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HYUNDAI F4GE N SERIES ENGINE REPAIR MANUAL

NSERIES
F4G TIER 3
Agricultural applications (Hyundai)
F4GE9484F*J608
F4GE9454J*J604
Technical and Repair manual

THIS ENGINE IS USED IN
HYUNDAI MACHINES,
KOBELCO MACHINES, Excavators
IVECO
CASE 440CT SKIDSTEER

TABLE OF CONTENTS:
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General specifications
Fuel
Agricultural applications
Overhaul and technical specifications
Tools
Safety prescriptions Appendix

SECTION 1 General Specifications
LUBRICATION
OIL VAPOUR RECIRCULATING SYSTEM
COOLING SYSTEM
AIR INDUCTION BOOST DIAGRAM
- Boosting version engines
- Description
- Inter-cooled engine version
- Description
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR)
SECTION 2 Fuel
4-CYLINDER ENGINES WITH BOSCH VE 4/12 F
ROTARY MECHANICAL PUMP
- General information
- Description of working principles
FEED PUMP
- Example of identification
PRIMING PUMP
FUEL FILTER
SECTION 3 Agricultural application
GENERAL INFORMATION
CLEARANCE DATA
PART ONE -MECHANICAL COMPONENTS
OVERHAUL OF THE ENGINE
- Preface
- Engine setting operations for the assembly on turning stand
- Disassembly of application components
- Installation of rear components
- Flywheel installation
- Installation of front components
- Completion of engine
- Rotary feed pump disassembly and assembly pro-cedure
- Power take-off disassembly and assembly procedure
- Feed system bleed procedure
- Checks and inspections
PART TWO -ELECTRICAL EQUIPMENT
ELECTRICAL COMPONENT LAYOUT
- Cooling liquid temperature sensor
- Starter
- KSB Water temperature sensor
- Electromagnets assembled to feed pump
- Oil pressure sensor
- Alternator
- Pre-post heating resistor
PART THREE - TROUBLESHOOTING
PART FOUR -MAINTENANCE PLANNING
MAINTENANCE SCHEDULE
- Checks not included in maintenance planning-daily checks
MAINTENANCE PROCEDURES
- Checks and controls
- Engine oil level check
- Check of fuel system
- Cooling system check
- Lubricating system check
- Check of water presence within fuel filter or pre-filter
- Check of drive belt tensioning
- Check of belts tear and wear status
- Check and setting of tappet clearance
- Oil motor and filter replacement
- Fuel filter replacement
- Alternator belt replacement
SECTION 4 Overhaul and technical specifications
GENERAL SPECIFICATIONS
CLEARANCE DATA
TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS VE 4/12 F
ENGINE OVERHAUL
ENGINE REMOVAL AT THE BENCH
REPAIR OPERATIONS
CYLINDER UNIT
- Checks and measurements
- Checking head supporting surface on cylinder unit TIMING SYSTEM
- Camshaft
- Checking cam lift and pin alignment
BUSHES
- Bush replacement
- Tappets
- Fitting tappets camshaft
OUTPUT SHAFT
- Measuring journals and crankpins
- Replacing oil pump control gear
- Fitting main bearings
- Finding journal clearance
- Checking output shaft shoulder clearance
CONNECTING ROD PISTON ASSEMBLY
- Piston pins
- Conditions for proper pin-piston coupling
- Split rings
- Connecting rods
- Bushes
- Fitting connecting rod-piston assembly
- Connecting rod-piston coupling
- Fitting split rings
- Fitting connecting rod-piston assembly into cylinder barrels
- Finding crankpin clearance
- Checking piston protrusion
CYLINDER HEAD
- Removing the valves
- Checking cylinder head wet seal
- Checking cylinder head supporting surface
VALVES
- Removing carbon deposits, checking and grinding valves
- Checking clearance between valve stem and valve
guide and valve centering
VALVE GUIDE
VALVE SEATS
- Regrinding replacing the valve seats
VALVE SPRINGS
FITTING CYLINDER HEAD
- Refitting the cylinder head
TIGHTENING TORQUE
SECTION 5 Tools
Appendix SAFETY PRESCRIPTIONS

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Model Specification: HYUNDAI F4GE N SERIES ENGINE F4G TIER 3
LANGUAGE: English
FORMAT: PDF
Requirements: Adobe PDF Reader & WinZip.
ZOOM IN/OUT: YES
Downloadable: YES
COMPATIBLE: All Versions of Windows & Mac

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WITH THIS MANUAL, YOU MAY MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR OWN. WITH STEP BY STEP INSTRUCTION & HIGHLY DETAILED EXPLODED PICTURES & DIAGRAMS TO SHOW YOU HOW TO COMPLETE THE REQUIRED JOB CORRECTLY & EFFICIENTLY. ALL REPAIR PROCEDURES ARE COVERED. IT'S THE SAME TYPE OF MANUAL THAT YOUR LOCAL DEALER/MECHANIC WOULD USE.

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Tons of pictures and diagrams at your fingertips!!

All pages are printable, so run off what you need & take it with you into the garage or workshop.

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