FPT F5AE9484 Engine Workshop Manual

FPT ENGINE 1
FPT F5AE9484 ENGINE WORKSHOP MANUAL
Section
General information 1
Supply 2
Industrial appliance 3
Overhaul and specifications 4
Tools 5
FPT Engine Parts contact: Phone: 269 673 1638
Email: engineparts2@gmail.com
Website: www.FPTIndustrialEngineParts.com Safety rules Appendix
FPT F5AE9484 ENGINE WORKSHOP MANUAL SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General
Page
TECHNICAL CODING . . . . . . . . . . . . . . . . . . . . . 3
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Counterotating mass balancing device . . . . . . . 9
- Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE OIL VAPOUR RECIRCULATION . . . . . . 11
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 12
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Working system . . . . . . . . . . . . . . . . . . . . . . . 13
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . 14
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . . . 15
EGR EXHAUST GAS RECIRCULATION . . . . . . . . 16
F5AE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 3
TECHNICAL CODING
Technical Code
F5AE9484A
F5AE9484B
F5AE9484G
F5AE9454A
F5AE9454G
TECHNICAL DESIGNATION
TYPE PART NUMBER
F 5 A E 9 4 8 4 A * A 0 0 1 -
Progressive production number

Variant number
Level of Gas Emissions (Tier 3)
Engine torque and power level
Use (eg 4 = tractors)
Air feed + injection (TCA, direct injection diesel engine)
Number of cylinders
5 - External EGR
9 - Internal EGR
Engine (invariable) A 48 kW / 2300 rpm
B 57 kW / 2300 rpm
Engine family evolution (also irrespective of the displacement)
G 65 kW / 2300 rpm
Indicates the engine family

Website: www.FPTIndustrialEngineParts.com
4 SECTION 1 - GENERAL SPECIFICATIONS F5AE ENGINES
ENGINE VIEWS
Figure 1
120013
FRONT VIEW OF ENGINE
Figure 2
120014
LEFT SIDE VIEW OF ENGINE

Figure 3
120015
RIGHT SIDE VIEW OF ENGINE
Figure 4
120016
REAR VIEW OF ENGINE

Figure 5
120017
TOP VIEW OF ENGINE

LUBRICATION The lubrication system also comprises the heat exchanger, the
centrifugal blower for the versions with turbosupercharger
Forced circulation lubrication is controlled by the rotor oil and eventually the compressor if the compressed air system
pump housed in the front part of the engine basement and is also fitted.
driven by the toothed gear splined on the shank of the engine
drive shaft. All the above mentioned components vary depending on their
use and therefore will be illustrated in the specific section.
From the oil pan, the lubrication oil is distributed to the engine
drive shaft, the camshaft and the valve control.
Figure 6
Pressurized oil
Dropping oil
120007
LUBRICATION SYSTEM LAYOUT
1. Turbocharger lubrication feed pipe - 2. Heat exchanging unit - 3. Heat exchanger -

4. Oil pump - 5. Oil filter
Oil pump
Figure 7
119405
PUMP SPECIFICATIONS
Rotating speed 750 rpm - 4200 rpm
Feed pressure 2 Bar - 4 Bar
Rated flow 12.2 l/min - 75.9 l/min
Oil type SAE 20/30
Max oil temperature 80 C
1. Main gear - 2. Secondary gear - 3. Pump unit - 4. Drive shaft - 5. Secondary shaft
6. Cover - 7. Internal rotor - 8. External rotor - 9. Bush
Counterotating mass balancing device

Figure 8
119717
1. Reference notches for alignment and timing - 2. Balancing masses -3. Bushes - 4. Shouldering fifth wheels - 5. Shaft - 6. Box.
Engine oil filter

Figure 9
119406
1. Protective cover - 2. Cartridge
Booster pressure 20 bar (ISO 4548/3)

Dynamic pressure: 0-15 bar (1Hz) > 50,000 cycles (ISO 4548/5)
Operating temperature: -40 / + 140 C
Torque wrench setting: 18 ±2Nm
Maximum flow: 50 l/min.
Load loss at the end of life cycle: 2.5 bar
Accumulation: > 15 gr with 2.5 bar load loss (ISO 16889)
ENGINE OIL VAPOUR RECIRCULATION
Figure 10
119407
1. Valve - 2. Breather - 3. Tappet cover

On the tappet cover (3) there is a valve (1) having the duty to cause condensation of oil vapours making them drop by gravity
on the underlying tappet cover (3).
The remaining non condensed vapours will be duly conveyed through the breather (2), for instance by suction (appropriate connec-
tion must be provided by the outfitter).

12 FPT F5AE9484 ENGINE WORKSHOP MANUAL F5AE ENGINES
COOLING SYSTEM - heat exchanger cooling the lubricant oil. This component
may vary depending on the specific engine fitting.
The closed circuit forced circulation engine cooling system is
composed of the following parts: - centrifugal water pump positioned in the front part of the
engine basement;
- expansion tank: position, form and dimensions may vary
depending on the engine fitting. - thermostat controlling cooling liquid circulation.
- radiator dissipating the heat absorbed by the engine
cooling liquid. This components position and dimensions
may vary depending on the outfit.
- fan increasing the radiators cooling power. This
component may vary depending on the specific engine
fitting.
Figure 11
Closed thermostat
Open thermostat
Water inflow
Engine cooling water
Water outflow from thermostat
120018
COOLING SYSTEM LAYOUT

WATER PUMP
Figure 12
120047
WATER PUMP SECTION

1. Hub - 2. Shaft with bearing - 3. Pump unit - 4. Sheath - 5. Impeller.
The water pump is a centrifugal blade turbine type pump. The pumps bearing (2) is connected to the impellers shaft as a whole.
Water tight between the pump unit (3) and the shaft (2) is ensured by the sheath (4).
THERMOSTAT
Figure 13
119412
THERMOSTAT DIAGRAM
Working system
When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermostat, which
cuts out water circulation to the radiator. This way, water circulation will only be possible in the pump-engine circuit, insofar allowing
engine heat-up quickly. The thermostat valve starts opening at nearly 80 C, allowing water circulation into the radiator and also
obstructing direct return towards the engine. Check the thermostat efficiency and replace it in case of doubtful functioning.
1. Stroke starts at 79 ± 2 C
2. 7 mm stroke at 94±2C
HEAT EXCHANGER
Figure 14
SECTION A-A
SECTION B-B
119408
The heat exchanger within the engine cooling system has the duty to control the engine oil temperature, reducing it by absorbing
heat throughout the engine cooling liquid.
TURBOCHARGING
The turbocharging system is composed of the following parts:
- air filter;
- turbosupercharger.
Figure 15
Sucked air
Heated compressed air
Engine exhaust gas

120019

EGR EXHAUST GAS RECIRCULATION

The exhaust gas can be partially recycled to cylinders to reduce maximum temperature values of combustion that produce nitrogen
oxides (NOx).
The exhaust gas recycle system (EGR) reduces combustion temperature and therefore is an efficient NOx emission control system.
INTERNAL EGR
The specific design of suction cams of the internal EGR system allows part of exhaust gas to be recycled to engine cylinders.
This type of EGR, called internal EGR, is not equipped with any electronic control, the system is always active. Its configuration
requires no additional parts such as control valves, pipelines or heat exchangers therefore engine profile remains unchanged.
Besides main lobe, suction cam has an additional lobe as to configuration without EGR. During concerned cylinder exhaust phase,
this lobe allows a shaft advanced opening of intake valve. In this way, part of the exhaust gas is trapped in the suction duct and later,
during cylinder suction phase, this gas is recycled to cylinder inlet for combustion phase.
Aspiration cam profile

Figure 16
X. Angolo rotazione camma - Y. Alzata camma
114026
F5AE ENGINES SECTION 2 - SUPPLY 1
SECTION 2
Supply
Page
SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PIPE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Working System Description . . . . . . . . . . . . . 5
SUPPLY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Identification coding example . . . . . . . . . . . . . 6
WORKING SYSTEM DESCRIPTION . . . . . . . . . . . 7
- Supply phase . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Delivery phase . . . . . . . . . . . . . . . . . . . . . . . . . 7
- End of delivery phase . . . . . . . . . . . . . . . . . . . . 8
- Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- L.D.A. Load Delivery Adjustment device . . . . . 9
- Working system . . . . . . . . . . . . . . . . . . . . . . . 9
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL FILTER ............................. 11

2 SECTION 2 - SUPPLY F5AE ENGINES
SUPPLY
The engine supply system consists of the following components:
- Fuel tank (aboard the vehicle)
- Fuel delivery and return pipes
- Fuel pre-filter (if fitted, it is placed nearby the engine on the vehicles chassis)
Priming pump, fitted on the engine and driver by the engine camshaft
- Fuel filter (its position on the engine may vary depending on the outfit and use)
- Supply rotary pump
- Injector feed pipe (from the fuel supply pump to the fuel injectors)
- Injectors
Figure 1
119420
SUPPLY SYSTEM DIAGRAM

1. Injectors - 2. Fuel filter - 3. Tank - 4. Supply rotary pump - 5. Ignition pump.

PIPE LAYOUT
Figure 2
118976
1. Injector feed pipe - 2. Fuel exhaust pipe from injectors - 3. Supply rotary pump - 4. Union for pressure gauge pipe within
LDA intake manifold - 5. KSB thermal bulb - 6. Solenoid valve - 7. Injector

Figure 3
119961
Working system description
The fuel (5) is primed from the fuel tank from the priming Then, the fuel reaches the valve controlling fuel pressure within
pump (6). The latter is fitted on the engine basement and is the supply pump.
driven by the engine camshaft.
The distributor piston further increases such pressure and
Throughout the filter (4), fuel is conveyed to the transfer delivers the fuel to the injectors (1) throughout the delivery
pump, which is placed inside the supply rotary pump (2), pipe fitting.
which is a turbine blade pump type. The supply rotary pump
The fuel leak (3) from the injectors is recovered and sent back
duty is to increase the fuel pressure based on the increase of
to the fuel tank.
engine revolutions number.
SUPPLY PUMP
The rotary type supply pump is driven by a gear which is coupled to the engine camshaft gear.
Identification coding example

V = rotary distributor piston pump
E = pump dimensions
4 = four cylinder engines
12 = distributor piston size in mm
1150 = no. of pump rev./min.
RV = Counterclockwise rotation direction
Figure 4
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
Ignition pump longitudinal section

1. Membrane - 2. Setting ring - 3. Feeler pin - 4. Drive lever - 5. Speed regulator - 6. Transfer pump - 7. Drive shaft -
8. Cam disk - 9. Spark lead adjuster - 10. Distributor piston - 11. Feed pipe fitting - 12. Hydraulic head - 13. Control plate -
14. Adjusting pin - 15. Counter spring.
WORKING SYSTEM DESCRIPTION

Supply phase
Figure 5
119415
1. Fuel supply pipe - 2. Solenoid valve - 3. Axial groove - 4. Compression chamber - 5. Fuel delivery pipe from pump to
injectors - 6. Distributor piston - 7. End of delivery port - 8. Cursor - 9. Injector.
The distributor piston (6) is at B.D.C. and the cursor (8) closes the delivery port (7). The fuel is delivered to the compression
chamber (4) through the feed pipe (1) which is kept open by the solenoid valve (2).
Delivery phase
Figure 6
119416
1. Fuel feed pipe - 2. Compression chamber - 3. Distributor piston inner pipe

4. Fuel delivery pipe from pump to injector - 5. Distributor piston - 6. Injector.
The distributor piston (5) driven by the cam disk, goes up to the T.D.C. and simultaneously rotates on its own axle. The combination
of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within the chamber (2). The
distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to the injectors (6).
End of delivery phase

Figure 7
119417
1. Fuel feed pipe - 2. Compression chamber - 3. Fuel delivery pipe - 4. End of delivery pipe -
5. Cursor - 6. Distributor piston.
The distributor piston (6) moving towards the T.D.C. connects the high pressure inner chamber to the pipe (1), thereby establishing
pressure balance between the distributor piston inner chamber, the injectors delivery pipe and the pump interior.
Since such pressure is lower than the one required to start the injector, end of delivery will be determined.
Engine stop
Figure 8
119418
1. Fuel feed pipe - 2. Mobile cap - 3. Spring - 4. Solenoid valve - 5. Compression chamber.
Engine stop is provoked cutting out the starter contact.

The electric flux to the solenoid valve (4) is cut out. The solenoid valve, throughout its spring (3), drives the mobile cap to the
end of stroke (2) and the mobile cap obstructs the fuel feed pipe (1).
L.D.A. Load Delivery Adjustment device

Figure 9
119419
Working system
The duty of the L.D.A. device is to adjust the fuel delivery depending on the air pressure within the intake manifold.
Air pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4) there is a
conical housing (5) in which the feeling pin runs (6).
The setting pin (4) axial motion drives the feeling pin (6) shift and the latter acts on the stop lever (7). The stop lever rotates on
its own axle (8) and acts on the control plate in order to adjust the fuel delivery depending on the air quantity within the cylinders.
PRIMING PUMP
The priming pump duty is to prime the fuel from the tank and convey it to the fuel supply pump. It is fitted on the engine basement
and driven by the engine camshaft.
Figure 10
88209
1. Pump - 2. Control lever - 3. Camshaft

FUEL FILTER
The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water from the
fuel in which it is contained.
At the bottom of the filtering cartridge there may be a water drainage device; depending on the appliance (use in cold climate
conditions), the fuel filter support may be equipped with a heater and a temperature sensor. Some versions are also equipped
with a water detecting sensor at the bottom of the cartridge filter.
Figure 11
119411
1. Fuel filter support - 2. Cartridge filter- 3. Water drainage device (not available on all versions).
F5AE ENGINES 1
SECTION 3
FPT F5AE9484
Page
MAIN SPECIFICATIONS . . . . . . . . . . . . . . . . . . 3
PART ONE -
MECHANICAL COMPONENTS . . . . . . . . . 5
ENGINE DISASSEMBLY ON BENCH . . . . . . . . 7
- BOSCH VE 4/12F pump . . . . . . . . . . . . . . . . . 8
- Timing gearcase . . . . . . . . . . . . . . . . . . . . . . . 11
- Rear side component assembly . . . . . . . . . . . 13
- Flywheel assembly . . . . . . . . . . . . . . . . . . . . . 13
- Front side component assembly . . . . . . . . . . . 14
- Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Piston projection measurement . . . . . . . . . . . 16
- Inspection and checks . . . . . . . . . . . . . . . . . . 21
- Check of injection pump static advance on engine

at the TDC of cylinder 1 . . . . . . . . . . . . . . . . . 22
PART TWO - ELECTRICAL EQUIPMENT . . . 23
ELECTRIC CABLE TO CONNECT KSB

WITH CERA . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Engine cooling liquid temperature sensor . . . . 26
- Oil pressure switch . . . . . . . . . . . . . . . . . . . . 27
- KSB cooling liquid temperature sensor . . . . . . 28
- Engine pulse transmitter . . . . . . . . . . . . . . . . . 29
PART THREE - DIAGNOSIS . . . . . . . . . . . . . . 31
DIAGNOSIS BY FAILURE . . . . . . . . . . . . . . . . . 33
Email: engineparts2@gmail.com PART FOUR - SCHEDULED MAINTENANCE 39
Website: www.FPTIndustrialEngineParts.com SCHEDULED MAINTENANCE . . . . . . . . . . . . . 41
- Servicing plan . . . . . . . . . . . . . . . . . . . . . . . . . 41
- Basic checking and maintenance operations . . 41

2 SECTION 3 - INDUSTRIAL APPLICATION F5AE ENGINES
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 3
MAIN SPECIFICATIONS
Type F5AE9454 A F5AE9484 A F5AE9454 D
Cycle Diesel 4 strokes

Feeding Turbocharged with intercooler
Injection Direct
N. of cylinders 4 on-line
Diameter mm 99
Stroke mm 104
+ + +.. = Total displacement cm3 3202
Compression ratio 17 0.5 : 1
Max. power KW 44 48 55
(HP) (60) (65) (75)
rpm 2500 2300 2300
Max. torque Nm 210 260 220

(kgm) (21) (26) (22)
rpm 1400 1400 1400
Loadless engine
idling rpm
1150 50
Loadless engine
peak rpm
2750 50

Type F5AE9484 B F5AE9484 G

Feeding Turbocharged with intercooler
Injection Direct
N. of cylinders 4 on-line
Diameter mm 99
Stroke mm 104
Compression ratio 17 0.5 : 1
Max. power KW 57 65
(HP) (77) (88)
rpm 2300 2300
Max. torque Nm 315 340

(kgm) (32) (34)
rpm 1400 1400
Loadless engine
idling rpm
1150 50
Loadless engine
peak rpm
2750 50

DIAGNOSI
PART ONE - FPT F5AE9484 MECHANICAL COMPONENTS

zl
540110 ENGINE DISASSEMBLY ON Figure 2

BENCH
NOTE Engine disassembly operations to remove the

engine from the vehicle are described in the specific
section. Engine disassembly operations, as well as
engine overhaul, must be executed by qualified
engineers only, duly provided with the specific
tools required.
NOTE Depending on the appliance, some units may have

different position on the engine.
119720
NOTE Before fitting the engine on the rotary stand
380000978, disassemble the parts which may - Remove the L.D.A. pipe. Remove the fast clutch fuel
interfere with the bracket assembly. Depending on pipes from the priming pump to the filter (1) and from
the appliance, it may be necessary to remove the the filter to the ignition pump (2), then fit the specially
starter and the oil filter. provided caps to the pipes, the pumps and the filter.
Unscrew the screws (3), fastening the fuel ignition pipes
- Drain the engine oil from the oil pan collecting it in a and remove them.
suitable container.
Figure 3
Warning! Avoid skin contact with the engine oil: in
case of contact wash your skin with running water.
The engine oil is highly polluting: waste disposal must

be executed complying with the laws and regulations
in force.
- Remove the electric wiring from the injection pump.
Figure 1
119106
- Unscrew the pump fastening screws on the rear part of

the gear cover. To disassemble the pump, fit tool
99340025 to the pump wheel and fix it with the three
screws (1).
Using the specially provided wrench, slowly tighten the
screw (2) holding the rear part of the pump removing
the pump completely.
NOTE Before removing the pump verify if, for the model
used, a shaft block system exists. In that case, block
the engine by means of the specific tool in the
corresponding position, to the TDC of cylinder 1,
119718 (at compression end, as shown in the procedure at
- Remove oil delivery pipe connected to the turbocharger page 19). Now block with the specific system the
(3) and t the oil return pipe (1). pump shaft; this way the pump should be timed, so
that when refitting (if no maintenance intervention
- Remove the turbocharger unit (2). is required on it) no adjustment is necessary.
- Duly hold the starter (5), unscrew the fastening screws
and remove the starter.
- Remove the water hose (4).
zl
BOSCH VE 4/12F Pump

Figure 4
118976
1. Fuel delivery pipes - 2. Fuel recovery pipes - 3. Mechanical pump - 4. LDA - 5. Wax KSB - 6. Injectors.

Figure 5 Figure 7
120021
119721
- Place a container under the diesel fuel filter and unscrew - Loosen the screw (1) and the relevant screw nut on the
the condense drainage faucet under said filter; belt tensioning bracket (3).
completely drain the diesel fuel container therein. - Loosen the screw (2, Figure 8) in order to withdraw the
belt (2).
- Disassemble the diesel fuel filter (1), the filter support
(2), the priming pump (3), the oil filter (4), the oil filter - Remove the belt tensioning bracket (3).
support (5), and the KSB water sensor (6). - Disassemble the pulleys and the guide rollers.
Figure 8
Warning! The oil filter contains a certain quantity of

engine oil.
Collect the engine oil and dispose it complying with
the applicable laws and regulations in force.
Figure 6
119722
- Duly hold the alternator (1) and detach it from its

support loosening the screw (2): recover nut and
washer.
Figure 9
120020
- Unscrew the injector support fastening screws (1),

disassemble the injector supports and remove the
injectors (2).
- Loosen the screws (3) and remove the tappet covers.
- Remove the intake manifold (6).
- Remove the thermostat unit (4) and the exhaust
manifold (5).
119109
NOTE On the central cover there is a lubrication oil
vapour blow-by valve. - Place a container under the heat exchanger (2) to collect
the cooling liquid contained therein.
All the gaskets must always be replaced in phase of
assembly. - Loosen the screws (1) and disassemble the heat
exchanger unit (2).
Figure 10 Figure 12
119112
119723
- Fit tool (1) 380000988 to the flywheel box and, using a

- Remove the electromagnetic joint support (1) and the
wrench, lock the flywheel rotation.
water pump (2).
- Loosen the screws fastening the flywheel to the engine
- Loosen the screw (4) and remove the pulley (3).
drive shaft.
Figure 11
Figure 13
119724
- Screw two average length screws (2), to sling the

flywheel with a lifting device.
- By means of two guide pins (4) previously screwed in the
engine drive shaft ports (3), guide the flywheel (1)
withdrawal throughout a hoist.
- Withdraw the flywheel casing grommet.
- Withdraw the grommet of the timing gearcase.
119111
- Unscrew the fastening screws (1) and remove the

camshaft holding overhead assembly (2), recovering the
two seals (3).
Timing gearcase
Figure 14
119725
- Remove the rear cover (2) from the transmission Figure 15

gearbox (1).
119115
- Remove the tappet rods (1).

- Disassemble the cylinder head;
loosen the cylinder head (3) fastening screws (2);
hook the brackets with metal ropes and, throughout a
hoister, detach the cylinder head with valves from the
basement.
- Remove the cylinder head gasket.
Figure 16 Figure 18
119726
119117
- Turn the engine upside down.

- Loosen the screws (1) and remove the oil pump (2).
- Remove the screws (2) and detach the oil sump (1).
- Remove the suction rose
Figure 19
Figure 17
1
119118
- Loosen the rocker arm fastening screw (1) from the

disassembled rocker arm holding unit and then remove
the rocker arm.
2
Figure 20
120148
- Remove the seal (3).

- Unscrew the screws (1) which fasten the additional mass
box (2) and remove it.
119119
- Withdraw the rocker arm (1) from one side recovering

the equalizers (2) from the other.
Rear side component assembly Figure 22

Figure 21
119729
SCHEME FOR THE APPLIANCE OF LOCTITE 5699 119730

SEALER ON THE TIMING GEARCASE
- Fit the specific tool 99346259 (5) to the rear shank (6)
- Accurately clean the timing gearcase and the engine of the engine drive shaft, fix it with the screws (4) and
basement. spline the new grommet (3) thereon.
- Position part (1) on part (5), tighten the screw nut (2)
until the grommet has been fitted (3) into the flywheel
It is absolutely necessary to clean the surface to be casing (7).
! sealed in order to obtain perfect tightness.
Apply LOCTITE 5699 sealer on the gearcase in Flywheel assembly
order to form a sealing bead of 1,5 + 0,2
0,5
mm. Figure 23
The sealing bead must be homogeneous (no lumps),
free of air bubbles, thinner areas and gaps.
Any imperfection must be corrected as soon as
possible.
Avoid the excess of sealer: too much sealing material
would leak and pour out on both sides of the joint
parts and, as a consequence, obstruct the passage of
the lubricant.
After having applied the sealer, the parts must be
joined within 10 minutes.
119731
- Screw two handling hooks (2) or eyebolts on the

flywheel (4).
- By means of a hoister, draw the flywheel up to its housing
inside the casing.
NOTE The flywheel has a reference dowel that couples

with the relevant seat on the box.
- Screw two pins (1) of appropriate length into the shafts

ports (3) and, using them as a guide, duly fit the engine
flywheel (4) into its casing.
- Tighten the screws fastening the engine flywheel to the
engine drive shaft. Fit the tool (380000988) to the
flywheel casing in order to lock the engine flywheel
rotation.
Figure 24 Figure 26
119732 119733
Tighten the engine flywheel (2) fastening screws (1) in two

steps: SCHEME FOR THE APPLIANCE OF LOCTITE 5699
SEALER
- Step 1: 30 5 Nm torque setting ;
- Step 2: 90º ± 5º angular fastening. NOTE BIt is absolutely necessary to clean the surface to
be sealed in order to obtain perfect tightness.
NOTE Angular fastening must be executed using tool
380000304. Apply LOCTITE 5699 sealer on the gearcase in
Before assembly, always check that the port order to form a sealing bead of 1,5 + 0,2
0,5
mm.
threads and the screws show no trace of wear and The sealing bead must be homogeneous (no
dirt. lumps), free of air bubbles, thinner areas and gaps.
Any imperfection must be corrected as soon as
possible.
Avoid the excess of sealer: too much sealing
material would leak and pour out on both sides of
the joint parts and, as a consequence, obstruct the
passage of the lubricant.
Front side component installation
After having applied the sealer, the parts must be
Figure 25 joined within 10 minutes.
- Assemble the front case (1) and tighten the fastening

screws to the prescribed torque wrench.
119117
- Assemble the oil pump (2).
- Screw the fastening screws (1) without fully locking
them.
- With magnetic base comparator, check the clearance
among the engine shaft gear and the oil pump gear: it
must be 0.068 ÷ 0.168 mm.
- Fully tighten the fastening screws (1).
Timing Figure 28
Figure 27
119735
- Fit the ignition pump cogwheel (1) into its housing.

- Fit the pre-set ignition pump into its housing on the
engine, inserting the shaft into the gear hole.
- Tighten the three screw nuts on the rear part of the
timing gearcase and the front cover fixing the shaft to the
gear.
among the engine shaft gear and the oil pump gear: it
must be 0.068 ÷ 0.168 mm.
- Fit the new gasket using the centring pins (2) on the
casing for its correct positioning.
- Fit the casings cover using the centring pins (2) to
correctly position it and then tighten the fastening
screws to the prescribed torque wrench.
119734
Figure 29
- Seize the 45 bevel tooth (1) of the engine drive shaft
gear with the timing gear tooth marked with two
notches (2), as shown in the figure.
- Rotate the camshaft keeping the timing gear fix until the
camshafts pin fits into the relevant housing within the
timing gear.
- Screw the screws of the transmission gear without fully
tightening them.
among the engine shaft gear and the cam shaft gear: it
must be 0.068 ÷ 0.168 mm.
- Screw the fastening screws (1) of the transmission gear.
119736
- Fit the inner part of tool 99346262 to the front shank of

the engine drive shaft. Make sure that the engine drive
shaft pin is correctly fitted into the tool spline in order
to avoid damaging it. Fix it with the screw (1) and spline
the new grommet thereon.
- Place the outer section of the tool on the previously
fitted one, tighten the screw nut (2) until completely
fitting the grommet (3) into the casing.
Figure 30 Figure 32
70221
- Fit a new grommet (2) to the water pump (1). 119573
- Assemble the water pump (1).

- Tighten the fastening screws to the prescribed torque - Fit the gasket (1) on the basement centring it taking the
wrench. pins (2) as a reference. The gaskets thickness must be
selected based on the piston projection in respect to the
upper plan of the basement.
NOTE Check that the blocks laying plan is clean.

Do not grease the gasket. It is recommended to
keep the gasket inside its wrapping until it has to be
fitted.
The fitting direction is univocal and defined by the
centring pins on the basement, which must match
with the ports on the gasket.
Piston projection measurement
Figure 31
Figure 33
119462
119115
Piston projection Engine gasket thickness
from basement B A
((mm)) NOTE Always use new head bolts for assembly.
Thickness (mm)
From 0.07 to -0.07 0.80
- Place the head (3) on the block taking the centring pins
From -0.08 to -0.22 0.70 as a reference.
- Measure the piston projection and refer to the table - Lubricate the head bolts (2) and tighten them to
above to select the appropriate thickness of the gasket. the prescribed torque wrench.
Figure 34 Figure 36
122432
119723 - Mount the discharge manifold (3) complete of new seal

(2) and tighten the nuts (1) with the stud bolts applying
- Reassemble the electromagnetic joint support (1). the required torque.
- Reassemble the pulley (2).
Figure 37
- Reassemble the pulley (3), tighten the fastening screw
(4) to the prescribed torque setting.
- Reassemble the heat exchanger reminding to replace the
old gasket with a new one; tighten the fastening screws
to the prescribed torque setting.
Figure 35
32655
Before reassembly, check that the rocker arm rods must not
be deformed; there must be no trace of wear or seizure on
the spherical housings of the rocker arm adjusting screws as
well as on the tappets (pointers); otherwise these parts must
be replaced. The suction valve rods are identical and
therefore interchangeable.
- Fit the control rods in their housing.
Figure 38
119108
- Put the alternator back in place (1, Figure 8).

- Screw up without tightening (2).
- Fit the drive belt on the pulley and the guide rollers.
- Tension the drive belt rotating the alternator as shown
in the figure.
- Tighten the screw (1) and the screw nut (2, Figure 8)
fastening the alternator to the support.
119119
- Fit the rocker arm positioning the equalizer couples: the
suction equalizer first (short rod) and then the exhaust
equalizer (long rod) (2).
- Screw the fastening screws.
Figure 39 Figure 41
119128
- Make the holes (1) for fuel exhaust all face the same
direction.
Figure 42
119111
- Replace the seals (3), refit the camshaft holding overhead

(2) and tighten the screws (1) applying the required
torque.
119721
- After having completed the assembly, check that the
rocker arms are correctly positioned on the valves and
the tappet control rods. - Reassemble the KSB water temperature sensor (6), the
oil filter support (5), the priming pump (3), the diesel fuel
filter support (2), the fuel filter (1) and the oil filter (4).
Figure 40
Figure 43
120020
- Reassemble the injectors (2) replacing the grommets.

Tighten the fastening screws(1) to the prescribed torque 119905
setting.
- Fit the head covers (1) replacing the gaskets (2).
- Replace the thermostat unit (4).
Figure 44 Figure 46
119716
- Reassemble the fuel exhaust pipes (1).
Figure 45
112012
Position the engine shaft at the TDC of cylinder 1, rotating

the flywheel until the following conditions are achieved:
- the notch (2) can be seen from the inspection window;
- the tool 380000150 (1) is inserted through the guard in
the hole located on the flywheel.
Figure 47
120034
- Reassemble the whole intake manifold (1) replacing the

gasket (2).
FPT Engine Parts contact:

Phone: 269 673 1638
119727
Website: www.FPTIndustrialEngineParts.com In the above conditions (correct engine timing), mount the
box containing the additional masses (1) taking care that the
reference notches (2) coincide as shown in figure. Position
the new seal (3) on the engine block.
Remove the tool 380000150 (1, Figure 46).
Figure 48 Figure 50
119105
112011
- Reassemble the pipe from the pump to the injector and

tighten the brackets fastening screws (3). NOTE Verify that the misalignment between flywheel
- Reassemble the pipe from the pump to the fuel filter (2) cover box (1) and oil sump (2) is within the range
and from the fuel filter to the priming pump (1). 0 0.1 mm
- Reassemble the L.D.A. pipe.
Figure 51
Figure 49
119726 119718
- Fit the suction rose.

- Reassemble the turbocharger (2) unit.
- Mount the oil sump (1). Screw screws (2) and tighten
them applying the required torque. - Reassemble the pipe (4) and fit the clip in the correct
housing.
NOTE Before mounting, verify that the threads of the - Reassemble the oil delivery pipe (3) and the return pipe
holes and the screws are not worn or dirty. (1).
- Refit the starter (5).
Figure 52 Checks and inspections
The following checks must be executed after the

! engine fitting on vehicle.
Check that the liquid refuelling or top up has been
provided to the correct levels prescribed.
Start the engine, keep it running at a number of

rev./min. slightly over idling and wait until the cooling
liquid temperature reaches the value prescribed for
thermostat valve opening and then provide checking
the following:
119728 - check there is no water leak from the manifolds

connecting the engine cooling circuit pipes and the cabin
- Disconnect the fuel filter pipe (1) and act on the priming interior heating pipes, eventually further tightening the
pump (2) drainage lever. O-rings.
- Continue drainage until fuel discharge is completed. - Carefully check the fuel filter pipe fittings.
- Connect the pipe (1) to the filter. - Check there is no oil leakage from cylinder head and
cover, oil pan and basement, heat exchanger oil filter and
relevant housings in between the various lubrication
circuit pipes.
- Check there is no fuel leakage from the fuel pipes.
- Check there is no air leak from the pneumatic pipes (if
fitted).
- Check that the warning lights on the instrument panel
and equipment disconnected upon engine
disconnection efficiently work.
- Check and carefully bleed the engine cooling system
throughout reiterated drainage.
Check of injection pump static advance on

engine at the TDC of cylinder 1
(demonstrative figure)
87720
With the injection pump inserted in its seat and loosened

fastening screws, mount the comparator 380000228 (2) and
the comparator holder tool 380000229 (1), precharging the
rod of 2.5 mm.
- Rotate the engine shaft to move from the condition of
1st cylinder at the TDC compression phase end.
- Rest the comparator and rotate the engine shaft in the
opposite direction until it returns to the condition of 1st
cylinder at the TDC in compression phase. In this
position, on the comparator applied on the pump you
should read the following value:
0,76 ± 0,05 mm (engines 48 kW; 57 kW; 65 kW);
0,88 ± 0,5 mm (engines 55 kW).
The prelifting values shown are provisional. They

! may change.
- Rotate the pump anticlockwise if the run is lower, or

clockwise if the run is higher until you reach the required
run.
- Verifying these conditions, lock the pump tightening the
nuts applying the required torque.
PART TWO -
FPT F5AE9484
ELECTRICAL EQUIPMENT
ELECTRIC CABLE TO CONNECT KSB WITH CERA

Figure 1
120035
1. Interface - 2. KSB signal - 3. Air sensor - 4. STOP

Engine cooling liquid temperature sensor

The sensor is fitted on the thermostat unit. It consists of two NTC thermistors with two reophores.
Figure 2
Calibration Calibration Calibration

80 C 20 C 10 C
[k ] [k ] [k ]
0.304 - 0.342 2.262 - 2.760 8.244 - 10.661
119454
Characteristics
Working temperature range
- Connectors side -40 C ÷ 130 C; 150 C for periods < 10 min.
- Bulbs side on engine -40 C ÷ 140 C
Voltage 6 ÷ 28 V
Tightening torque 20 30 Nm

Oil pressure switch

Figure 3
120036
Characteristics
Voltage 12 ÷ 24 V
Calibration 0.6 ÷ 0.9 bar
Tightening torque 35 Nm

Cooling liquid temperature sensor for KSB

Figure 4
119455
Characteristics
Operating tension 12 - 24 V
Contact opening with raising temperature 63 3 C
Contact closing with decreasing temperature 53 3 C
Tightening torque 30 Nm MAX

Engine pulse transmitter

It is an inductive type sensor placed on the front left side of the engine.
It generates signals obtained by the magnetic flow lines closing up through the openings of a phonic wheel splined on the engine
drive shaft. The same signal is used to pilot the electronic revolution counter eventually fitted on the vehicle instrument panel.
It is connected to the Electronic Control Unit pins 25C (signal) and 24C (signal). The third pin is for shielding. The Sensors resistance
value is nearly 900 .
Figure 5
119457
Torque setting 8 2 Nm

PART THREE - FPT F5AE9484 ENGINE DIAGNOSIS

POSSIBLE ROOT CAUSE RECOMMENDED TESTS
FAILURE NOTES
(*) = if applicable to the appliance OR REMEDY
The engine does not start. Discharged of damaged battery. Check the battery and recharge it.
F5AE ENGINES
Replace the battery if necessary.

Battery terminal connections corroded or Clean, check and tighten the battery ter-
loose. minal screw nuts. Replace the terminals
and the screw nuts if excessively cor-
roded.
Nettoyer, examiner et serrer les écrous
des bornes de la batterie. Remplacer les
DIAGNOSIS BY FAILURE
cosses et les écrous sils sont excessive-

ment oxydés.
Incorrect timing of the ignition pump. Check the ignition pump timing. Apply to CNH Technical Service.
Deposits or water presence in the fuel Disconnect the pipes and clean them with Always bleed the supply system.
tank. compressed air jet. Disassemble the igni-
tion pump and clean it. Eliminate any pres-
ence of water in the fuel tank and refuel.
Insufficient fuel reserve. Refuel.
No supply. Overhaul or replace the supply or transfer
pumps.
Air bubbles in the fuel pumps or in the Check the pipes to ascertain the cause of
ignition pump. air presence and the supply pump. Elimin-
ate any air from the ignition pump interior
loosing the specially provided cap and
manually operating the supply pump.
Defective starter. Repair or replace the starter.
SECTION 3 - INDUSTRIAL APPLICATION
33
34
FAILURE NOTES
The engine does not start at low tem- Supply system obstruction by formation Change the existing fuel with other fuel
peratures. of paraffin crystals due to the use of suitable for low temperatures. Replace
unsuitable fuel. the fuel filter.
K.S.B. device for cold spark lead change is Overhaul or replace the supply pump. Apply to CNH Technical Service.
incorrectly working.
The engine stops. Idle too low. Adjust the idle level throughout the
adjusting screw.
Ignition pump irregular delivery. Regulate delivery. Apply to CNH Technical Service.
Impurities or presence of water in the fuel Disconnect the pipes and clean them with Always bleed the supply system.
pipes. compressed air jet. Disassemble the igni-
tion pump and clean it. Eliminate any pres-

ence of water in the fuel tank and refuel.
Fuel filter clogged. Disassemble and replace the fuel filter if
necessary.
Presence of air in the supply and ignition Check the pipes for cracks or loose pipe
systems. fittings. Replace the worn parts. Eliminate
air any air from inside the pipes and then
bleed the ignition pump and the fuel filter
loosing the specially provided caps and
manually operating the priming pump.
Ignition pump controls broken. Replace the ignition pump.
Incorrect slack between camshaft and Adjust the slack replacing the adjusting
tappets. plates.
Burnt, corroded or cracked. Replace the valves, overhaul or replace
the valve housings on the cylinder head.
F5AE ENGINES
FAILURE NOTES
The engine excessively heats up. Defective water pump. Check the whole unit and replace it if
F5AE ENGINES
necessary; replace the sheath.

Defective thermostat. Replace the thermostat.
Incrustation within the various cooling Accurate washing is necessary. Follow the
liquid passages of the cylinder head and instructions prescribed for the specific
unit. incrustation removal product to be used.
Insufficient tension of the water pump Check the belt tensioning and adjust it. In case of appliances equipped with auto-
drive belt. matic tensioning device, check that the
device is correctly working.
Cooling liquid level too low. Top up the radiator cooling liquid to the
level required.
Incorrect engine timing. Check timing.
Ignition pump incorrect calibration (too Adjust the pump delivery on bench. Igni- Apply to CNH Technical Service.
high or too low). tion must be set up according to the pre-
scribed delivery.
Obstructed air filter. Clean the air filter and replace it if necess-
ary.
Insufficient engine power and irregular Ignition pump incorrect timing. Check timing and proceed setting up the
functioning. ignition pump correctly.
Defective spark lead automatic changing Test the ignition pump functioning on Apply to CNH Technical Service.
device. bench. If the values detected to not com-
ply with the prescribed ones, replace the
changing device spring.
K.S.B. automatic spark lead changing Adjust or replace the ignition pump.
device failure.
Piston excessive wear. Proceed with engine overhaul and
replacement of worn parts.
Incorrect speed regulator calibration. Check the regulator and calibrate it. Apply to CNH Technical Service
35
36
FAILURE NOTES
Insufficient engine power and irregular Partial nozzle obstruction or defective Clean the nozzles throughout the
functioning. injectors. specially provided equipment and over-
haul the injectors.
Impurities or presence of water in the Accurate cleaning is necessary as well as Always bleed the supply system.
supply and ignition systems. refuelling.
Incorrect slack between camshaft and Check the slack and adjust it.
tappets.
Defective turbocharger. Replace the whole unit.
Obstructed air filter. Clean the air filter or replace it.
Defective L.D.A. device. Check that the membrane is not perfor- Apply to CNH Technical Service.
ated and that the counter spring is
appropriate and correctly loaded (test on
bench).
Check the pressure within the intake
manifold is correct in relation to the
engine speed at full load.
Incorrect adjustment of the tie rods con- Adjust the tie rods in order to be able to
necting the accelerator pedal and the take the control lever to maximum deliv-
regulators lever. ery position.
Defective injectors. Replace the injectors.
Obstructed fuel pipes. Disassemble the pipes, clean them and
replace those that are seriously dented.
Ignition pump incorrect setting. Correct the pump setting so that ignition Apply to CNH Technical Service.
may be carried out according to the pre-
scribed spark lead angle.
F5AE ENGINES
FAILURE NOTES
Anomalous engine strokes. Engine strokes cause excessive slack of Grind the engine drive shaft pins and fit
F5AE ENGINES
one or more crankshaft bearings or big undersize bearings. Replace the thrust
end bearings or excessive shoulder slack. bearing half rings.
Unbalanced engine drive shaft. Check the engine drive shaft alignment.
Loose flywheel fastening screws. Replace the loose screws and tighten
them to the prescribed torque setting.
Connecting rod misalignment. Replace the connecting rod.
Noisy piston pins for excessive slack of Replace the piston pin and/or the piston
piston hubs and connecting rod bush. and the connecting rod bush.
Loose bushes in their housing on the con-
necting rod.
Noisy timing. Adjust the slack between camshaft and
tappet and check there are no broken
springs. Furthermore, check that the slack
between valve stems and valve guides as
well as tappets an relevant seat.
Anomalous engine fumes. Black or dark Excessive pump maximum delivery. Disconnect the pump and adjust its deliv- Apply to CNH Technical Service.
grey fumes. ery referring to the calibration table of the
screw nuts.
Defective or incorrectly adjusted K.S.B. Adjust the ignition pump or replace it. Apply to CNH Technical Service.
device.
The ignition pump is excessively delayed Correct setting, check the spark lead
(or spark lead changing device is defec- changing device.
tive).
37
38
FAILURE NOTES
Anomalous engine fumes. Black or dark Ignition pump spark lead is excessive. Correct the adjustment.
grey fumes.
The nozzles (or some of them) are par- Replace the injectors with a series or new
tially or totally obstructed. injectors or, as an alternative, clean and
recondition the original ones using the
specific equipment.
Clogged or deteriorated air filter. Clean or replace the air filter.
Loss of compression within the engine Overhaul the engine or limit the inspec-
due to: tion to the parts of interest.
worn or stuck snap rings;
worn cylinder barrel;

deteriorated or incorrectly calibrated
valves.
Unsuitable injectors type, different type Replace the injectors.
of injectors or incorrectly calibrated injec-
tors.
Incorrect ignition pipe internal diameter, Check the conditions of the pipe ends or
dented pipe ends due to repeated locking. pipe fittings and eventually replace the
pipes.
Blue, blue-grey and whitish grey fumes. Excessive spark lead. Adjust the pump setting. Apply to CNH Technical Service.
K.S.B. automatic cold spark lead device is Calibrate the ignition pipe or replace the Apply to CNH Technical Service.
not malfunctioning. K.S.B. unit.
Defective injectors. Replace the injectors.
Remplacer les injecteurs.
Oil leakage from the piston rings caused Overhaul the engine.
by worn or stuck rings or barrels worn
inside.
Engine oil leaking through the intake valve Recondition the cylinder head.
guides, due to worn guides or valve stems.
Engine is too cold (thermostat is not Replace the thermostat.
working or defective)
F5AE ENGINES
PART FOUR
FPT F5AE9484 ENGINE
SCHEDULED
MAINTENANCE
SCHEDULED MAINTENANCE
Servicing Plan
Engine lubrication frequency has been calculated presuming the use of fuel with content of Sulphur < 0.5%.
! WARNING! In case of use of fuel containing a percentage of Sulphur e > 0.5 %, the engine oil replacement interval must
be halved.
Use engine oil SAE 15W40 T2
Overhaul and/or basic maintenance
Checks and regular servicing Frequency (hours)
Engine visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily

Check for presence of water in the fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . Daily
Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Check air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Check battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every six months
Check cooling liquid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Check the wear conditions of the alternators belt and of the water pump . . . . . 300 (2)
Check for presence of water in the pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 (1)
Check for presence of water in the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every six months (1)
Check the compressors belt wear conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Ignition pump overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000
Check turbo-compressor and clean it if necessary . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Tappet check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Change engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replace engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replace fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 (1)
Replace fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 (1) (3)
Replace the alternators belt and the water pump . . . . . . . . . . . . . . . . . . . . . . . . 1200
Replace air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 (2)
Replace the compressors belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
Change the cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 2 years or 1200 hours
(1) Using fuel complying with EN590 Standard

(2) Depending on appliance
(3) Using filters with filtering degree < 12 and > 200 filtering efficiency

F5AE ENGINES SECTION 4 - MECHANICAL OVERHAUL 1
SECTION 4
FPT F5AE9484
Engine Overhaul Specifications
Mechanical Overhaul
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
DATA - ASSEMBLY SLACK . . . . . . . . . . . . . . . 4
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . 10
ENGINE DISASSEMBLY ON BENCH . . . . . . . . 10
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 11
- Checks and measurements . . . . . . . . . . . . . . . 11
- Checking head base surface on cylinder unit . 12
TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Cam lift and pin alignment check . . . . . . . . . . 13
BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Tappet - Camshaft assembly . . . . . . . . . . . . . . 15
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . 16
FPT Engine Parts contact: - Main journals and crankshaft bearing pin
measurement . . . . . . . . . . . . . . . . . . . . . . . . . 16
Phone: 269 673 1638
Email: engineparts2@gmail.com - Crankshaft bearing assembly . . . . . . . . . . . . . 18
- Main journal assembly slack measurement . . . 18
- Engine drive shaft shoulder slack check . . . . . . 19
CONNECTING ROD-PISTON UNIT . . . . . . . 19
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Piston diameter measurement . . . . . . . . . . . . 20
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Conditions for the correct pin-piston coupling 21

2 SECTION 4 - MECHANICAL OVERHAUL F5AE ENGINES
Page Page
- Valve disassembly . . . . . . . . . . . . . . . . . . . . . . . 25
- Snap rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Cylinder head base surface check . . . . . . . . . . 26
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 22
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Valve scaling, checking and grinding . . . . . . . . 26
- Connecting rod-piston unit assembly . . . . . . . . 23
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Snap ring assembly . . . . . . . . . . . . . . . . . . . . . . 23
- Valve guide replacement . . . . . . . . . . . . . . . . . 27
- Snap ring fixing . . . . . . . . . . . . . . . . . . . . . . . . . 23
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Connecting rod-piston unit fixing into
cylinder barrel . . . . . . . . . . . . . . . . . . . . . . . . . 24 VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Connecting rod assembly slack measurement 24 CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . 28
- Piston projection check ................. 25 - Cylinder head assembly . . . . . . . . . . . . . . . . . . 28
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 25 TORQUE SETTING . . . . . . . . . . . . . . . . . . . . . . 29

Phone: 269 673 1638
FPT F5AE9484 SPECIFICATIONS
Type 4 CYLINDERS

Power See the specifications reported in Section 3
Injection Direct
Number of cylinders 4
Bore mm 99
Stroke mm 104
TIMING
start before T.D.C. A 19 30

end after B.D.C. B 37 30
start before B.D.C. D 61 30

end after T.D.C. C 21 30
Checking timing
mm
X 0.20 to 0.30
mm
X 0.45 to 0.55
Checking operation
mm
X 0.20 to 0.40
mm
0.45 to 0.65
FUEL FEED
Injection
Type: Bosch VE 4/12F
Nozzle type BOSCH DSLA138PV 33
Injection sequence 1-3-4-2

FPT F5AE9484 SPECIFICATIONS - DATA
Type 4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

1
99.000 ÷ 99.020
Cylinder barrels 1
X
1
504155506S Repair Sleeve-Cylinder Liner
Restores cylinder to standard
Spare pistons
1 type:
X Size X 10
2 Outside diameter 1 98.908 ÷ 98.918
Pin housing 2 36.003 ÷ 36.009
Piston cylinder barrels 0.082 ÷ 0.112
Piston diameter 1 0.4
X
Piston protrusion X -0.22 ÷ +0.07
3 Piston pin 3 35.990 ÷ 35.996
Piston pin pin housing 0.004 ÷ 0.019

Type 4 CYLINDERS

X1* 2.21
X1 Split ring slots X2 2.05 ÷ 2.070
X2 X3 2.540 ÷ 2.560
X3 * theoretical measurement
on a Ø of 96 -0.25 mm
S 1 S 1* 2.068 ÷ 2.097
S 2 Split rings S2 1.970 ÷ 1.990
S 3 S3 2.470 ÷ 2.490
* measured at 1.5 mm from
external Ø
1 -
Split rings - slots 2 0.06 ÷ 0.100
3 0.05 ÷ 0.09
Split rings 0.4
X1 Split ring end opening
X 2 in cylinder barrel:
X1 0.20 ÷ 0.35
X3
X2 0.60 ÷ 0.80
X3 0.30 ÷ 0.60
1 Crankshaft bearing bush

seat 1 42.987 to 43.553
Big end bearing seat
2 X 67.833 ÷ 67.841
2 0 67.842 ÷ 67.848
Crankshaft bearing bush

diameter
3 Internal 3 36.010 ÷ 36.020
4* 39.570 ÷ 39.595
4
S Red 1.875 ÷ 1.884
Crankshaft half bearings Blue 1.883 ÷ 1.892
Green 1.891 ÷ 1.900
* dimension not measurable
at free state
Piston pin bush 0.011 ÷ 0.024
Big end half bearings 0.254; 0.508

Type 4 CYLINDERS

X Measurement quota X 125
Maximum error on
parallelism of
connecting rod axles
Maximale Abweichung 0.09
des Parallelismus
der Pleuelachsen
1 2
Crankshaft bearing pins
No. 1-2-3-4 1 76.182 ÷ 76.208
No. 5 1 83.182 ÷ 83.208
Big end bearing pins 2 64.015 ÷ 64.038
S 1 S 2
Crankshaft half bearings S 1 2.165 ÷ 2.174
Big end half bearings S 2 1.876 ÷ 1.883
Main bearings
3 No. 1-2-3-4 3 80.588 ÷ 80.614
No. 5 3 87.588 ÷ 87.614
Half bearings Journals

No. 1-2-3-4 0.064 0.095
No. 5 0.059 0.100
Half bearings - Crankpins 0.033 to 0.041
Crankshaft half bearings
0.127; 0.254; 0.508
Big end half bearings
Crankshaft pin for

shoulder X1 31.85 ÷ 32.150
X 1
Crankshaft support for

shoulder X2 32.50 ÷ 32.55
X 2
X 3
Shoulder half-ringser X3 2.51 ÷ 2.56
Engine drive shaft shoulder 0.095 ÷ 0.270

Type 4 CYLINDERS
CYLINDER HEAD TIMING SYSTEM mm

1
Valve guide seats on

cylinder head 1 12.960 ÷ 12.995
2 8.023 ÷ 8.038
Valve guides
3 12.950 ÷ 12.985
3
4 Valves:
4 7.985 ÷ 8.000
60 30 ± 0 10
4 7.985 ÷ 8.000
60 30 ± 0 10
Valve stem and guide 0.040 ÷ 0.053
Housing on head for
valve seat:
1 39.987 ÷ 40.013
1 1 43.787 ÷ 43.813
Valve seat outside diameter;

valve seat angle on cylinder
2
head:
2 40.063 ÷ 40.088
60 ± 1
2 40.863 ÷ 43.88
60 ± 1
X 0.3 0.7
X Recessing of valve X 0.3 0.7
0.050 ÷ 0.101
Between valve seat
and head 0.050 ÷ 0.101
Valve seats -

Type 4 CYLINDERS

Valve spring height:
free spring H 44.6

H H1
H 2 under a load equal to:
270 N H1 34
528 N H2 23.8
Injector protrusion X 1.7 ÷ 2.35

X
Seat for camshaft no. 5 bush
(Timing System side) 59.222 ÷ 59.248
Camshaft seats
No. 2-3-4 50.069 ÷ 50.119
1 23 4 5 No. 1 40.069 ÷ 40.119
2
Camshaft supporting pins
1 39.975 ÷ 40.025
2 4 49.975 ÷ 50.025
1 3 5 53.995 ÷ 54.045
Bush inside
5
diameter 5 54.083 to 54.147
Bushes and journals 0.038 ÷ 0.162

Cam lift:
H H 5.5105
H 6.213

Type 4 CYLINDERS

1
Tappet cap housing
on block 1 15.000 ÷ 15.018
2
3 Tappet cap outside
diameter: 2 14.776 ÷14.780
3 14.950 ÷ 14.970
2
Between tappets and housings -
Tappets -
1
Rocker shaft 1 18.979 ÷ 19.000
Rockers 2 19.020 ÷ 19.033
2
Between rockers and shaft 0.020 ÷ 0.054

ENGINE OVERHAUL Figure 3

ENGINE DISASSEMBLY ON BENCH
To execute the operations described here following, it is

necessary to fit the engine on the rotary stand after having
removed all the appliances specific components (see Section
3 of the herein manual).
This section illustrates all the more important procedures of
engine bock overhaul.
119546
Figure 1
The third main bearing cap (1), the central one, and its support,
have the half bearing (2) provided with shoulder.
NOTE Note down the assembly position of the upper and

lower half bearings since, in case of reuse after the
overhaul, they will have to be reassembled in the
same position.
Figure 4
70158
Loosen the screws(1) fastening the connecting rod caps (2)

and remove the fastening the connecting rod caps.
Withdraw the pistons with the connecting rods from the
upper part of the crankcase.
NOTE Keep the half bearings in their respective housings

since, in case of reuse after the overhaul, they will
have to be reassembled in the same position.
120037
Using tool 380000362 (1) and a hoister, remove the engine

drive shaft (2) from the crankcase.
Figure 2
Figure 5
120173
119545
Loosen the screws (1) and disassemble the crankshaft bearing Disassemble the crankshaft half bearings (1).
caps (2). Loosen the fastening screws (2) and disassemble the oil
nozzles (3).
zs
Figure 6 REPAIRS
CYLINDER UNIT
Checks and measurements
Figure 9
119548
Loosen the fastening screws (1) and disassemble the

camshaft (3) holding plate (2).
70166
NOTE Note down the plate assembly position (2). Once completed the engine disassembly, carefully clean the
cylinder-crankcase units.
Use suitable eyebolts to handle the cylinder unit. Carefully
check the crankcase has for cracks. Check the conditions of
the processing caps: replace them if oxidized or in case their
Figure 7 tight is doubtful. Check the surface of the cylinder barrels:
there must be no trace of meshing, scratches, oval or conical
shaping and excessive wear.
Cylinder barrel inner diameter check to detect any oval or
conical shaping or wear shall be executed throughout the
bore meter (1) equipped with comparator, which must be
previously be reset on the ring calliper (2) of the cylinder
barrel diameter.
NOTE If the ring calliper is unavailable, use a micrometer

for reset.
119549
Figure 10
Carefully withdraw the camshaft (1) from the engine bock.
Figure 8
70167
The measurements must be made for each cylinder, at three
different heights from the barrel and on two perpendicular
planes: one parallel to the engine longitudinal axle (A) and the
other perpendicularly (B). Generally, maximum wear is
detected on the perpendicular plane (B) and with the first
measurement.
If oval or conical shaping or wear is detected, proceed boring
and grinding the cylinder barrels. Cylinder barrel grinding
70165
must be executed based on the spare pistons diameter plus
0,4 mm of the rated value and at the prescribed assembly
Withdraw the tappets (1) from the engine bock. slack.
Figure 11 Check the crankshaft bearing seats proceeding as follows:

- fit the crankshaft bearing caps on the supports without
bearings;
- tighten the fastening screws to the prescribed torque
setting;
- with a suitable comparator, check that the inner barrel
diameter corresponds to the prescribed value.
If the detected value is higher, replace the crankcase.
Checking head supporting surface on cylinder

unit
After having detected any deformed areas, grind the head
base surface using a grinding machine.
Planarity error must not exceed 0.075 mm. Check the
conditions of the cylinder unit processing caps: replace them
if oxidized or in case their tight is doubtful.

Phone: 269 673 1638
119550
NOTE In case of grinding, all the barrels must result having

the same oversize (0.4 mm).
TIMING SYSTEM
Camshaft
Figure 12
119551
MAIN DATA ABOUT CAMSHAFT PINS
The surface of the camshaft pins and of cams must be BUSH

extremely smooth. In case any trace of meshing or scratches
are detected, replace the shaft and the relevant bushes. Figure 14
Cam lift and pin alignment check

Place the camshaft on footstocks and, throughout a
centesimal comparator placed on the central support, check
that the radial oscillation does not exceed 0.015 mm
otherwise replace the shaft.
Figure 13
70172
The bush (2) of the camshaft must be forced in its housing.

The internal surfaces must have no trace of seizure or wear.
Measure the diameter of the bush with the bore control tool
(3).
The measurements must be carried out on two
perpendicular axes.
70171
Using a micrometer (1), check the diameter of the camshaft

(2) supporting pins on the two perpendicular axles.
Figure 15
119552
MAIN DATA OF THE CAMSHAFT BUSH AND RELEVANT SEAT

* Quota to obtain after bush fixing.

Bush replacement Tappet - camshaft assembly

Figure 16 Figure 18
70176
70174
Lubricate the tappets (1) and fit them into the relevant seats
Use the beater 380000667 (2) and handgrip 380000999 (3) on within the crankcase.
to disassemble and replace the bush (1).
Figure 19
NOTE In phase of assembly, the bush (1) must be oriented

making the lubrication ports coincide with those on
the crankcase.
119549
Lubricate the camshaft supporting bush and assemble the

camshaft (1) paying attention, during the aforesaid operation,
not to damage the bush or the shafts seats.
Tappets
Figure 20
Figure 17
119554
119553 Position the camshaft (3) holding plate (1) with the slot
towards the upper side of the crankcase and the marking
TAPPET AND RELEVANT SEAT ON CRANKCASE towards the operator; tighten the fastening screws (2) to the
MAIN DATA prescribed torque setting.
Figure 21 ENGINE DRIVE SHAFT

Measurement of main journals and crankshaft
bearing pins
Figure 23
119555
Check the camshaft axial shaft (1).

The prescribed value is 0.23 0.13 mm. 119557
Figure 22 In case meshing, scratches or excessive oval shaping is

detected on the main journals and crankshaft bearing pins, it
is necessary to grind the pins. Before proceeding with pin (2)
grinding, measure the shaft pins by means of a micrometer
(1) in order to establish to which diameter the pins must be
reduced.
NOTE it is recommended to note down the values

detected in a prospect
See Figure 24.
Undersize classes are: 0.254 - 0.508 mm.
70180
Fit the nozzles (2) and tighten the fastening screws (1) to the NOTE The main journals and crankshaft bearing pins must
prescribed torque setting. always be grinded to the same undersize classes in
order not to alter the shafts balance.
Figure 24
120038
PROSPECT REPORTING MEASUREMENT VALUES OF

THE ENGINE DRIVE SHAFT MAIN JOURNALS AND CRANKSHAFT BEARING PINS
* Rated value
Figure 25
120039
ENGINE DRIVE SHAFT MAIN TOLERANCES
TOLERANCES CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity / /
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY
TIMING SIDE BENCH INTERMEDIATE BENCHES FIRST BENCH ON FRONT

SIDE
119574

Crankshaft bearing assembly Measurement of main journal assembly slack
Figure 26 Figure 27
120037
120173
Assemble the engine drive shaft (2).
NOTE If it is not necessary to replace the crankshaft Check the slack between the engine drive shaft main journals
bearings, these shall be reassembled in the same and the respective crankshaft bearings proceeding as follows:
order and position they were before disassembly.
Figure 28
The spare crankshaft bearings (1) have undersize internal

diameter of 0.254 - 0.508 mm.
NOTE Do not adapt on bearings.
Carefully clean the crankshaft half bearings (1) having

lubrication port and fit them in their respective seats.
The penultimate crankshaft half bearing (1) is provided with
shoulder half rings. 119962
- clean accurately the parts and remove any trace of oil;

- place on the engine drive shaft pins (4) in parallel with
longitudinal axle, a piece of gauged wire (3);
- fit the caps (1) and the half bearings (2) on the relevant
supports.
NOTE Always use new main bolts

Figure 29 Engine drive shaft shoulder slack check
Figure 32
70187
Tighten the pre-lubricated screws (1) and tighten them in

three subsequent phases:
- 1st phase with torque wrench setting at 50 ± 5 Nm. 70190
- 2nd phase with torque wrench setting at 80 ± 6 Nm.
The check of the shoulder clearance is performed with a
Figure 30 magnetic based comparator (2) placed on the engine shaft
(3) as indicated in the figure.
If the clearance is above the one prescribed replace the
semi-crankshaft bearings of the thrust hold rear support next
to the last (1) and check again the clearance between the
engine shaft pins and the semi-crankshaft bearings.
119559
- 3rd phase using tool 380000304 (1) fitted as shown in
the figure and further tighten the screws (2) by 90º ± 5º
angle. CONNECTING ROD PISTON ASSEMBLY
Figure 31
Figure 33
119560 70191
- Remove the caps from their support.
The slack between the crankshaft bearings and the relevant CONNECTING ROD-PISTON UNIT COMPONENTS
pins should be detected comparing the width measured by
the gauge wire (2) in the point of maximum flattening with 1. Grommets. - 2. Pin. - 3. Piston. - 4. Snap rings. -
the scale graduation reported on the shield (1) of the gauge 5. Screws - 6. Half bearings. - 7. Connecting rod. - 8. Bush.
wire. The numbers reported on the scale indicate the
coupling slack in millimetres.
If the slack detected differs from the prescribed value, replace
the half bearings and repeat the measurement; once NOTE The spare pistons are supplied with standard
achieving the slack prescribed, lubricate the crankshaft dimensions or oversize by 0.4 mm.
bearings and finally assemble the supports tightening the
fastening screws as described previously.
Figure 34 Pistons
Piston diameter measurement
Figure 37
32613
32615
Using pincers 380000221 (3), remove the snap rings (1) from Using the micrometer (2), measure the piston diameter (1)
the piston (2). to determine the assembly slack.
NOTE The diameter must be measured at 10 mm from

Figure 35 the base of the piston shell.
Figure 38
32614
Remove the piston pin (1) grommet using the nail (3).
70192
The slack between piston and cylinder barrel can also be

measured by means of calliper and gauge (1), as shown in the
Figure 36 figure.
119561
MAIN DATA OF THE PISTON, PINS AND SNAP RINGS

* Quota detected on Ø 96 mm.
Piston pins Figure 42

Figure 39
18857 32620
Measurement of the piston pin diameter (1) throughout a Check the slack between the grommets (3) of the 2nd and
micrometer (2). 3rd slots and relevant housing on the piston (2) using calliper
Conditions for the correct coupling of pins and and gauges (1).
pistons
Figure 40 Figure 43
32619
41104
Lubricate the pin (1) with engine oil and the relevant seat on SCHEME FOR THE MEASUREMENT OF SLACK
the piston hubs; the pin must fit into the piston applying a BETWEEN THE FIRST PISTON SLOT AND THE
slight pressure with fingers and must not slip out for gravity. TRAPEZOIDAL GROMMET
Due to the particular for of the first grommet, having
trapezoidal section, the slack between said grommet and the
Snap rings slot must be measured as follows: the piston (1) must be
Figure 41 projected from the crankcase so that nearly half of the
grommet (2) in question comes out of the cylinder barrel (3).
In this position, using a gauge calliper, measure the slack (X)
between grommet and slot: the slack must comply with the
prescribed value.

Phone: 269 673 1638
16552
Check the thickness of the grommets (2) throughout a

micrometer (1). Website:
www.FPTIndustrialEngineParts.com
Figure 44 Figure 46
70194
Measurement of slack between the snap ring ends (2) fitted

into the cylinder barrel (3) throughout gauge calliper (1).
Connecting rods
Figure 45 119563
A. Class of weight - B. Part number - C. Date of

production (DD/MM) - D. Date of production (year) -
E. Marking for connecting rod-cap coupling.
NOTE In phase of assembly, ensure that all the connecting

rods belong to the same manufacturer and class of
weight.

Phone: 269 673 1638
119562
NOTE The connecting rod-connecting rod cap surfaces

are knurled to ensure better coupling. Therefore,
it is recommended not to remove the knurling.
Bushes Figure 49
Check that the connecting rod shoe bush is not loose and
that there is no trace of meshing or scratches otherwise
replace it.
Disassembly and reassembly must be executed using a
suitable beater.
When fixing it, make sure that the ports for oil passage on the
bush and on the connecting rod coincide. Throughout a
boring machine, bore the bush in order to obtain the
prescribed diameter.
Connecting rod-piston unit assembly

Connecting rod-piston coupling 72705
Figure 47 Fit the pin (1) snap rings (2).
Piston ring fixing

Figure 50
119564
The following references are marked on the piston crown:

1. Spare part number and modification number;
2. Indicative sign for piston assembly in the cylinder barrel;
it must be turned towards the flywheel;
3. Mark stating t the 1st slot insert
4. Date of manufacture.
32613
Use the pincers 380000221 (3) to fit the piston rings

(1) to the piston (2).
Figure 48 The piston rings must be fitted with ”TOP” marking
upwards. Furthermore, ring opening must be
misaligned by 120º.
NOTE The piston rings are available in the

following sizes:
- standard;
- oversize by 0.4 mm.

119565
Throughout the pin (3), connect the piston (2) to the

connecting rod (4) following the indication of the reference
arrow (1) to correctly fixing the piston (2) into the cylinder
barrel, also taking into consideration the numbers (5) printed
on the connecting rod (4), as shown in the figure.
Figure 51 Figure 53
119566
70200 SCHEME FOR CORRECTLY FIXING THE

CONNECTING ROD-PISTON UNIT INTO THE
HOLLOW
Fit the half bearings (1) on the connecting rod and cap.
- The snap rings openings must be misaligned by 120º;
- all the connecting rod/piston units must have the same
NOTE If it is not necessary to replace the big end bearings, weight;
reassemble the existing ones in the same order and
position they were before disassembly. - the engine drive shaft sign (1) printed on the piston
crown must be turned towards the flywheel while the
Do not adapt the half bearings.
notch on the piston shield must match the oil nozzles
position.
Warning! The connecting rod must not collide with

the cylinder wall.
Connecting rod assembly slack measurement

Figure 54
Fitting connecting rod-piston assembly into

cylinder barrels
Figure 52
70203
For slack measurement proceed as follows:

- carefully clean the parts eliminating any oil residuals;
- place a piece of gauge wire (2) on the engine drive shaft
pins (1);
70201
- fit the connecting rod caps (3) and the relevant half
Lubricate the pistons, the snap pins and the cylinder barrel bearings (4).
interior.
Using the band 380000210 (2), fit the connecting rod-piston
unit (1) into the cylinder barrel, checking that :
NOTE Always use new connecting rod bolts
- the number of each connecting rod corresponds to the
coupling cap number.
Figure 55 In case the slack measured differs from the prescribed value,
replace the half bearings and measure the slack again.
Piston projection check
NOTE See page 16 of Section 3.
70204
- Lubricate the fastening screws (1) with engine oil and CYLINDER HEAD
tighten them to the prescribed torque setting (50 ± 5
Nm) using a torque wrench.
Valve disassembly
Figure 58
Figure 56
75750
70205
The intake valves (1) and exhaust valves (2) have different
- Fit the tool 380000304 (1) to the socket wrench and head diameter.
then further tighten the screws (2) by 70º ± 5º.
Figure 57
NOTE Number the valves before removing them from the
cylinder head in order to be able to reassemble
them in the same order in case replacement is not
necessary.
A = intake side

Phone: 269 673 1638
70206
- Remove the cap and measure the slack comparing the Website: www.FPTIndustrialEngineParts.com
width measured by the gauge wire (1) with the scale
graduation reported on the gauge wire shield (2).
Figure 59 VALVES
Figure 62
EXHAUST INTAKE
VALVE VALVE
119567
Valve disassembly must be executed using tool 380000302

(1) to slightly press the plate (3) so that, compressing the
spring (4), it is possible to remove the half cone (2). Then
remove the plate (3) and the spring (4).
Repeat the operation in correspondence of each valve.
119569
Turn the cylinder head upside down and withdraw the valves
(5). INTAKE AND EXHAUST VALVE MAIN
Figure 60 SPECIFICATIONS
Valve scaling, checking and grinding
Figure 63
18625
119568
Remove the grommets (1 and 2) from their valve guides. Eliminate carbon deposits from the valves using the specially
provided metal brush.
Check the valves for meshing, cracks or burns.
Cylinder head base surface check If necessary, grind the valve seats removing as less material as
possible.
Any deformation detected on the whole length of the
cylinder head must not exceed 0.20 mm. Figure 64
In case higher value is detected, grind the cylinder head in
order to obtain the prescribed value. Refer to the main
specifications reported here following and follow the
instructions accompanying the figures below.
Figure 61
18882
119591
Using a micrometer (2) measure the valve stem (1): the
A rated thickness of the cylinder head is 90 ± 0,1 mm. prescribed value is 7,985 ÷ 8,000 mm.
VALVE GUIDE Valve guide replacement

Figure 65 Valve guide assembly and disassembly is performed with
beater 380000219.
Insert the valve guide in the cylinder head so that they stick
out from it for 8.1 ÷ 8.9 mm.
INTAKE EXHAUST
119570
Using a bore meter, measure the valve guide inner diameters,

which must correspond to the values reported in the figure
below.
VALVE SEATS
Figure 66
122433
VALVE SEAT SPECIFICATIONS

A. Seat of the aspiration valve - B. Seat of the discharge valve.
If the valve seat are damaged replace them with the spare Heat cylinder head up to 80º ÷ 100ºC and with the beater
ones included in the supply. With the tools and being careful assemble the new valve seats previously cooled in them.
not to indent the cylinder heads, remove as much material
as possible form the valve seats until removal from cylinder
head is possible by means of a punch.

Phone: 269 673 1638
VALVE SPRINGS Figure 69

Figure 67
119567
50676
Place the spring (4) and the upper plate (3) on the cylinder
head. Using tool 380000302 (1), compress the spring (4) and
MAIN SPECIFICATIONS FOR INTAKE AND EXHAUST
constrain the parts to the valve (5) throughout the half cones
VALVE SPRING TEST
(2).
Before assembly, test the valve spring flexibility using specific
tool. Compare the load and elastic strain test results with the
technical specifications of the new springs, reported in the
table below.
Cylinder head reassembly

Elastic strain Under load of Figure 70
mm N
H (free) 44.6 0
H1 34 270 14
H2 23.8 528 26
CYLINDER HEAD ASSEMBLY

Figure 68
119573
Check that the cylinder head and crankshaft coupling

surfaces are clean.
Do not foul the cylinder head sheath.
Fit the gasket (1) on the crankshaft in the correct centred
position, taking the pins as reference (2).

119572 Phone: 269 673 1638
Lubricate the valve stems (1) and fit them in the relevant Website: www.FPTIndustrialEngineParts.com
valve guides in the same position they were before
disassembly.
Fit the grommets (2 and 3) to the valve guide using tool
380000134.
FPT F5AE9484 BOLT TIGHTENING TORQUE SETTINGS SPECIFICATIONS

TORQUE
DESCRIPTION
Nm kgm
Side cap M6 40 5 4 0.5
Oill Pann Uniitt
Side caps M22 50 5 5 0.5

Front cap M35 40 5 4 0.5
Fixing of sump 70 5 7 0.5
Main bolts Crankshaft caps
- pre-tightening 50 5 5 0.5
- tightening 80 6 8 0.6
o k
- angle tightening 90 5

g e bloc
Piston cooling nozzle 18 2 1,8 0.2

3/8 conical threaded cap 40 5 4 0.5
Enngin
1/8 conical threaded cap 15 5 1.5 0.5

Water drainage cap 25 5 2.5 0.5
Oil turbo delivery pipe fixing 40 5 4 0.5
Conical threaded cap 15 5 1.5 0.5
Gear cooling nozze 15 5 1.5 0.5
Cover fastening (M8x1.25 6g x 35) 25 5 2.5 ± 0.5
rcase
Cover fastening (M8x1.25 6g x 35) 25 5 2.5 ± 0.5

e rc
Cover fastening (M8x1.25 6g x 16.5) 25 5 2.5 ± 0.5

Timing gea
Ignition pump screw stud 4 1 4 ± 0.1

Timing pin seat cap 25 5 2.5 ± 0.5
Ti
Gearcase fastening (M8x1.25 6g x 25) 25 5 2.5 ± 0.5

Case fastening M8 35 5 3.5 ± 0.5

Flywheel
casse
h
Case fastening M12 120 5 12 ± 0.5
Head Bolts (M15x 1.5 6g x 193)

First phase 130 10 13 1
Second phase 90 5
h ad
Third phase 90 5

Cylilinder he
Head Bolts (M12x 1.5 6g x 165)

First phase 65 5 6 ± 0.5
Second phase 90 5
Third phase 60 5
Threaded cap fastening 40 5 4 ± 0.5
Rocker arm dowel 25 5 2.5 ± 0.5
rheaad
Overhead fastening (M8x1.25 6g x 30) 25 5 2.5 ± 0.5

Overh
Overhead fastening (M8x1.25 6g x 50) 25 5 2.5 ± 0.5

Valve adjusting nut 20 5 2.5 ± 0.5
Inspection cover fastening 25 5 2.5 ± 0.5

Phone: 269 673 1638
FPT F5AE9484 BOLT TIGHTENING TORQUE SETTINGS SPECIFICATIONS

TORQUE
DESCRIPTION
Nm kgm
Intake manifold fastening (M8x1 .25 6g x 60) 25 5 2.5 ± 0.5

maniifold
Intake
k
f
Throw fastening to intake manifold 25 5 5 ± 0.5
Exhaust manifold fastening 35 5 3.5 ± 0.5

maniifold
Exhaaust
f
Turbo-blower stud screw 15 5 1.5 ± 0.5

Engine drive shaft pulley fastening 350 15 35 ± 1.5
Connecting rod bolt cap fastening
onnec
od
e
tinng ro
- pre-tightening 50 5 5 ± 0.5
Co

Phonic wheel fastening 15 3 1.5 ± 0.3
Flywheel fastening
- pre-tightening 30 5 3 ± 0.5
Thrust block fastening 25 5 2.5 ± 0.5
ming
Timi
Gear fastening 36 5 3.6 ± 0.5

Injector stud screw fastening 25 5 2.5 ± 0.5
t rs
n ctor
Injector fastening nut

Injec
- pre-tightening 15 5 1.5 ± 0.5

- tightening 30 2 3 ± 0.5
Pipe fixing on manifold side 20 5 2 ± 0.5
DA
LD
Pipe fixing on pump side 20 5 2 ± 0.5

Engine drive shaft speed sensor fixing 10 5 1 ± 0.5
Injeccttor
sensor
s
Water temperature sensor fixing 36 5 3.6 ± 0.5
Union fixing to support 25 5 2.5 ± 0.5

filtter
Fuuele
e
Fuel filter fastening 25 5 2.5 ± 0.5

Supply pump fastening 25 5 2.5 ± 0.5
Suppllyy
u p
pum
Inlet 25 5 2.5 ± 0.5

Fast clutch 25 5 2.5 ± 0.5
Injector fastening 10 5 1 ± 0.5
Injeccttor
scaar
Pump fastening 25 5 2.5 ± 0.5

Collector fastening screw nuts 25 5 2.5 ± 0.5
Oil delivery inlet fixing 25 5 2.5 ± 0.5
blower
Turbo
Delivery pipe fastening screw nut 25 5 2.5 ± 0.5

Exhaust pipe fixing to heat exchanger 25 5 2.5 ± 0.5
Exhaust pipe fixing to turbo 15 5 1.5 ± 0.5

Phone: 269 673 1638
TORQUE
D FPT F5AE9484 BOLT TIGHTENING TORQUE SETTINGS SPECIFICATIONS
Nm kgm
ooling Water pipe fixing to the heat exchanger 25 5 2.5 ± 0.5
pipee Water pipe fixing to the support 25 5 2.5 ± 0.5
Co
3/8 conical threaded cap 40 5 4 ± 0.5

Oil level
check
Oil pressure control valve fastening 45 5 4.5 ± 0.5

Suction
rose
Fixing of suction rose to the sump 10 2 1 ± 0.2
Cartridge union 45 5 4.5 ± 0.5

ter
Oilil filte
bodyo y
Oil filter fastening 25 5 2.5 ± 0.5

Oil filter cartridge fastening 18 2 1.8 ± 0.2
Oil pump fastening
1st step 15 5 1.5 0.5
2nd step 25 5 2.5 0.5
Threaded caps 45 5 4.5 ± 0.5
h ger
excchange
Heatt
Exchanger unit fixing 25 5 2.5 ± 0.5

Heat exchanger fastening 25 5 2.5 ± 0.5
Thermostat unit fixing 25 5 2.5 ± 0.5
rmo-
Therm
stat
a
Bleed vent fixing 40 5 4 ± 0.5

Water pump fastening 25 5 2.5 ± 0.5
Bearing fixing 40 5 4 ± 0.5
p rt
suuppor
Fan support fixing 25 5 2.5 ± 0.5

Fan
F
Pulley fixing 40 5 4 ± 0.5

Support fastening to block 50 5 5 ± 0.5
or
Alternnato
Alternator fastening (screw + nut) 50 5 5 ± 0.5

g oup
gro u
Push rod fixing 50 5 5 ± 0.5

Al
Alternator push rod fixing (screw + nut) 50 5 5 ± 0.5

Front hook fastening 50 5 5 ± 0.5
Rear hook fastening 70 5 7 ± 0.5
Oil temperature sensor fixing 25 5 2.5 ± 0.5
Impulse transmitter fixing 10 2 1 ± 0.2
Air pressure sensor fixing 10 2 1 ± 0.2
Pump gear fixing
e tion
- pre-tightening 18 2 1.8 ± 0.2

pump
- tightening 90 5 9 ± 0.5
Injjec
Fuel pump fastening nuts 25 5 2.5 ± 0.5

masses
ancing
Bal-
Masses box fastening 70 5 7 ± 0.5
Fastening of support 40 5 4 ± 0.5

Conntrol
socket
k
t
Cover fastening 25 5 2.5 ± 0.5

Phone: 269 673 1638
F5AE ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Pagina
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 SECTION 5 - TOOLS F5AE ENGINES
TOOLS
TOOL No. DEFINITION
- Puller for the gear coupling the injection pump to the engine
- Shrink fitter for the assembly of the drive shaft rear gasket
- Shrink fitter for the assembly of the drive shaft front gasket
Adapter for counterpressure checking in cylinders (use with

- 380001006)
- Brackets for fastening the engine to the rotatory stand 99322205
- Dynamometric wrench (20 -120 Nm) with 1/2 square coupling

TOOL No. DEFINITION
- Dynamometric wrench (60 -320 Nm) with 1/2 square coupling
380000134 Shrink fitter for valve guide gasket assembly
380000150 Tool for engine P.M.S. positioning
380000219 Beater for valve guide disassembly and reassembly
380000220 Ring for plunger introduction into the cylinder barrel (60 ÷ 125 mm)
380000221 Pliers for plunger snap ring disassembly and reassembly (65 - 110 mm)
TOOL No. DEFINITION
380000222 Sleeker for valve guide
380000228 Comparator (0 to 5 mm)
Comparator holding tool for rotatory injection pump phasing (use

380000229 with 380000228)
380000302 Tool for engine valve disassembly and reassembly
Pair of measuring devices for angular tightening with 1/2 and 3/4
380000304 square coupling
380000362 Tool for drive shaft lifting

TOOL No. DEFINITION
Comparator holding base for miscellaneous measures (use with

380000364 380000228)
Beater for distribution shaft bush disassembly and reassembly

380000667 (use with 380000999)
380000670 Tool for cartridge filter disassembly
Rotary stand for overhauling units (capacity 1000 daN, torque 120
380000978 daNm)
380000988 Tool for stopping the engine flywheel
380000999 Handle for interchangeable beaters

TOOL No. DEFINITION
380001006 Diesel engine cylinder compression control device

F5AE ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
2 APPENDIX F5AE ENGINES
F5AE ENGINES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

Standard safety prescriptions necessary instructions.
Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different
must be followed absolutely in a standard working area and operation from the ones theyve been designed and
whose non fulfillment will make any other measure useless provided for: serious injury may occur.
or not sufficient to ensure safety to the personnel in-charge - In case of test or calibration operations requiring engine
of maintenance. running, ensure that the area is sufficiently aerated or
Be informed and inform personnel as well of the laws in force utilize specific vacuum equipment to eliminate exhaust
regulating safety, providing information documentation gas. Danger: poisoning and death.
available for consultation.
- Keep working areas as clean as possible, ensuring During maintenance
adequate aeration.
- Never open filler cap of cooling circuit when the engine
- Ensure that working areas are provided with emergency is hot. Operating pressure would provoke high
boxes, that must be clearly visible and always provided temperature with serious danger and risk of burn. Wait
with adequate sanitary equipment. unit the temperature decreases under 50ºC.
- Provide for adequate fire extinguishing means, properly - Never top up an overheated engine with cooler and
indicated and always having free access. Their efficiency utilize only appropriate liquids.
must be checked on regular basis and the personnel
must be trained on intervention methods and priorities. - Always operate when the engine is turned off: whether
particular circumstances require maintenance
- Organize and displace specific exit points to evacuate intervention on running engine, be aware of all risks
the areas in case of emergency, providing for adequate involved with such operation.
indications of the emergency exit lines.
- Be equipped with adequate and safe containers for
- Smoking in working areas subject to fire danger must be drainage operation of engine liquids and exhaust oil.
strictly prohibited.
- Keep the engine clean from oil tangles, diesel fuel and or
- Provide Warnings throughout adequate boards signaling chemical solvents.
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of - Use of solvents or detergents during maintenance may
emergency. originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
Prevention of injury
- Do not leave rags impregnated with flammable
- Do not wear unsuitable cloths for work, with fluttering substances close to the engine.
ends, nor jewels such as rings and chains when working - Upon engine start after maintenance, undertake proper
close to engines and equipment in motion. preventing actions to stop air suction in case of runaway
- Wear safety gloves and goggles when performing the speed rate.
following operations: - Do not utilize fast screw-tightening tools.
- filling inhibitors or anti-frost
- lubrication oil topping or replacement - Never disconnect batteries when the engine is running.
- utilization of compressed air or liquids under pressure - Disconnect batteries before any intervention on the
(pressure allowed: 2 bar) electrical system.
- Wear safety helmet when working close to hanging - Disconnect batteries from system aboard to load them
loads or equipment working at head height level. with the battery loader.
- Always wear safety shoes when and cloths adhering to - After every intervention, verify that battery clamp
the body, better if provided with elastics at the ends. polarity is correct and that the clamps are tight and safe
- Use protection cream for hands. from accidental short circuit and oxidation.
- Change wet cloths as soon as possible - Do not disconnect and connect electrical connections
in presence of electrical feed.
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections. - Before proceeding with pipelines disassembly
Ensure that hands and feet are dry and execute working (pneumatic, hydraulic, fuel pipes) verify presence of liquid
operations utilizing isolating foot-boards. Do not carry or air under pressure. Take all necessary precautions
out working operations if not trained for. bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
- Do not smoke nor light up flames close to batteries and Non fulfillment of these prescriptions may cause serious
to any fuel material. injury and poisoning.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.
4 APPENDIX F5AE ENGINES
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

incorrect tightening may seriously damage engines
components, affecting engines duration. - Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
- Avoid priming from fuel tanks made out of copper alloys personnels safety and health shall be adopted.
and/or with ducts not being provided with filters.
- Be informed and inform the personnel as well of laws in
- Do not modify cable wires: their length shall not be force regulating use and exhaust of liquids and engine
changed. exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that
equipment unless specifically approved by CNH. personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Do not modify fuel systems or hydraulic system unless
CNH specific approval has been released. Any - Collect exhaust oils in adequate specially provided
unauthorized modification will compromise warranty containers with hermetic sealing ensuring that storage is
assistance and furthermore may affect engine correct made in specific, properly identified areas that shall be
working and duration. aerated, far from heat sources and not exposed to fire
danger.
For engines equipped with electronic gearbox:
- Handle the batteries with care, storing them in aerated
- Do not execute electric arc welding without having environment and within anti-acid containers. Warning:
priory removed electronic gearbox. battery exhalation represent serious danger of
- Remove electronic gearbox in case of any intervention intoxication and environment contamination.
requiring heating over 80ºC temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.

Phone: 269 673 1638
LAST PAGE

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FPT ENGINE 1

FPT F5AE9484 ENGINE WORKSHOP MANUAL

Overhaul and specifications 4

ENGINE OIL VAPOUR RECIRCULATION . . . . . . 11

TYPE PART NUMBER

Progressive production number

Level of Gas Emissions (Tier 3)

Engine torque and power level

Use (eg 4 = tractors)

Air feed + injection (TCA, direct injection diesel engine)

Indicates the engine family

FPT Engine Parts contact: Phone: 269 673 1638

FRONT VIEW OF ENGINE

LEFT SIDE VIEW OF ENGINE

RIGHT SIDE VIEW OF ENGINE

REAR VIEW OF ENGINE

TOP VIEW OF ENGINE

LUBRICATION SYSTEM LAYOUT

1. Turbocharger lubrication feed pipe - 2. Heat exchanging unit - 3. Heat exchanger -

Counterotating mass balancing device

Engine oil filter

1. Protective cover - 2. Cartridge

Booster pressure 20 bar (ISO 4548/3)

ENGINE OIL VAPOUR RECIRCULATION

1. Valve - 2. Breather - 3. Tappet cover

FPT Engine Parts contact: Phone: 269 673 1638

Engine cooling water

Water outflow from thermostat

COOLING SYSTEM LAYOUT

WATER PUMP SECTION

Heated compressed air

Engine exhaust gas

FPT Engine Parts contact: Phone: 269 673 1638

EGR EXHAUST GAS RECIRCULATION

Aspiration cam profile

X. Angolo rotazione camma - Y. Alzata camma

- Working System Description . . . . . . . . . . . . . 5

- Identification coding example . . . . . . . . . . . . . 6

WORKING SYSTEM DESCRIPTION . . . . . . . . . . . 7

- End of delivery phase . . . . . . . . . . . . . . . . . . . . 8

- L.D.A. Load Delivery Adjustment device . . . . . 9

FUEL FILTER ............................. 11

SUPPLY SYSTEM DIAGRAM

FPT Engine Parts contact: Phone: 269 673 1638

FPT Engine Parts contact: Phone: 269 673 1638

Working system description

Identification coding example

Ignition pump longitudinal section

WORKING SYSTEM DESCRIPTION

1. Fuel feed pipe - 2. Compression chamber - 3. Distributor piston inner pipe

End of delivery phase

Engine stop is provoked cutting out the starter contact.

L.D.A. Load Delivery Adjustment device

1. Pump - 2. Control lever - 3. Camshaft

ENGINE DISASSEMBLY ON BENCH . . . . . . . . 7

- BOSCH VE 4/12F pump . . . . . . . . . . . . . . . . . 8

- Rear side component assembly . . . . . . . . . . . 13

- Front side component assembly . . . . . . . . . . . 14

- Piston projection measurement . . . . . . . . . . . 16

- Inspection and checks . . . . . . . . . . . . . . . . . . 21

- Screw two pins (1) of appropriate length into the shafts

NOTE Check that the blocks laying plan is clean.