Iveco F4GE0454C and F4GE0484C Engines Service Manual

Iveco F4GE0454C and F4GE0484C Engines Service Manual

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Manufacturer: IVECO
Manual For: F4GE0454C and F4GE0484C  Engines
Format: PDF
Language: English
No: 9-88900

IVECO F4GE0454C and F4GE0484C Engines Service Manual – 116 Pages

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Description

IVECO F4GE0454C and F4GE0484C Engines Service Manual

Manufacturer: IVECO
Manual For: F4GE0454C and F4GE0484C  Engines
Format: PDF
Language: English
No: 9-88900

IVECO F4GE0454C and F4GE0484C Engines Service Manual – 116 Pages

How to Use this Manual

This Service Manual is applicable to the F4GE0454C and F4GE0484C  family of industrial diesel engines. Unless otherwise specified, these engines have common parts and components as well as data and specifications. Illustrations used in this Service Manual are based on the F4GE0454C and F4GE0484C engines.

1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.

2. Common technical data such as general maintenance items, service specifications, and tightening torques are included in the “General Information” section.

3. Each section is into sub-sections dealing with disassembly, inspection and repair, and reassembly. The section ENGINE ASSEMBLY is an exception. This part is divide into three sections to facilitate quick indexing.

4. When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page.

5. For the sake of brevity, self-explanatory removal and installation procedures are not mention. More complex procedures are covered in detail.

INDEX OF SECTIONS
Section 1 — Diagnostics EW–1–1
Section 2 — Engine F4GE0454C — F4GE0484G overhaul EW–2–1
Section 3 — Recharging and start–up EW–3–1

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F4GE0454C Engine . . . . . . . . . . . . . . . . EW–2–3
F4GE0484G Engines . . . . . . . . . . . . . . . EW–2–3
Coding of source engines . . . . . . . . . EW–2–4
Main engine features . . . . . . . . . . . . . . EW–2–5
General engine features . . . . . . . . . . . EW–2–6
Assembling play — specifications . . . EW–2–8
Tightening torque . . . . . . . . . . . . . . . . . EW–2–14
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–15
Graphic indications and symbols . . . EW–2–16
General remarks . . . . . . . . . . . . . . . . . . EW–2–17
F4GE0454C engine . . . . . . . . . . . . . . . . EW–2–17
F4GE0484G engines . . . . . . . . . . . . . . . EW–2–18
Description of main mechanic engine
components . . . . . . . . . . . . . . . . . . . . . . EW–2–19
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–19
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–20
Connecting rods . . . . . . . . . . . . . . . . . . . . EW–2–21
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–22
Distributing shaft . . . . . . . . . . . . . . . . . . . EW–2–23
Valve control . . . . . . . . . . . . . . . . . . . . . . . EW–2–24
F4GE0454C engine cylinder head . . . . EW–2–25
F4GE0484G engine cylinder head . . . . EW–2–26
Valves and valve seats . . . . . . . . . . . . . . EW–2–27
Valve guides . . . . . . . . . . . . . . . . . . . . . . . EW–2–28
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW–2–29
Auxiliary component drive . . . . . . . . . . . EW–2–30
Additional weights . . . . . . . . . . . . . . . . . . EW–2–31
Lubrication . . . . . . . . . . . . . . . . . . . . . . . EW–2–32
Heat exchanger . . . . . . . . . . . . . . . . . . . . EW–2–33
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–34
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–35
F4GE0484G *D660 / F4GE0454C * D660 Engines .
EW–2–35
F4GE0484G *D665 Engine . . . . . . . . . . EW–2–35
Oil vapour recirculation . . . . . . . . . . . . . . EW–2–36
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–37
Water pump . . . . . . . . . . . . . . . . . . . . . . . EW–2–38
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–39
Mechanic injection feeding system . EW–2–39
Mechanic fuel pump . . . . . . . . . . . . . . . . EW–2–40
Injection assembly . . . . . . . . . . . . . . . . EW–2–41
Version F4GE0484G . . . . . . . . . . . . . . . . EW–2–42
Engine bench–overhaul . . . . . . . . . . . . EW–2–42
Disassembling the engine . . . . . . . . . . . EW–2–42
Replacing the seal ring . . . . . . . . . . . . . . EW–2–44
Removing the injection pump . . . . . . . . . EW–2–45
Removing the rocker arm assembly . . . EW–2–47
Repair work on cylinder cluster . . . . . EW–2–50
Checks and measurements . . . . . . . . . . EW–2–50
Checking the surface supporting the head on the
cylinder cluster . . . . . . . . . . . . . . . . . . . . . EW–2–51
Checking the eccentric lift and the pin alignment . . .
EW–2–52
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . EW–2–52
Distributing shaft . . . . . . . . . . . . . . . . . . . EW–2–52
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–53
Replacing the bushings . . . . . . . . . . . . . . EW–2–54
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–54
Mounting the tappets – Distributing shaft EW–2–54
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . EW–2–55
Measuring the journals and crankpins . EW–2–55
Replacing the oil pump drive gears . . . . EW–2–58
Mounting the main bearings . . . . . . . . . . EW–2–58
Measuring the journal assembling play EW–2–58
Checking the drive shaft shoulder play . EW–2–59
Connecting rod–piston assembly . . . EW–2–60
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–61
Measuring the piston diameter . . . . . . . EW–2–61
Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW–2–62
Conditions for correct pin/piston matching EW–2–62
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . EW–2–62
Connecting rods . . . . . . . . . . . . . . . . . . . . EW–2–63
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–64
Checking the connecting rods . . . . . . . . EW–2–64
Checking the torsion . . . . . . . . . . . . . . . . EW–2–64
Checking the flexion . . . . . . . . . . . . . . . . EW–2–64
Mounting the connecting rod–piston
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–65
Connecting rod–piston match . . . . . . . . EW–2–65
Mounting the piston rings . . . . . . . . . . . . EW–2–65
Mounting the connecting rod/piston
assemblies in the cylinder liners . . . . . . EW–2–66
Measuring the crankpin assembling play EW–2–66
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–67

Distribution gearbox case . . . . . . . . . . . . EW–2–67
Checking piston protrusion . . . . . . . . . . . EW–2–67
Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW–2–68
Injection pump – 1st phase . . . . . . . . . . EW–2–69
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–69
Assembly of additional masses . . . . . . . EW–2–69
Timing of additional masses . . . . . . . . . . EW–2–70
Flywheel cover case . . . . . . . . . . . . . . . . EW–2–71
Engine flywheel . . . . . . . . . . . . . . . . . . . EW–2–72
Replacing the engine flywheel ring gear EW–2–72
Injection pump – 2nd phase . . . . . . . . . . EW–2–73
Mounting the injection pump – 2nd phase EW–2–73
Mounting the oil and water pumps . . . . EW–2–73
Mounting the water / oil heat exchanger EW–2–75
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW–2–75
Removing the valves . . . . . . . . . . . . . . . . EW–2–75
Checking the cylinder head supporting
surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–76
Checking the cylinder head water seal . EW–2–77
Valve descaling, check and grinding . . . EW–2–77
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–77
Valve seats . . . . . . . . . . . . . . . . . . . . . . . EW–2–78
Valve seat reconditioning — replacement EW–2–78
Valve guide . . . . . . . . . . . . . . . . . . . . . . . EW–2–78
Checking the play between the valve stem,
valve guide and valve centring . . . . . . . EW–2–78
Mounting the cylinder head . . . . . . . . EW–2–80
Valve springs . . . . . . . . . . . . . . . . . . . . . EW–2–80
Rocker arm assembly . . . . . . . . . . . . . . . EW–2–81
Reattaching the cylinder head . . . . . . . . EW–2–81
Mounting the injectors . . . . . . . . . . . . . . . EW–2–82
Replacing the injectors . . . . . . . . . . . . EW–2–85
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–85
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW–2–86
Rocker arm removal/reassembling . EW–2–86
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–86
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW–2–86
Adjusting the tappets . . . . . . . . . . . . . . EW–2–87

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