Vetus VF4 User manual

Service Manual
VF4.140E
VF4.170E
VF5.220E
VF5.250E
VF4
VF5
Marine Diesel Engine

2 402102.01 Service manual VF4 VF5
Copyright © 2009 Vetus N.V. Schiedam
Holland
Reproduction of text and illustrations,
in whole or in part, is strictly prohib-
ited.
The information contained in this
manual is not binding and providing
the basic specication of the model
described herein is not aected VETUS
reserve the right to introduce any
changes in their products without
obligation immediately to update this
publication .

402102.01 3
Service manual VF4 VF5
Contents
1 Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Performance curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Values and ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Cylinder head and valve gear. . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Valve timing diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Cylinder head gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Repair data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.1 Camshaft housing. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.2 Lower cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.3 Camshaft housing. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.1 Main journal identication . . . . . . . . . . . . . . . . . . . . . 41
4.3 Engine ywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4 Crankshaft phonic wheel for rpm and timing sensor replace
with crankshaft removed . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.5 Connecting rod small end bush (one) replace . . . . . . . . . . . . . 57
4.6 Set of pistons, gudgeon pins and seals (replace) . . . . . . . . . . . 59
4.7 Toothed timing belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.8 Fuel lter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.9 Engine coolant temperature sensor. . . . . . . . . . . . . . . . . . . . 66
4.10 Pressure relief sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.11 Engine rpm sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.12 Cam angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.13 Variable geometry turbocharger . . . . . . . . . . . . . . . . . . . . . 70
4.14 Pressure pump support VF4 . . . . . . . . . . . . . . . . . . . . . . . . 73
4.15 Pressure pump support VF5 . . . . . . . . . . . . . . . . . . . . . . . . 76

4 402102.01 Service manual VF4 VF5
Specications1
VF4.140E VF4.170E
Cycle Diesel 4 stroke
Valve gear With 2 camshaft on the cylinder
head
Fuel system Direct injection common rail
Number of cylinder 4 in line 4 in line
∅
Bore mm 82 82
Stroke mm 90.4 90.4
+ + + . . . =
Total displacement cm31910 1910
+
= CR
Compression ratio 18 : 1 18 : 1
Maximum output CEE
kW (CEE) 103 125
hp (CEE) 140 170
1/min 4000 4000
Maximum torque CEE
Nm (CEE) 301 345
kgm (CEE) 30.1 34.5
1/min 2400 2400

402102.01 5
Service manual VF4 VF5
VF5.220E VF5.250E
Cycle Diesel 4 stroke
Valve gear With 2 camshaft on the cylinder
head
Fuel system Direct injection common rail
Number of cylinder 5 in line 5 in line
∅
Bore mm 82 82
Stroke mm 90.4 90.4
+ + + . . . =
Total displacement cm32387 2387
+
= CR
Compression ratio 18 : 1 18 : 1
Maximum output CEE
kW (CEE) 162 184
hp (CEE) 220 250
1/min 4200 4200
Maximum torque CEE
Nm (CEE) 401 454
kgm (CEE) 40.1 45.4
1/min 2400 2600

6 402102.01 Service manual VF4 VF5
Performance curves2
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
VF4.140E VF4.170E
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
Performance curves according to ISO 8178.

402102.01 7
Service manual VF4 VF5
VF5.220E VF5.250E
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
Performance curves according to ISO 8178.

8 402102.01 Service manual VF4 VF5
Values and ts3
Crankcase3.1
Crankcase Values [mm]
1
L1
∅
L2 L
Main bearing
housing
L21.720 ÷ 21.800
L1 -
L2 -
Ø63.705 ÷ 63.718
∅
Cylinder liner seat Ø-
∅
Cylinder liner
∅
A82.000 ÷ 82.010
B82.010 ÷ 82.020
C82.020 ÷ 82.030
2
∅2
∅1
Cylinder liner
Ø1 -
Ø2 -
-
2 - 1 Cylinder liner - Crankcase -
1
23
11
10 98
7
6
5
4

402102.01 9
Service manual VF4 VF5
Crankcase Values [mm]
3
X
∅
Piston
X 8
∅
A81.920 ÷ 81.930
B81.930 ÷ 81.940
C81.940 ÷ 81.950
0.4
∅
Piston pin bore dia Ø26.006 ÷ 26.014
Ring groove
width
12.080 ÷ 2.100
22.020 ÷ 2.040
32.020 ÷ 2.040
Piston weight dierence ± 5 gr
3 - 1 Piston protrusion - Crankcase 0.014 ÷ 0.294
3 - 2
Piston protrusion - Liner -
3 - 1 Piston – Cylinder liner 0.070 ÷ 0.090
3 - 2 Piston – Cylinder liner -
4
∅
Piston pin
Ø 25.982 ÷ 25.987
0.4
4 - 3 Piston pin - Seat pin 0.012 ÷ 0.022

10 402102.01 Service manual VF4 VF5
Crankcase Values [mm]
5
L
∅
Piston ring
11.970 ÷ 1.995
21.970 ÷ 1.995
31.970 ÷ 1.990
0.4
5 - 3
Piston ring -
Ring clearance
in piston
10.105 ÷ 0.150
20.050 ÷ 0.090
30.030 ÷ 0.070
5 - 1 Piston ring gap
10.20÷ 0.35
20.60 ÷ 0.80
30.25 ÷ 0.50
5 - 2 Piston ring gap
1-
2-
3-
6
∅2
∅1
Small end bore diameter Ø1 -
Big end bore
diameter
∅2
1-
2-
3-
Connecting rod weight dierence ± 2.5 g
6
∅2
∅1
Small end bush I.D. Ø1 26.006÷ 26.014
Big end I.D. Ø2 53.897 ÷ 53.909
Connecting rod weight dierence ± 2.5 g
7
∅2∅1
Small end bush
Ø1 29.018 ÷ 29.038
∅2
25.279 ÷ 25.512

402102.01 11
Service manual VF4 VF5
Crankcase Values [mm]
4 - 7 Piston pin - Small end bush 0.018 ÷ 0.030
7 - 6 Small end bush - Bush seat 0.046 ÷ 0.099
8
L
∅2
∅1
L1
Main journal
∅1
159.994 ÷ 60.000
259.988 ÷ 59.994
359.982 ÷ 59.988
Crankpin
A50.799 ÷ 50.805
B50.793 ÷ 50.799
C50.787 ÷ 50.793
L-
L1 26.829 ÷ 26.879
9
L
∅
Main bearing
11.831 ÷ 1.837
21.836 ÷ 1.844
31.843 ÷ 1.849
0.127
9 - 8 Main bearing - Journal 0.031 ÷ 0.051
10
L
∅
Connecting rod
bearing
L
A1.527 ÷ 1.531
B1.530 ÷ 1.534
C1.533 ÷ 1.537
0.127
10 - 8 Connecting rod bearing - Pin 0.030 ÷ 0.056
11
s
Thrust washer S2.469 ÷ 2.485
0.127
11 - 8 Thrust crankshaft 0.059 ÷ 0.221

12 402102.01 Service manual VF4 VF5
Cylinder head and valve gear3.2
Cylinder head and valve gear Values [mm]
12
∅
Intake valve guide housing Ø29.600 ÷ 29.611
Exhaust valve guide housing Ø27.600 ÷ 27.611
αL
Valve housing
α
45° ±1’
45° ± 1’
LCirca 2.7
∅
Camshaft support end exhaust dia.
VF4
I43.646 ÷ 43.671
II 43.446 ÷ 43.471
III 43.246 ÷ 43.271
IV 43.046 ÷ 43.071
V30.045 ÷ 30.070
∅
Camshaft support end exhaust dia.
VF5
I43.846 ÷ 43.871
II 43.646 ÷ 43.671
III 43.446 ÷ 43.471
IV 43.246 ÷ 43.271
V43.046 ÷ 43.071
VI 30.045 ÷ 30.070
∅
Tappet housing bore dia. Ø37.010 ÷ 37.030
12
16
15
17
20
13
14
19

402102.01 13
Service manual VF4 VF5
Cylinder head and valve gear Values [mm]
13
∅2
∅1
Valve guide
Ø1
∅1
8.022 ÷ 8.040
14.010 ÷ 14.030
14.010 ÷ 14.030
0.05 - 0.10 - 0.25
13 - 12
Valve guide 0.033 ÷ 0.080
Seat in cylinder head 0.033 ÷ 0.080
14
∅2
∅1
α
Valve
Ø1 5.982 ÷ 6.000
Ø2 27.40 ÷ 27.60
α45° 30’ ± 5’
Ø1 5.972 ÷ 5.990
Ø2 25.40 ÷ 25.60
α45° 30’ ± 5’
14 - 13 Valve – Valve guide 0.030 ÷ 0.066
15
P1
P2
H1H2
Internal valve spring
P1 daN -
H1 -
P2 daN -
H2 -
16
P1
P2
H1H2
External valve spring
P1 daN 20.47 ÷ 21.84
H1 34.0
P2 daN 44.81 ÷ 47.59
H2 24.5
17
L
∅
Journal camshaft and exhaust
Ø26.000 ÷ 26.015
L19.250 ÷ 19.330
Cam lift intake / exhaust
8
8

14 402102.01 Service manual VF4 VF5
Cylinder head and valve gear Values [mm]
17 - 12
Journal camshaft - Seat in cylinder
head
VF4
I 43.600 ÷ 43.615
II 43.400 ÷ 43.415
III 43.200 ÷ 43.215
IV 43.000 ÷ 43.015
V 30.000 ÷ 30.015
Journal camshaft - Seat in cylinder
head
VF5
I 43.800 ÷ 43.815
II 43.600 ÷ 43.615
III 43.400 ÷ 43.415
IV 43.200 ÷ 43.215
V 43.000 ÷ 43.015
VI 30.000 ÷ 30.015
17-12
Journal camshaft - Cylinder head
support
radial 0.030 ÷ 0.070
axial 0.100 ÷ 0.230
19
∅
Tappet Ø36.975 ÷ 36.991
19 - 12 Tappet - Cylinder head 0.019 ÷ 0.065
20
s
Shim
0.05
S
3.25 ÷ 4.90
17 - 20
For timing check
0.50
0.50
Normal cold
0.30 ± 0.05
0.35 ± 0.05

402102.01 15
Service manual VF4 VF5
Valve timing diagram3.3
A
B
D
C
A
Intake
Opens B.T.D.T. 10°
B Closes A.B.D.C. 18.5°
C
Exhaust
Opens B.B.D.C. 40°
D Closes A.T.D.C. 9°
Cylinder head gasket3.4
Fit the cylinder head, the gasket should have the thickness indicated below in order to maintain compression
ratio within the prescribed limits:
Piston protrusion (mm) Gasket thickness (mm) Identication notches
-0.020 ÷ +0.100 0.82 ± 0.05 0
+0.101 ÷ +0.200 0.92 ± 0.05 1
+0.201 ÷ +0.295 1.02 ± 0.05 2

16 402102.01 Service manual VF4 VF5
Lubrication3.5
Lubrication Values [mm]
Lubrication circuit engine
with forced circulation, by
means of pump to gears
with cartridge lter in
series.
Oil pump: type With gears, located the
front cover crankshaft
Driving pump With a chain command
from the crankshaft
Oil pressure regulation valve Incorporated in the crank-
shaft front cover
Oil lter full ow With cartridges
Insucient oil pressure sender Electrical
Between the body pump and the
gear -
Between the gears periphery and
the body pump 0.110 ÷ 0.180
Between the superior side of the
gears and the pump cover -
Between the superior side of the
gears and the cover pump 0.016 ÷ 0.086
Between the gear and the conductor 0.30
bar
Operation pressure
temperature of
100°C
@ minimal rpm > 1 bar
@ 4000 / min > 4 ÷ 4.5 bar
@ maximum
rpm -

402102.01 17
Service manual VF4 VF5
Lubrication Values [mm]
P1
P2
H1H2
Valve spring oil
pressure regulation
P1 daN 12.19 ÷ 13.00
H1 35
P2 daN -
H2 -
Cooling system3.6
Cooling system
Cooling system circuit To circulation of coolant by means of pump command
from thermostatic switch.
Command coolant pump By means of timing belt
Engine coolant thermostat
Opening tem-
perature 74° ÷ 83°C
Fully open at 101° ÷ 105°C
Valve stroke 12 mm
Pressure for held control system 1.08 bar
Exhaust valve control on the cap of the additional
expansion tank 1.08 bar
Fuel system3.7
Fuel system VF4 VF5
Firing order 1 - 3 - 4 - 2 1 - 2 - 4 - 5 - 3
Distributor type injection pump Bosch EDC 16 C39
Calibration pressure injectors 1800 bar
Rpm minimal engine 800 ± 20 1/min
Rpm maximal engine to empty 5000 ± 20 1/min
Supercharging3.8
Supercharging (Gas exhaust turbocharger) VF4 VF5
Turbocharger to variable geometry Garret GT 17 59V Garret GT 22 56 V
Pressure of the maximum supercharging to 2400/min 1.05 bar

18 402102.01 Service manual VF4 VF5
Repair data4
Position the camshaft housing (1 a) in a vice using the tool (1b)
Undo the bolt (1 a) and remove the cam angle sensor (1b).
Camshaft housing4.1.1
Cylinder head4.1

402102.01 19
Service manual VF4 VF5
Remove plugs (1 a) and t camshaft timing tools (1b) on the cam-
shaft housing.
Check that the tools are correctly tted in the housings in the
camshaft.
Undo the bolts xing the camshaft gears (1)
Undo the bolt (1 a) and remove the exhaust side camshaft toothed
drive pulley (1b).

20 402102.01 Service manual VF4 VF5
Remove the camshaft timing tools from the cylinder head exten-
sion.
Withdraw the camshaft (1 a), as far as necessary and remove the
camshaft gears (1b)
Using a suitable drift, extract the inlet side camshaft (1 a) and plug
(1b).
Using suitable drift, extract the exhaust side camshaft (2 a) and oil
seal (2b).
Undo and remove the engine oil lubrication duct plugs (1).