Engine Iveco Vector 8. Manual — part 18

Figure 77

- On the bench, fit the previously removed fittings onto

the compressor (1): suction (2) and compression (3)
fittings: thread M26 = 100 Nm.

Change the gasket (4) at the fitting mounted on the
compression port.

- Insert the gear (5), flat washer (6) and screw down the

nut (7), tightening to a torque of from 160

÷ 180 Nm.

- Fit the low-pressure pump (8), inserting the universal

joint (9) and O-ring (10).

Change the gaskets (10), (11) and (12).

Should compressor have been dismounted jointly
with spacer, tighten (M12x1.75) screws securing it
to gears box at 42 ÷ 51 Nm tightening torque.

- Put compressor into its seat by tightening (M12x1.75) at

74 ÷ 90 Nm Nm torque.

- Secure bracket (13, Figure 77) to engine block.

- During assembly, check that the coupling drive (9) and

the teeth on the front of the secondary circuit cooling
pump gear show no signs of wear or cracks. Change any
damaged parts.

- Fit support bracket (13) and tighten the screws securing

the low—pressure pump support to the air compressor
to the prescribed torque: 42÷51 Nm.

For DRAGON applications

89697

NOTE

NOTE

89698

Figure 78

NOTE

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SECTION 3 - INDUSTRIAL APPLICATION

VECTOR 8 ENGINES

Base - April 2006

Print P2D32V001E

- Fit the low—pressure pump (2) together with the

coupling drive (4), O—ring and spacer (3) on the back of
the gearbox: tighten the screws (1) to the prescribed
torque.

Figure 79

Figure 80

Figure 81

- Fit the cooling pump.

- If the same pump is used replace seal (3).

- If necessary, replace the pump gear (1) tightening the

bolt (2) to the recommended torque.

- During assembly, check that the coupling drive and the

teeth on the front of the secondary circuit cooling pump
gear show no signs of wear or cracks. Change any
damaged parts.

- Tighten the screws securing the low—pressure pump

support to the gearbox to the prescribed torque.

Having to tighten screw (2), it is necessary to
prevent the gear (1) from turning in an appropriate
manner without damaging the parts. Before
tightening, lubricate the screws with UTDM oil or
alternatively with engine oil. (The gear has a
left-hand locking screw).

- At the front of the gearbox, fit the secondary system

cooling circuit pump together with the gears.

- Supporting the pump place it in its seat. Tighten the

M10x1.5 nuts securing the water pump to the front gear
cover 33

÷ 40 Nm.

- Then fit the pipe (1) securing it to the actual pump and

the hose (2) using the two bolts (1).

Whilst fitting the drive coupling, check that the front
drive teeth on the pump gear are properly housed
inside the splining.

89792

103475

103229

For all applications

NOTE

For G-DRIVE / SPRINKLER and GRIFFON applications

NOTE

SECTION 3 - INDUSTRIAL APPLICATION

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VECTOR 8 ENGINES

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Base - April 2006

Figure 82

COMMON RAIL ASSEMBLY PROCEDURE

Preparing for assembly

- This procedure allows to have the best assembling,

reducing the stress on the CR components due to
tolerances and misalignments and will avoid the risk to
have dangerous fuel leakage under pressure, during all
typical condition of the Vector engines operative duty.

- This procedure will apply during first CR assembling in

manufacturing plant as well as during maintenance and
replacement of one or more CR components

Cleaning and preparation

- Before mounting, assure that each pipe is protected with

appropriate plastic cap supplied by Bosch. Remove by
hands the protective caps just before the installation. Do
not use sharp tooling that might cause damage on the
sealing surface. All pipes have to be cleaned up and to
be particulate free, and the sealing surface have to be
without any defect.

- All sealing surfaces, nuts and threads have to be

lubricated with clean engine oil (for example: 15W40).

Assembly procedure

- The high pressure pump (HPP) and the injector’s are

mounted firmly in average position of bolt clearance,
with the defined tightening torque.

- All the pipes are fitted by only tightening the areas

connected to the HPP, the rails and the injectors
manually (J1.1 - J8.2, V1.1 - V3.2: see Figure Figure 84).
Fit the centre support plate (1) closing the fastenings for
the pipes from the HPP to the rails, from the rails to the
injectors and on the intermediate pipe checking that the
centre pipes are kept in a horizontal position and are flat.
Apply a pre-tightening torque of 20 Nm and then a
pre-tightening torque of 50 Nm to all the connectors.

Figure 83

112491

It is vital to use a special torque wrench for the
fitting procedure described here.

NOTE

- The rails are installed on their supports, previously fixed

on the cylinder heads by the related screws tightened
with proper tightening torque of 25 Nm (screws 1). The
rails have to be in horizontal position and aligned and the
fixing caps have to be positioned with the related screws
loose on the support (screws 2).

82259

- lubricate all the connectors with clean oil.

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Figure 84

103480

- Tighten the connectors for the pipes from the HPP to

the rails (V1.1 and V2.1) to the interface with the HPP
to torque checking that the pipes are kept in a horizontal
position and are flat. Apply a tightening torque of 140
+ 5 Nm.

- Tighten the connectors (V1.2 and V2.2) to the interface

with the rails checking that the pipes are kept in a
horizontal position and are flat in order to ensure the
seal between the contact surfaces. Apply a tightening
torque of 130 + 5 Nm.

- Tighten the connectors for the V3 pipe to a torque of

130 + 5 Nm in total for both parts.Check the horizontal
alignment of the pipe.

- Tighten the injector/rail connecting pipes to the

interface with the common rails in the following order:
J 8.2 - J 7.2 - J 6.2 - J 5.2 - J 4.2 - J 3.2 - J2.2 - J1.2. During
this fitting procedure the flow limiters should be kept
against the tightening direction.Apply a torque of 115 +
5 Nm.

- Tighten the connectors for the injector/rail connecting

pipes to the interface with the injectors in the following
order: J 8.1 - J 7.1 - J 6.1 - J 5.1 - J 4.1 - J 3.1 - J 2.1 - J
1.1.During this fitting procedure the injectors should be
kept against the tightening direction.Apply a torque of
95 + 5Nm.

- Tighten all the bolts for the common rail supports to the

caps (bolts (B)) to the recommended torque of 25 Nm.

- Any leaks are checked when the engine is switched on.

Test procedure for checking for diesel leaks
from the Common Rail system.

The following procedure is carried out on the engine to
check that there are no diesel leaks from the Common Rail
system after repair operations.

The aim of this test is to let the rail pressure reach maximum
values with the engine running in no load idling conditions.

Equipment to be used: IST or ELTRAC tool

Order of operations:
1) Switch on the engine and let it reach idle speed.
2) Key in the DIAGNOSTICS window on the IST
3) Select DIAGNOSTIC TESTS
4) Select FUEL RAIL PRESSURE TEST
5) Key in START at the bottom
6) Key in STEP UP several time up to 150-160 Mpa with the
engine idling.
7) Check that there are no leaks from all the connectors.
If a leak is detected, switch off the engine and carry out the
procedures describe previously.
8) Return to the nominal pressure using the STEP DOWN
button.
9) When running in the engine, check the tightening
torques of all fittings at least once and adjust. The aim of this
operation is to tighten any fittings that have become loose
due to settlement. Do not unscrew any fittings but simply
tighten to the specified installation torque. After running in
the engine, tighten all the fittings to the specified torques
using a torque wrench. Check the remaining torques as
indicated in the installation procedure.

SECTION 3 - INDUSTRIAL APPLICATION

39

VECTOR 8 ENGINES

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Base - April 2006