Iveco Daily Euro 4. Manual — part 42
160
F1C ENGINE
D
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4
SYSTEM OPERATION
295
. . . . . . . . . . . . . . . . . . . .
- Self-diagnosis — BLINK CODE
295
. . . . . . . . . . . . .
- Immobilizer recognition
295
. . . . . . . . . . . . . . . . . .
- Checking fuel temperature
295
. . . . . . . . . . . . . . . .
- Checking engine coolant temperature
295
. . . . . . .
- Checking quantity of fuel injected
295
. . . . . . . . . . .
- Checking idling adjustment
295
. . . . . . . . . . . . . . . .
- Fuel cut-off in release phase
295
. . . . . . . . . . . . . . .
- Checking cylinder balancing on idling
295
. . . . . . . .
- Checking regular engine rotation (anti-sawing)
295
.
- Checking smokiness at exhaust on acceleration
295
- Checking exhaust gas recirculation (E.G.R.)
295
. . .
- Checking top speed limit
295
. . . . . . . . . . . . . . . . .
- Checking regular rotation on acceleration
295
. . . .
- Checking glow plug control unit
295
. . . . . . . . . . . .
- Checking activation of air-conditioning system
295
.
- Checking fuel pump
295
. . . . . . . . . . . . . . . . . . . . .
- Checking diesel warming
296
. . . . . . . . . . . . . . . . .
- Checking cylinder position
296
. . . . . . . . . . . . . . . .
- Checking pilot and main injection timing
296
. . . . .
- Checking injection pressure closed cycle
296
. . . . .
- Fuel supply
296
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Correcting flow rate according to water temperature
296
- Correcting flow rate to avoid noise, smoke or
overloading
296
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- De-rating
296
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injection timing electronic test
296
. . . . . . . . . . . . .
- Speed governor
296
. . . . . . . . . . . . . . . . . . . . . . . .
- Engine starting
296
. . . . . . . . . . . . . . . . . . . . . . . . .
- Cold starting
297
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Warm starting
297
. . . . . . . . . . . . . . . . . . . . . . . . .
- Run up
297
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- After run
297
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cut-off
297
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cylinder balancing
297
. . . . . . . . . . . . . . . . . . . . . .
- Synchronization search
297
. . . . . . . . . . . . . . . . . . .
OPERATION
298
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
HYDRAULIC SYSTEM
298
. . . . . . . . . . . . . . . . . . . . .
- Fuel pipes
298
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEED SYSTEM AND FUEL RECIRCULATION
299
. .
HYDRAULIC SYSTEM
301
. . . . . . . . . . . . . . . . . . . . .
- Fuel pump
301
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- ”Filtrauto” fuel filter
302
. . . . . . . . . . . . . . . . . . . . .
- ”UFIfilters” fuel filter
303
. . . . . . . . . . . . . . . . . . . . .
- CP3.2 high-pressure pump
304
. . . . . . . . . . . . . . . .
- Pressure regulator
305
. . . . . . . . . . . . . . . . . . . . . .
- Replacing pressure regulator
305
. . . . . . . . . . . . . . .
- Hydraulic accumulator (rail)
306
. . . . . . . . . . . . . . .
ELECTRO-INJECTORS
307
. . . . . . . . . . . . . . . . . . . .
- Operation
307
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing an electrical injector
307
. . . . . . . . . . . . .
ELECTRIC/ELECTRONIC COMPONENTS
308
. . . . .
- Electronic control unit EDC 16
308
. . . . . . . . . . . .
- Glow plug electronic control unit
309
. . . . . . . . . . .
- Glow plugs
309
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSORS
309
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Engine speed sensor
309
. . . . . . . . . . . . . . . . . . . . .
- Camshaft timing sensor
309
. . . . . . . . . . . . . . . . . .
- Air temperature and pressure sensor
310
. . . . . . . .
- Fuel temperature sensor
310
. . . . . . . . . . . . . . . . .
- Fuel pressure sensor
310
. . . . . . . . . . . . . . . . . . . . .
- Atmospheric pressure sensor
310
. . . . . . . . . . . . . .
- Engine coolant temperature sensor
310
. . . . . . . . .
- Throttle pedal position sensor
310
. . . . . . . . . . . . .
- Clutch pedal position sensor
310
. . . . . . . . . . . . . .
- Brake pedal position sensor
310
. . . . . . . . . . . . . . .
- Vehicle speed sensor
310
. . . . . . . . . . . . . . . . . . . .
- Differential pressure sensor - delta p (Dp)
310
. . . .
- Exhaust gas temperature sensor
310
. . . . . . . . . . . .
ACTUATORS
311
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- PWM (Pulse Width Modulation) controls
311
. . . .
MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE
Keep to the following instructions before doing any work on the engine involving components of the fuel supply system.
- Before doing any work on the engine, perform the engine/vehicle fault diagnosis with specific IVECO diagnosis
equipment and print out the results.
- Replacement of the MS6.3 or EDC 16control unit must be authorized by the Help Desk. Replacing operation
requires reprogramming as described in specific section.
- Following components in feed system cannot be overhauled but have to be replaced: pressure relief valve, if present,
fuel pressure sensor, hydraulic accumulator, complete CP3 high pressure feed pump, pressure control valve, electric
injectors.
- All the parts of the Common Rail system are packaged by the supplier in sheets of oiled paper and are stored in
cardboard boxes. They must therefore be protected against moisture and unpacked just prior to assembly.
- The greatest care must be taken over the cleanliness of parts, making sure that when handling or assembling
(starting with straightforward filter and pre-filter replacement) no dirt of foreign bodies can get inside. For this
reason, the plugs protecting the hydraulic parts and sensors must be removed just prior to positioning in their seats.
- Take care over the direction of assembly for all electrical connections.
- All threaded connections must be tightened to the prescribed torque.
- All the quick-coupling connectors (on the engine they are found on the high-pressure pump and on the diesel drain
manifold) must be fully inserted. To drive them out, press on the tabs at the base of the connectors.
Electro-injector
None of the couplings/unions/nuts on the injector body may be handled. It is neither necessary nor permitted to
dismantle the nozzle body or the electromagnet.
If working on the high-pressure pipe, the hexagon on the injector side must be kept stationary with a wrench.
Before working on pipes, make sure the injector is stationary in its seat on the cylinder head.
When assembling/disassembling the injector drain, the retaining spring must not be removed from its seat in the injector:
pushing the spring towards the engine and applying a vertical force on the connector frees the recirculation. When
assembling, rest the recirculation connector in its seat and apply a vertical force while keeping the retaining spring
pressed in the direction of the engine. Fitting in has to be easy.
Replacing one or more electrical injectors requires central unit programming as described in specific section.
CP3 High-pressure pump
If working on the high-pressure pipe, the hexagon on the pump side must be kept stationary with a wrench.
Before working on the high-pressure pipe, make sure the pump is secured in its seat.
High-pressure pipes
Each high-pressure pipe must be replaced after disassembly operations.
The couplings must be tightened or loosened with the injectors, hydraulic accumulator (rail) and high-pressure pump
well secured and taking care to keep the hexagon on the component side stationary, space permitting.
Hydraulic accumulator (rail) and accessories
The pressure sensor can be assembled five consecutive times; after that, it must be replaced. They must be lubricated
with a thin layer of oil before being mounted.. Replacing the sensor requires central unit programming as described in
specific section.
F1C ENGINE
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D
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Service procedures to be performed after
replacing high-pressure feeding system and/or
exhaust
gas
post-treatment
system
components
For engine correct operation, E.D.C. 16 central unit stores,
into memory non volatile area, information relating to engine
parameters originally set or acquired during operation.
Consequently, whenever a component of high pressure feed
system and/or of the post-treating system for below listed
exhaust gasses, the central unit has to be reprogrammed by
IVECO diagnosis tool: MODUS - E.A.SY. - IT 2000; then the
procedure to replace affected component has to be carried
out, following below indications provided by diagnosis tools:
- replace injector;
- replace all injectors;
- replace flow rate meter (flow meter);
- replace hydraulic accumulator (common rail);
- replace E.D.C. 16 central unit;
- refill engine oil;
- replace D.P.F. catalyst;
- replace filter differential pressure (
∆p) sensor;
- replace components relevant to emissions;
- necessarily perform a forced regeneration;
- replace central unit.
162
F1C ENGINE
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E
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4
540110
POWER UNIT REMOVAL/REFITTING
108628
Removal
Place the vehicle on the pit or auto lift.
Lift the engine hood (26), undo the fastening screws (27) and
then remove the hood; remove supporting rod (28).
Disconnect negative cable (4) and positive cable (11) from
battery (10), then remove the latter from the engine
compartment.
Disconnect electric connections (5, 7, 8 and 9) and engine
cable (6) from the EDC control unit, then release the engine
cable from the straps securing the same to the cab.
Unhook cable (1) from the hood opening control devices.
Disconnect front headlamp electric connections (12).
Remove screws (19), then take off cover (18).
Remove fastening screws (32), then take off headlamp inserts
(13).
Do not change the assembly position of headlamp
insert (13) threaded bush (14, detail D).
NOTE
Remove the screws and/or fastening nuts, then remove
crosspiece (33).
Remove the screws and/or fastening nuts, then remove
bumper (17).
Remove expansion tank (3) cap (2).
Act as follows, from under the vehicle (see figure 4):
- undo fastening screws (12 and 13), then remove lower
side guards (14);
- undo fastening screws (16), then remove lower central
guard (26).
Apply a tube (16) to radiator pipe union (detail C), then
unscrew cap (15) and drain the coolant into a suitable
container.
If the vehicle is equipped with a cab air-conditioning
unit, proceed as follows:
- fit the unit 99309146 pipes to connections (23),
then blow the gas off the air-conditioning unit as
described in the respective charter of the
”Bodywork and chassis” section;
- disconnect electric connection (29) from the
drying filter pressure switch;
- disconnect pipes (20) from air-conditioner
compressor (21);
- remove nuts (25), then disconnect pipes (22)
from expansion valve connection (24).
NOTE
Seal the air-conditioning unit pipes and their
respective mounts, to prevent moisture and
impurities from penetrating into the system.
NOTE
Figure 1
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D
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