6-47.9 lbft)
Fuelliftpump20-28
Nm(14.8-20.7 lbft)
CoolingSystemandComponents
WaterPumpM8x1.25x2520-28
Nm(14.8-20.7 lbft)
WateroutletconnectionM8x1.25x3520-28
Nm(14.8-20.7 lbft)
M8x1.25x7020-28
Nm(14.8-20.7 lbft)
FansupportM10x1.5x2028-38
Nm(20.7-28.0 lbft)
FanpulleyM68-12
Nm(5.9-8.9 lbft)
M1027-49
Nm(19.9-36.1 lbft)
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10

INTRODUCTION
Specialtools
F4DE9484,F4HE9484,F4HE0484G*J109,F4HE0484G*J102,F4HE9484C*J102,F4HE9484C*J103,F4DE9684,F4DE9687,F4HE9684,F4HE9687,
F4HE9687G*J100,F4DE9684M*J101,F4DE9684M*J103,F4DE9684B*J111
ToolNo.DescriptionImage
380000301Revolvingenginestand
REVOLVINGSTAND1
380000665Crankshaftfrontsealpuller
FRONTSEALPULLER2
380000663Crankshaftrearsealpuller
REARSEALPULLER3
380001099Injectorpuller
INJECTORPULLER4
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11

INTRODUCTION
ToolNo.DescriptionImage
380000666Crankshaftfrontseal
installer
FRONTSEALINSTAL5
380000664Crankshaftrearseal
installer
CRANKREARSEALIN6
380000670Oillterwrench
OILFILTERWRENCH7
380000302Valvespringcompressor
VALVESPRINGCOMP8
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12

INTRODUCTION
ToolNo.DescriptionImage
380000221Pliersforremoving/retting
pistonrings65-110
mm
(2.559-4.331
in)
PISTONRINGPLIER9
380000667Beaterforremoving/retting
camshaftbushes
CAMBUSHBEATER10
380000362Toolforliftingthecrankshaft
CRANKHOIST11
380000216Engineliftingrig
ENGINEHOIST12
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13

INTRODUCTION
ToolNo.DescriptionImage
380000661Bracketsforfasteningthe
enginetotherevolving
stand
STANDBRACKETS13
380000669Sealremover
SEALREMOVER14
380000668Handgripfor
interchangeablebeaters
HANDGRIP15
380000364Gaugebasefordialindicator
GAUGEBASE16
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