Steyr f4 dfe413r tier 4b (final) engine service repair manual

SERVICEMANUAL
Engine
NEF
Tier 4 (final)
SERVICE MANUAL
NEF
Tier 4B (final)
Engine
See the following page for engine model numbers
Copyright © 2014 CNH Industrial America LLC. All Rights Reserved.
Part number 47606132
1st
edition English
August 2014
Part number 47606132

SERVICE MANUAL
F4DFE4131*B001 , F4DFE4131*B002 , F4DFE4132*B001 , F4DFE4132*B002 ,
F4DFE413R*B001 , F4DFE413S*B001 , F4DFE413T*B001 , F4DFE413U*B001 ,
F4DFE6132*B001 , F4DFE613B*B001 , F4DFE613B*B002 , F4DFE613B*B003 ,
F4DFE613B*B005 , F4DFE613B*B006 , F4DFE613H*B001 , F4DFE613H*B002 ,
F4DFE613H*B003 , F4DFE613J*B001 , F4DFE613J*B002 , F4DFE613J*B003 ,
F4DFE613J*B005 , F4DFE613J*B006 , F4DFE613K*B001 , F4DFE613K*B002 ,
F4DFE613K*B003 , F4DFE613K*B004 , F4DFE613K*B006 , F4DFE613K*B007 ,
F4DFE613K*B008 , F4DFE613L*B001 , F4DFE613M*B001 , F4DFE613M*B002 ,
F4DFE613M*B003 , F4DFE613N*B001 , F4DFE613N*B002 , F4DFE613N*B003 ,
F4DFE613N*B005 , F4DFE613N*B006 , F4DFE613P*B001 , F4DFE613P*B002 ,
F4DFE613P*B003 , F4HFE413H*B001 , F4HFE413H*B002 , F4HFE413L*B001 ,
F4HFE413M*B001 , F4HFE413N*B001 , F4HFE413P*B001 , F4HFE413V*B001 ,
F4HFE413W*B001 , F4HFE413X*B001 , F4HFE413Y*B001 , F4HFE6133*B001 ,
F4HFE6135*B001 , F4HFE613A*B001 , F4HFE613A*B002 , F4HFE613B*B001 ,
F4HFE613B*B002 , F4HFE613B*B003 , F4HFE613B*B005 , F4HFE613B*B006 ,
F4HFE613C*B001 , F4HFE613C*B002 , F4HFE613C*B004 , F4HFE613C*B006 ,
F4HFE613D*B001 , F4HFE613E*B001 , F4HFE613F*B001 , F4HFE613F*B002 ,
F4HFE613F*B004 , F4HFE613G*B001 , F4HFE613G*B002 , F4HFE613H*B001 ,
F4HFE613H*B003 , F4HFE613J*B001 , F4HFE613J*B002 , F4HFE613J*B004 ,
F4HFE613J*B005 , F4HFE613K*B001 , F4HFE613K*B002 , F4HFE613R*B001 ,
F4HFE613R*B002 , F4HFE613R*B005 , F4HFE613R*B006 , F4HFE613S*B001 ,
F4HFE613S*B002 , F4HFE613S*B003 , F4HFE613S*B004 , F4HFE613T*B001 ,
F4HFE613T*B002 , F4HFE613T*B005 , F4HFE613T*B006 , F4HFE613U*B001 ,
F4HFE613U*B002 , F4HFE613W*B001 , F4HFE613W*B002 , F4HFE613W*B003
, F4HFE613W*B005 , F4HFE613W*B006 , F4HFE613X*B001 , F4HFE613Y*B001
, F4HFE613Y*B002 , F4HFE613Y*B003 , F4HFE613Z*B001 , F4HFE613Z*B002
47606132 25/08/2014
EN

Contents
INTRODUCTION
Engine....................................................................................... 10
[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
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment ......................... 10.14
[10.400] Engine cooling system ........................................................... 10.15
[10.414] Fan and drive .................................................................... 10.16
[10.304] Engine lubrication system........................................................ 10.17
[10.408] Oil cooler and lines............................................................... 10.18
Electrical systems....................................................................... 55
[55.100] Harnesses and connectors......................................................... 55.1
[55.015] Engine control system.............................................................. 55.2
[55.201] Engine starting system ............................................................. 55.3
[55.301] Alternator........................................................................... 55.4
[55.202] Cold start aid ....................................................................... 55.5
[55.010] Fuel injection system............................................................... 55.6
47606132 25/08/2014

[55.014] Engine intake and exhaust system................................................. 55.7
[55.988] Selective Catalytic Reduction (SCR) electrical system ............................ 55.8
[55.012] Engine cooling system ............................................................. 55.9
[55.013] Engine oil system ................................................................ 55.10
[55.640] Electronic modules ............................................................... 55.11
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INTRODUCTION
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1

INTRODUCTION
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your CNH Sales and Service Networks.
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3

INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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4

INTRODUCTION
Safety rules - Ecology and the environment
Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment
of some of the substances required by advanced technology, sound judgment should govern the use and disposal of
products of a chemical and petrochemical nature.
NOTE: The following are recommendations that may be of assistance:
• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these
substances.
• Agricultural consultants will, in many cases, be able to help you as well.
Helpful hints
• Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be
harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper
way to comply with local legislation and available resources.
• Do not allow coolant mixtures to get into the soil Collect and dispose of coolant mixtures properly.
• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.
Your CNH dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the
system properly.
• Repair any leaks or defects in the engine cooling or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of
oils, coolant, etc.
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5

INTRODUCTION
Basic instructions - Shop and Assembly
Shimming
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up
the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value
indicated on each shim.
Rotating shaft seals
For correct rotating shaft seal installation, proceed as follows:
• before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
• thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
• position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction
and position the grooves so that they will deviate the fluid towards the inner side of the seal.
• coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
• insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
• whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes contact
with the thrust element, if required.
• to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
O-Ring seals
Lubricate the O-RING seals before inserting them in the seats, this will prevent them from overturning and twisting,
which would jeopardise sealing efficiency.
Sealing compounds
Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or
LOCTITE® RTV 598™ or LOCTITE® INSTANT GASKET 587™ BLUE. Before applying the sealing compound, prepare
the surfaces as directed on product container or as follows:
• remove any incrustations using a metal brush.
• thoroughly de-grease the surfaces using a locally approved cleaning agent such as safety solvent or brake parts
cleaner.
Spare parts
Only use "CNH Original Parts" or " CNH Parts".
Only genuine spare parts guarantee the same quality, duration and safety as original parts, as they are the same
parts that are assembled during standard production. Only "CNH Original Parts" or " CNH Parts" can offer this
guarantee.
When ordering spare parts, always provide the following information:
• machine model (commercial name) and serial number
• part number of the ordered part, which can be found in the "Microfiches" or the "Service Parts Catalogue", used for
order processing
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14

INTRODUCTION
Protecting the electronic/electrical system during charging or welding
To avoid damage to the electronic/electrical systems, always observe the following:
1. Never make or break any of the charging circuit connections, including the battery connections, when the engine
is running.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the combine or on any header
attached to the combine.
• position the welder ground clamp as close to the welding area as possible
• if welding in close proximity to a computer module, then the module should be removed from the combine
• never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding
is in progress
4. Always disconnect the negative cable from the battery when charging the battery in the combine with a battery
charger.
NOTICE: If welding must be performed on the unit, either the combine or the header (if it is attached), the battery
ground cable must be disconnected from the combine battery. The electronic monitoring system and charging system
will be damaged if this is not done.
Remove the battery ground cable. Reconnect the cable when welding is completed.
WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A
Tools
The tools that CNH suggests and illustrate in this manual have been:
• specifically researched and designed for use with CNH machines
• essential for reliable repair operations
• accurately built and rigorously tested so as to offer efficient and long-lasting operation
By using these tools, repair personnel will benefit from:
• operating in optimal technical conditions
• obtaining the best results
• saving time and effort
• working in safe conditions
NOTE: The terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from
the rear, facing in the direction of travel of the machine during operation.
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15

INTRODUCTION
Basic instructions - Shop and assembly
Shimming
For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a microm-
eter, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or
the rated value shown on each shim.
Rotating shaft seals
For correct rotating shaft seal installation, proceed as follows:
1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
3. Position the sealing lip facing the fluid.
NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that
they will move the fluid towards the inner side of the seal.
4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that
the seal makes contact with the thrust element, if required.
7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts or CNH Original Parts.
Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same
parts that are assembled during standard production. Only CNH Original Parts or CNH Original Parts can offer this
guarantee.
When ordering spare parts, always provide the following information:
• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
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16

INTRODUCTION
Protecting the electronic and/or electrical systems during charging and welding
To avoid damage to the electronic and/or electrical systems, always observe the following practices:
1. Never make or break any of the charging circuit connections when the engine is running, including the battery
connections.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine
attachment.
• Position the welder ground clamp as close to the welding area as possible.
• If you weld in close proximity to a computer module, then you should remove the module from the machine.
• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you
weld.
4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery
charger.
NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.
The electronic monitoring system and charging system will be damaged if this is not done.
5. Remove the battery ground cable. Reconnect the cable when you complete welding.
WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
W0111A
Special tools
The special tools that CNH suggests and illustrate in this manual have been specifically researched and designed for
use with CNH machines. The special tools are essential for reliable repair operations. The special tools are accurately
built and rigorously tested to offer efficient and long-lasting operation.
By using these tools, repair personnel will benefit from:
• Operating in optimal technical conditions
• Obtaining the best results
• Saving time and effort
• Working in safe conditions
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17

SERVICE MANUAL
Engine
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10

Contents
Engine - 10
[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
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment ........................... 10.14
[10.400] Engine cooling system ............................................................. 10.15
[10.414] Fan and drive ...................................................................... 10.16
[10.304] Engine lubrication system.......................................................... 10.17
[10.408] Oil cooler and lines................................................................. 10.18
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10

CONSUMABLES INDEX
Consumable Reference PAGE
Loctite® 5205 Engine block cover Front - Cleaning 10.2 / 9
Loctite® 5205 Engine block cover Rear - Cleaning 10.2 / 14
Loctite® 518™ Gasket
Eliminator®
Engine block cover Rear - Cleaning 10.2 / 17
Loctite® 5205 Timing gear housing - Cleaning 10.2 / 20
Loctite® 5205 Timing gear housing - Cleaning 10.2 / 23
Molykote® G-N Metal
assembly paste
Cylinder head - Install 10.4 / 11
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10

Engine - 10
Engine and crankcase - 001
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10.1 [10.001] / 1

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10.1 [10.001] / 1

Engine - Engine and crankcase
Engine - General specification
General specifications
Engine type 4 Cylinders 6 Cylinders
Cycle Four-Stroke diesel engine
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6
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 EDC17 CV41
Injector CRIN 2
Nozzle type 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 Honeywell GT25 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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10.1 [10.001] / 3

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)
Pistons 103.739 - 103.757 mm (4.084 - 4.085 in) (*)
Skirt height 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)
Pin 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 2.420 - 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
diameter
38.019 - 38.033 mm (1.497 - 1.497 in)
Big end bearing shell
thickness
1.955 - 1.968 mm (0.077 - 0.077 in)
Piston pin and bushing
clearance
0.019 - 0.039 mm (0.001 - 0.002 in)
Oversize big end bearing
shells
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
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
thickness
1.955 - 1.968 mm (0.077 - 0.078 in)
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
clearance
0.033 - 0.041 mm (0.001 - 0.002 in)
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)
Thrust bearing 37.28 - 37.38 mm (1.468 - 1.472 in)
Crankshaft end play 0.095 - 0.265 mm (0.004 - 0.010 in)
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10.1 [10.001] / 4

Clearance data
Cylinder head and components
Valve guide bore 7.042 - 7.062 mm (0.277 - 0.278 in)
Intake valves
Stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Face angle 59.75 - 60.25 °
Exhaust valves
Stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Face angle 44.75 - 44.25 °
Valve stem and guide clearance 0.052 - 0.092 mm (0.002 - 0.004 in)
Valve seat bore
Intake 34.837 - 34.863 mm (1.372 - 1.373 in)
Exhaust 34.837 - 34.863 mm (1.372 - 1.373 in)
Valve seat outside diameter:
Intake 34.917 - 34.931 mm (1.375 - 1.375 in)
Exhaust 34.917 - 34.931 mm (1.375 - 1.375 in)
Valve seat angle
Intake 60 °
Exhaust 45 °
Valve sink
Intake 0.59 - 1.11 mm (0.023 - 0.044 in)
Exhaust 0.96 - 1.48 mm (0.038 - 0.058 in)
Interference between valve seat and cylinder head
Intake 0.054 - 0.094 mm (0.002 - 0.004 in)
Exhaust 0.054 - 0.094 mm (0.002 - 0.004 in)
Valve spring height
Free 47.75 mm (1.880 in)
Under a load equal to:
330.8 - 348.8 N (74.4 -
78.4 lb)
35.33 mm (1.391 in)
Under a load equal to:
702 - 780 N (157.8 - 175.4 lb) 25.2 mm (0.992 in)
Camshaft bore
No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in)
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in)
Bushing and journal clearance 0.038 - 0.162 mm (0.001 - 0.006 in)
Cam lift
Intake 7.582 mm (0.299 in)
Exhaust 6.045 mm (0.238 in)
Tappet bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Tappet outside diameter
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Tappets and bore clearance 0.025 - 0.070 mm (0.001 - 0.003 in)
Rocker shaft 21.965 - 21.977 mm (0.865 - 0.865 in)
Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
Rockers and shaft clearance 0.024 - 0.162 mm (0.001 - 0.006 in)
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Engine - General specification
F4DFE4131*B001
F4DFE4131*B002
F4DFE4132*B001
F4DFE4132*B002
F4DFE4133*B001
F4DFE4133*B002
F4DFE4134*B001
F4DFE4134*B002
F4DFE413R*B001
F4DFE413S*B001
F4DFE413T*B001
F4DFE413U*B001
F4DFE6132*B001
F4DFE613B*B001
F4DFE613B*B002
F4DFE613B*B003
F4DFE613B*B005
F4DFE613B*B006
F4DFE613H*B001
F4DFE613H*B002
F4DFE613H*B003
F4DFE613J*B001
F4DFE613J*B002
F4DFE613J*B003
F4DFE613J*B005
F4DFE613J*B006
F4DFE613K*B001
F4DFE613K*B002
F4DFE613K*B003
F4DFE613K*B004
F4DFE613K*B006
F4DFE613K*B007
F4DFE613K*B008
F4DFE613L*B001
F4DFE613M*B001
F4DFE613M*B002
F4DFE613M*B003
F4DFE613N*B001
F4DFE613N*B002
F4DFE613N*B003
F4DFE613N*B005
F4DFE613N*B006
F4DFE613P*B001
F4DFE613P*B002
F4DFE613P*B003
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F4DECOMPLETE 1
The NEF F4DFE engines are turbocharged, four-stroke diesel engines with four or six cylinders and with four valves
per cylinder.
The NEF F4DFE engines have high-pressure fuel injection (common rail system). The control of the NEF F4DFE
engines is fully electronic in order to optimize the working process. The control of the NEF F4DFE engines also takes
into account the operating characteristics, the limitation of emissions and the fuel consumption as far as possible.
NOTE: Data, performance information and power are only valid if the configuration fully matches the installation guide-
lines that FPT (Fiat Powertrain Technologies) provided.
Furthermore, after an overhaul, the use of the device must correspond to the originally specified power and engine
speed for the engine.
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General specifications
Engine type 4 Cylinders 6 Cylinder
Cycle 4-stroke diesel
Performance Turbocharger with intercooler
Cycle Direct injection type
Number of cylinders 4 6
Bore 104 mm (4 in)
Stroke 132 mm (5 in)
Total displacement 4485 cm³ 6728 cm³
Settings for the engine control times
Start before T.D.C. 18.5 °
End after B.D.C. 29.5 °
Start after 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
Aux. EDC7 UC31
Injector CRIN 2
Injection nozzle type DLLA
Injection order: 1-3-4-2 1-5-3-6-2-4
Injector pressure 250 - 1600 bar (3625 - 23200 psi)
Naturally
Turbocharger With intercooler
Turbocharger type Honeywell GT25 Holset HX35
Lubrication
Oil pressure at low idle 0.7 bar (10 psi)
Oil pressure at high 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 System
Water pump Belt Driven
Thermo stat 79 - 83 °C (174 - 181 °F)
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Information about free play
Components of the cylinder block and components of the crankshaft
Cylinder Barrels 104.000 - 104.024 mm (4.094 - 4.095 in)
Oversize 0.4 mm (0.016 in)
piston 103.739 - 103.757 mm (4.084 - 4.085 in)
Apron height 49.5 mm (1.949 in)
Connector 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)
Piston pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Piston pin – piston pin
housing
0.01 - 0.022 mm (0.0004 - 0.001 in)
Piston ring landings
Top ring 2.705 - 2.735 mm (0.106 - 0.108 in)
Mid 2.420 - 2.440 mm (0.095 - 0.096 in)
Strippers 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Top ring 2.560 - 2.605 mm (0.101 - 0.103 in)
Mid 2.350 - 2.380 mm (0.093 - 0.094 in)
Strippers 3.970 - 3.990 mm (0.156 - 0.157 in)
Clearance between the piston ring and the ring grooves
Top ring 0.100 - 0.175 mm (0.004 - 0.007 in)
Mid 0.040 - 0.090 mm (0.002 - 0.004 in)
Strippers 0.040 - 0.080 mm (0.002 - 0.003 in)
End Gap
Top ring 0.30 - 0.40 mm (0.012 - 0.016 in)
Mid 0.60 - 0.80 mm (0.024 - 0.031 in)
Strippers 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rods
Housing of the small end of
the connecting rod
40.987 - 41.013 mm (1.614 - 1.615 in)
Housing of the big end of the
connecting rod
72.987 - 73.013 mm (2.874 - 2.875 in)
Internal diameter of the
bushing of the small end of
the connecting rod
38.019 - 38.033 mm (1.497 - 1.497 in)
Thickness of the rod bearing
cup
1.955 - 1.968 mm (0.077 - 0.077 in)
Free play between the piston
pin and the piston bushing
0.019 - 0.039 mm (0.001 - 0.002 in)
Oversize dimension of the
rod bearing cup
0.250 mm (0.010 in); 0.500 mm (0.020 in)
Crankshaft
Main Journals 82.99 - 83.01 mm (3.267 - 3.268 in)
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
Thickness of the main
bearing cup
2.456 - 2.464 mm (0.097 - 0.098 in)
Thickness of the rod bearing
cup
1.955 - 1.968 mm (0.077 - 0.078 in)
Main bearing bore
Decal No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
Decal No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
Free play between the bearings and the journals
Decal No. 1,5 / 1,7 0.041 - 0.119 mm (0.002 - 0.005 in)
Decal No. 2,3,4 / 2,3,4,5,6 0.041 - 0.103 mm (0.002 - 0.004 in)
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Free play between the bearings
and the crankpins
0.033 - 0.041 mm (0.001 - 0.002 in)
Main Journals 37.475 - 37.545 mm (1.475 - 1.478 in)
Main bearing bore 32.180 - 32.280 mm (1.267 - 1.271 in)
Main bearings on the start-up
side
37.28 - 37.38 mm (1.468 - 1.472 in)
Crankshaft end play 0.095 - 0.265 mm (0.004 - 0.010 in)
Cylinder head and components
Valve guide bore 7.042 - 7.062 mm (0.277 - 0.278 in)
Intake valves
Valve stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Seat angle 59.75 - 60.25 °
Exhaust valves
Valve stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Seat angle 44.75 - 44.25 °
Free play between the valve
stem and the valve seat
0.052 - 0.092 mm (0.002 - 0.004 in)
Valve seat bore
intake 34.837 - 34.863 mm (1.372 - 1.373 in)
Exhaust 34.837 - 34.863 mm (1.372 - 1.373 in)
External diameter of the valve seat:
intake 34.917 - 34.931 mm (1.375 - 1.375 in)
Exhaust 34.917 - 34.931 mm (1.375 - 1.375 in)
Valve seat angle
intake 60 °
Exhaust 45 °
Recessing of valve
intake 0.59 - 1.11 mm (0.023 - 0.044 in)
Exhaust 0.96 - 1.48 mm (0.038 - 0.058 in)
Clearance between the valve seat ring and the cylinder head
intake 0.054 - 0.094 mm (0.002 - 0.004 in)
Exhaust 0.054 - 0.094 mm (0.002 - 0.004 in)
Valve spring length
With the spring free 47.75 mm (1.880 in)
Under a preload of:
330.8 - 348.8 N (74.4 -
78.4 lb)
35.33 mm (1.391 in)
Under a preload of:
702 - 780 N (157.8 - 175.4 lb) 25.2 mm (0.992 in)
Camshaft bore
Number 1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in)
Decal No. 2,3,4,5 /
2,3,4,5,6,7
54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Internal diameter of the bearing
bushing
54.083 - 54.147 mm (2.129 - 2.132 in)
Free play between the bushing
and the bearing
0.038 - 0.162 mm (0.001 - 0.006 in)
Cam Lift
intake 7.582 mm (0.299 in)
Exhaust 6.045 mm (0.238 in)
Tappet bore 16.000 - 16.030 mm (0.630 - 0.631 in)
External diameter of the plunger
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Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Mid 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Free play between the plunger
and the bore
0.025 - 0.070 mm (0.001 - 0.003 in)
Rocker shaft 21.965 - 21.977 mm (0.865 - 0.865 in)
Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
Clearance between rocker arm
and shaft
0.024 - 0.162 mm (0.001 - 0.006 in)
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Engine - Dynamic description
NHIL13ENG0290FA 1
The NEF F4HFA 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 Fiat Power Train (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 - Component localisation
Location of main electrical components
CRIL04D081G01 1
(1) Coolant temperature sensor (8) Fuel temperature sensor
(2) Electro injector (9) EDC17 CV41
(3) Rail pressure sensor (10) Crankshaft sensor
(4) Air temperature/Pressure sensor (11) Oil level sensor
(5) Engine starter (12) Engine oil temperature/Pressure sensor
(6) Timing sensor (13) Heating element for pre-post heating
(7) Solenoid valve for pressure regulator
The NEF F4HFE engines are fully driven by the electronic engine control module, which is assembled directly to the
engine by means of a heat exchanger enabling it's cooling, utilizing rubber buffers to reduce vibration originated by
the engine.
Through the engine control module it is possible to verify the correct working of the engine.
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Engine - Dynamic description
NHIL13ENG0291FA 1
The NEF F4DFE 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 Fiat Power Train (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 - Component localisation
Location of main electrical components
NHIL13ENG0294GA 1
(1) Coolant temperature sensor (7) fuel temperature sensor
(2) Electro-injector (8) EDC17 CV41 electronic control module
(3) Starter (9) Crankshaft speed sensor
(4) Fuel pressure sensor (10) Engine oil pressure/temperature sensor
(5) Air pressure/temperature sensor (11) Pre-post heating resistor
(6) Timing sensor
The NEF F4DFE engines are fully driven by the electronic engine control module, which is mounted remotely on the
unit utilizing rubber buffers to reduce vibration originated by the engine.
Through the engine control module it is possible to verify the correct working of the engine.
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Engine - Service instruction Maintenance procedures
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
W0371A
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A
CAUTION
Burn hazard!
Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has
cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.
Failure to comply could result in minor or moderate injury.
C0043A
WARNING
Rotating parts!
The engine is running. Keep clear of rotating fans and belts.
W0275A
Engine oil level check
The check can be made using the dipstick (1) placed on
the right hand side of the Engine Control Unit (ECU).
NOTICE: The check must be executed when the engine is
off and possibly cool.
Draw off the rod from it's slot and check that the level is
within the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, pro-
ceed cleaning the rod using a clean cloth with no contami-
nation and put it back in it's slot. Draw it off again and check
the level.
In case the level results being close to the tag showing min-
imum level, provide filling lubrication of the engines com-
ponents.
Add oil through the upper top or through the lateral top (2).
During filling operation, the tops must be removed as well
as the rod in order to make the oil flow easier.
NHIL13ENG1373AA 1
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Combustion system inspection
The check must be executed both when the engine off and
when it is running.
The check operation consists in examining the fuel
pipelines running from the tank to the pre-filter (if provided
in the specific equipment), to the filter, to the high pressure
pump and to the rail diffuser and from this last one to the
head.
Special attention must be paid to the connections on the
high pressure pipelines.
Cooling system inspection
The check must be executed both when the engine is off
and when it is running.
Check the pipelines from the engine to the radiator, from
the expansion tank and vice-versa. Find out any blow-by,
verify the status of the pipes specially close to the holding
strips.
Verify that the radiator is clean, the correct working of the
fan flywheels, the presence of any leakage from the con-
nectors, from the manifold and from the radiating unit.
The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any
case every two years.
NOTE: In case of new filling, proceed bleeding the system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious inconve-
nience might be caused to the engine due to the presence
of air pockets in the engine's head.
Lubricating system inspection
The check must be executed both when the engine is off
and when it is running.
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan or from the heat exchanger.
Inspection of water presence within the fuel
filter or pre-filter
The components of the common rail system can be dam-
aged very quickly in presence of water or impurity within
the fuel.
Timely proceed operating on the pre-filter (not available on
the engine block) to carry out the drainage of the water
within the feed circuit.
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Inspection / replacement of blow-by filter
The filter in subject has been developed and equipped for
the collection , filtering and condense of the lubricating oil
vapors.
Within the valve cover (1) is a filter (2).
Remove the cover and check the filtering element.
93110965 2
Inspection of drive belt tensioning
The drive belt tensioning control is made using an au-
tomatic tensioning device therefore no intervention is
required apart from checking the wear status of the belt
itself.
Inspection and setting of tappet clearance
Adjust clearance between rockers and valves using
setscrew wrench (1), box wrench (2) and feeler gauge (3).
Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
NHIL13ENG0312AA 3
Engine oil and filter replacement
Due to the several applications, the pan shape and the
oil quantity can change slightly. However, the following
operations are valid for all applications.
We recommend to carry out the oil drainage when the en-
gine is hot.
Place a proper container for the oil collecting under the pan
connected with drain plug.
Unscrew the plug and then take out the control dipstick and
the inserting plug to ease the downflow of the lubrication oil.
After the complete drainage, screw the plug and carry out
the clean oil filling.
NOTICE: Use only recommended oil or oil having the re-
quested features for the correct engine functioning. In case
of topping up, don't mix oils having different features. If you
don't comply with these rules, the service warranty is no
more valid.
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.
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Steyr f4 dfe413r tier 4b (final) engine service repair manual

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