Iveco Daily. Manual — part 11
ENGINES 8140.43R/B/S/N
26
D
AILY
Base - May 2004
- Assembling main bearings
69
. . . . . . . . . . . . . . . . .
- Measuring main journals assembly clearances
70
. .
- Checking crankshaft end float
71
. . . . . . . . . . . . . .
- Checking alignment pulley crankshaft
71
. . . . . . . .
- Rear crankshaft cover
71
. . . . . . . . . . . . . . . . . . . .
- Front crankshaft cover
71
. . . . . . . . . . . . . . . . . . .
ENGINE FLYWHEEL
72
. . . . . . . . . . . . . . . . . . . . . .
- Replacing bearing supporting gearbox
input shaft
72
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing engine flywheel ring gear
72
. . . . . . . . .
CONNECTING ROD - PISTON ASSEMBLY
72
. . .
- Pistons
74
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring the pistons diameter
74
. . . . . . . . . . . .
- Piston gudgeon pins
74
. . . . . . . . . . . . . . . . . . . . .
- Conditions for correct pin-piston coupling
74
. . . .
- Piston rings
75
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting rods
76
. . . . . . . . . . . . . . . . . . . . . . . .
- Bushes
76
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking connecting rod for distortion
76
. . . . . .
- Checking torsion
77
. . . . . . . . . . . . . . . . . . . . . . .
- Checking bending
77
. . . . . . . . . . . . . . . . . . . . . . .
- Assembling connecting rod - piston assembly
77
.
- Coupling connecting rod - pistons
77
. . . . . . . . . .
- Checking for connecting rod - piston distortion
78
- Assembling piston rings
78
. . . . . . . . . . . . . . . . . .
- Assembling connecting rod - piston assemblies
in cylinder barrels
78
. . . . . . . . . . . . . . . . . . . . . . .
- Measuring connecting rod assembly clearance
79
.
- Checking piston protrusion
79
. . . . . . . . . . . . . . .
- Flywheel adjustment
80
. . . . . . . . . . . . . . . . . . . . .
CYLINDER HEADS
81
. . . . . . . . . . . . . . . . . . . . . . .
Page
- Disassembling camshaft
81
. . . . . . . . . . . . . . . . . .
- Checks
81
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and journal alignment
82
. . . . . .
VALVE TAPPET
82
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembling valves
82
. . . . . . . . . . . . . . . . . . . . .
- Checking cylinder head seal
83
. . . . . . . . . . . . . . .
- Checking cylinder head mating surface
83
. . . . . . .
VALVES
83
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing deposits, refacing and checking
valves
83
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking clearance between valve stem
and valve guide and centring valves
84
. . . . . . . . .
VALVE GUIDES
84
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing valve guides
84
. . . . . . . . . . . . . . . . . . .
- Reaming valve guides
84
. . . . . . . . . . . . . . . . . . . .
VALVE SEATS
84
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regrinding and replacing valve seats
84
. . . . . . . . .
VALVE SPRINGS
86
. . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING CYLINDER HEADS
86
. . . . . . . . . . .
- Assembling valves
86
. . . . . . . . . . . . . . . . . . . . . . .
- Assembling tappets
87
. . . . . . . . . . . . . . . . . . . . .
- Assembling camshaft
87
. . . . . . . . . . . . . . . . . . . .
- Adjusting tappet clearance
87
. . . . . . . . . . . . . . . .
- Refitting cylinder head
89
. . . . . . . . . . . . . . . . . . .
AUXILIARY MEMBER ASSEMBLY
90
. . . . . . . . . . . .
- Disassembling auxiliary member assembly
90
. . . .
- Oil pressure control valve
91
. . . . . . . . . . . . . . . .
OIL PUMP
91
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembling auxiliary member assembly
92
. . . . . .
- 6-element heat exchanger
94
. . . . . . . . . . . . . . . .
ENGINES 8140.43R/B/S/N
27
D
AILY
Base - May 2004
LUBRICATION
95
. . . . . . . . . . . . . . . . . . . . . . . . . .
- General
95
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil vapour recycling system
95
. . . . . . . . . . . . . . .
COOLING
97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Description
97
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation
97
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electromagnetic pulley
98
. . . . . . . . . . . . . . . . . . .
- Water pump
98
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostat
98
. . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING AND AUXILIARY MEMBER CONTROL
99
- Setting the timing system
99
. . . . . . . . . . . . . . . . .
- Checking and aligning electromagnetic
coupling pulleys
101
. . . . . . . . . . . . . . . . . . . . . . . .
- Checking alternator pulley alignment
102
. . . . . . . .
- Checking compressor pulley alignment
102
. . . . . . .
- Adjusting compressor - air-conditioner drive
belt tension
102
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjusting alternator - water pump
drive belt tension
102
. . . . . . . . . . . . . . . . . . . . . . .
- Timing system speed sensor
105
. . . . . . . . . . . . . . .
- Engine speed sensor
105
. . . . . . . . . . . . . . . . . . . . .
SUPERCHARGING
106
. . . . . . . . . . . . . . . . . . . . . . .
- Description
106
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Turbocharger
106
. . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRS
107
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE RELIEF VALVE
107
. . . . . . . . . . . . . . . . . .
- Checking and adjusting the pressure relief valve
107
- Changing the pressure relief valve
107
. . . . . . . . . .
- GARRET GT 2256 T variable
geometry turbosupercharger
108
. . . . . . . . . . . . . .
- General
108
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Operation at low engine rpm
108
. . . . . . . . . . . . . .
- Operation at high engine rpm
108
. . . . . . . . . . . . .
- Proportional solenoid valve controlling
turbocharger actuator
109
. . . . . . . . . . . . . . . . . . .
- Actuator
109
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRS
110
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking the actuator
110
. . . . . . . . . . . . . . . . . . .
FUEL SUPPLY
111
. . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM
(COMMON RAIL MS 6.3 OR EDC.16)
111
. . . . .
- General
111
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM OPERATION
113
. . . . . . . . . . . . . . . . . . . .
- Self-diagnosis - BLINK CODE
113
. . . . . . . . . . . . . .
- Immobilizer recognition
113
. . . . . . . . . . . . . . . . . .
- Checking fuel temperature
113
. . . . . . . . . . . . . . . .
- Checking engine coolant temperature
113
. . . . . . .
- Checking quantity of fuel injected
113
. . . . . . . . . . .
- Checking idling adjustment
113
. . . . . . . . . . . . . . . .
- Fuel cut-off in release phase
113
. . . . . . . . . . . . . . .
- Checking cylinder balancing on idling
113
. . . . . . . .
- Checking regulator engine rotation
(anti-sawing)
113
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking smokiness at exhaust on
acceleration
113
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking exhaust gas recirculation
(E.G.R. if present)
113
. . . . . . . . . . . . . . . . . . . . . . .
- Checking top speed limit
113
. . . . . . . . . . . . . . . . .
- Checking rotation regularity during
acceleration
113
. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINES 8140.43R/B/S/N
28
D
AILY
Base - May 2004
- Checking thermostart
113
. . . . . . . . . . . . . . . . . . . .
- Checking activation of air-conditioning system
113
.
- Checking fuel pump
113
. . . . . . . . . . . . . . . . . . . . .
- Checking diesel warming
114
. . . . . . . . . . . . . . . . .
- Checking cylinder position
114
. . . . . . . . . . . . . . . .
- Checking pilot and main injection timing
114
. . . . .
- Checking injection pressure closed cycle
114
. . . . .
- Fuel supply
114
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Correcting flow rate according
to water temperature
114
. . . . . . . . . . . . . . . . . . . .
- Correcting flow rate to avoid noise,
smoke or overloading
114
. . . . . . . . . . . . . . . . . . .
- De-rating
114
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjusting turbine speed (for variable geometry
turbocharger - when present)
114
. . . . . . . . . . . . .
- Injection timing electronic test
114
. . . . . . . . . . . . .
- Speed governor
114
. . . . . . . . . . . . . . . . . . . . . . . .
- Engine starting
114
. . . . . . . . . . . . . . . . . . . . . . . . .
- Cold starting
115
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Warm starting
115
. . . . . . . . . . . . . . . . . . . . . . . . .
- Run up
115
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- After run
115
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cut-off
115
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cylinder balancing
115
. . . . . . . . . . . . . . . . . . . . . .
- Synchronization search
115
. . . . . . . . . . . . . . . . . . .
- Operation
116
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEM
117
. . . . . . . . . . . . . . . . . . . . .
- Fuel pump
117
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Specifications
117
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Fuel filter
118
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Tightening torques
118
. . . . . . . . . . . . . . . . . . . . . .
Page
- Fuel pipes
118
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- High-pressure pump
119
. . . . . . . . . . . . . . . . . . . . .
- 3rd pumping element exclusion device
120
. . . . . .
- Pressure regulator
120
. . . . . . . . . . . . . . . . . . . . . .
- Hydraulic accumulator (rail)
121
. . . . . . . . . . . . . . .
- Flow limiters
121
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pressure relief valve
123
. . . . . . . . . . . . . . . . . . . . .
- Fuel recirculation and supply system
123
. . . . . . . . .
ELECTRO-INJECTORS
125
. . . . . . . . . . . . . . . . . . . .
- Operation
125
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC/ELECTRONIC COMPONENTS
126
. . . .
- Electronic control unit MS6.3
126
. . . . . . . . . . . . . .
SENSORS
126
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Engine speed sensor
126
. . . . . . . . . . . . . . . . . . . . .
- Camshaft timing sensor
126
. . . . . . . . . . . . . . . . . .
- Air temperature and pressure sensor
126
. . . . . . . .
- Fuel temperature sensor
126
. . . . . . . . . . . . . . . . .
- Fuel pressure sensor
127
. . . . . . . . . . . . . . . . . . . . .
- Atmospheric pressure sensor
127
. . . . . . . . . . . . . .
- Engine coolant temperature sensor
127
. . . . . . . . .
- Throttle pedal position sensor
127
. . . . . . . . . . . . .
- Clutch pedal position sensor
127
. . . . . . . . . . . . . .
- Brake pedal position sensor
127
. . . . . . . . . . . . . . .
- Vehicle speed sensor
127
. . . . . . . . . . . . . . . . . . . .
ACTUATORS
127
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- PWM (Pulse Width Modulation) controls
127
. . . .
EXHAUST GAS RECIRCULATION SYSTEM E.G.R.
(vehicles with homologation MI)
128
. . . . . . . . . . .
GUIDE TO TROUBLESHOOTING
129
. . . . . . . . . .
Figure 21
Gas emissions
Engine 8140.43R.43XX/44XX conforms to the Euro3
standards on gas emissions (measured on engine bench to
OICA mode 13 cycle), with the following limits fixed by EEC
regulation 1999/96:
—
CO (carbon monoxide)
< 2.1 g/kWh
—
NOx (nitrogen oxide)
< 5.0 g/kWh
—
HC (hydrocarbons)
< 0.66 g/kWh
—
Particulate
< 0.13 g/kWh
Test fuel: CEC RFT 73 - T - 90 - S
≤ 0.05 %.
Smokiness
Engine 8140.43R.43XX/44XX conforms to the smoke limits
required by EEC regulations 72/306 and R24-03 with the
following exhaust smoke values:
Maximum power (Bosch BSU opacimeter degrees)
1.5
Maximum torque (Bosch BSU opacimeter degrees)
2.5
Full load at 1000 rpm (Bosch BSU opacimeter degrees) 3.5
Noise emissions
Maximum mean noise level, Lpa, of the standard engines
measured according to ISO Std. 3745 (microphones at 1 m
from the engine surfaces):
Idling
(800 rpm)
dB A 76
Full power
(3600 rpm)
dB A 99
74943
Engine 8140.43R.43XX/44XX
ENGINES 8140.43R/B/S/N
29
D
AILY
Base - May 2004
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