Iveco Daily. Manual — part 102
CROSS-SECTION OF OIL PRESSURE CONTROL
VALVE MOUNTED IN CRANKCASE
Valve removed from crankcase L = 51.75 mm.
Valve fitted in crankcase L = 50.75 mm.
Start of opening 4 bar L = 49.5
maximum opening 4.6 bar L = 44.
75520
Figure 224
Figure 225
Figure 226
543070
Oil filter
75521
75523
Figure 227
PARTS COMPRISING THE OIL PRESSURE
CONTROL VALVE
1. Split ring — 2. Washer — 3. Spring — 4. Valve —
5. Valve casing.
75522
MAIN DATA OF THE OIL PRESSURE CONTROL
VALVE SPRING
Oil filter with single filtration with built-in by-pass valve —
opening pressure 2.5
± 0.3 bar.
543110
Modine heat exchanger
75524
Figure 228
Thoroughly clean the heat exchanger (1).
Always change the seals (2 and 4).
Built-in safety valve (3).
Opening pressure
0.82 - 1.03 bar
543475
Oil pressure control valve
F1A ENGINE
D
AILY
386
Base - May 2004
Figure 229
540480
Oil vapour recirculation system
Description
The oil vapours formed in the sump while the engine is
running, passing through the overhead cover, are channelled
into the separator / condenser filter known as the blow-by.
The filter is structured in two sections:
- The first one with a labyrinth, where most of the vapours
are condensed and return to the sump through an
umbrella outlet valve.
- The second one includes a coalescence filter that
condenses the remaining vapours that return to the
sump through another umbrella valve.
The portion of vapour that has not condensed is sent, via a
MANN-HUMMEL valve, to the intake duct and burnt during
normal engine operation.
75525
OIL VAPOUR RECIRCULATION DIAGRAM
1. MANN-HUMMEL valve — 2. Umbrella valves — 3. Blow-by filter — A. Labyrinth — B. Intake oil
vapour recovery flow — C. Oil return flow into sump — D. Flow of oil vapours from the sump —
E. Flow of oil vapours from the overhead — F. Coalescence filter.
The blow-by filter cannot be taken apart and must
therefore be replaced entirely.
NOTE
F1A ENGINE
387
D
AILY
Base - May 2004
Figure 230
5432
COOLING
Description
The engine cooling system is the type with forced circulation
in a closed circuit. It comprises the following parts:
- An expansion tank whose plug has two valves
incorporated in it: an outlet and an inlet, which govern
the pressure of the system.
- A coolant level sensor at the base of the expansion tank.
- An engine cooling module to dissipate the heat taken
from the engine by the coolant with a heat exchanger
for the intercooler.
- A heat exchanger to cool the lubricating oil.
- A heat exchanger to cool the exhaust gases (engines
with EGR).
- A centrifugal water pump incorporated in the crankcase.
- An electric fan comprising an electromagnetic coupling
on whose shaft a hub turns idle that is fitted with an
axially mobile metal plate on which is mounted the
impeller.
- A 3-way thermostat governing the circulation of the
coolant.
Operation
The water pump driven by a poly-V belt by the crankshaft
sends coolant into the crankcase and with a greater head into
the cylinder head.
When the coolant temperature reaches and exceeds the
working temperature, it causes the thermostat to open and
the fluid is channelled from here to the radiator and cooled
by the fan.
The pressure in the system due to the change in temperature
is governed by the outlet (2) and inlet (1) valves incorporated
in the expansion tank filler plug (detail A).
The outlet valve (2) has a twofold function:
- to keep the system slightly pressurized so as to raise the
boiling point of the coolant;
- to discharge into the atmosphere the excess pressure
produced in case of high coolant temperatures.
The function of the inlet valve (1) is to permit transferring the
coolant from the expansion tank to the radiator when a
lower pressure is created in the system due to the reduction
in volume of the coolant as a result of its temperature
lowering.
Outlet valve opening 1
± 0.1 kg/cm
2
.
Inlet valve opening 0.005 — 0.02 kg/cm
2
.
75526
Hot
Very hot
Cold
F1A ENGINE
D
AILY
388
Base - May 2004
CROSS-SECTION OF THE ELECTROMAGNETIC JOINT
Characteristics
Transmissible torque at 20
°C with clutch run in
45 Nm
Voltage
12 Volts
Power input
26 W
The electric fan control relay is activated or deactivated
according to the temperatures of: the engine coolant, the fuel
supercharging air and the pressure of the air conditioner fluid
(if present).
Coolant temperature
(if the sensor is not defective)
It activates at > 96
°C and deactivates at < 84°C.
Turbocharging air temperature
It activates at > 75
°C and deactivates at < 65°C.
Fuel temperatures
(if the coolant temperature sensor is acknowledged to be
defective by the EDC control unit)
It activates at > 20
°C and deactivates at < 10°C.
With climate control system
With pressure in the system
it turns on
18.5
± 0.98 bar
it turns off
14.58
± 0.98 bar
75527
Figure 231
Figure 232
The water pump (3) cannot be overhauled. In case of coolant
leaking from the seal or damage, it must be replaced. The
water pump casing (1) is also used as a mounting for the
high-pressure pump. The seals (3 and 4) must always be
replaced.
75528
543212
Electromagnetic pulley
543210
Water pump
LONGITUDINAL CROSS-SECTION OF THE
WATER PUMP
1. Pump casing — 2. Pump drive shaft together with
bearing — 3. Seal — 4. Impeller.
Figure 233
75529
The by-pass thermostat (1) needs no adjustment.
If there is any doubt about its operation, replace it.
The thermostat casing is fitted with the thermometric
switch/transmitter and water temperature sensor.
A. — A1 Start of stroke at 78
°C ±2°C.
B.
Valve (1) stroke at 94
°C = 7 mm.
B1
Valve (2) stroke 94
°C, 6.4 mm
The stroke of 7 mm less than 60”.
543250
Thermostat
Figure 234
75530
F1A ENGINE
389
D
AILY
Base - May 2004
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