Iveco Daily. Manual — part 77
Revi - February 2005
F1A ENGINE
D
AILY
290
Base - May 2004
- De-rating
398
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injection timing electronic test
398
. . . . . . . . . . . . .
- Speed governor
398
. . . . . . . . . . . . . . . . . . . . . . . .
- Engine starting
398
. . . . . . . . . . . . . . . . . . . . . . . . .
- Cold starting
399
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Warm starting
399
. . . . . . . . . . . . . . . . . . . . . . . . .
- Run up
399
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- After run
399
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cut-off
399
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cylinder balancing
399
. . . . . . . . . . . . . . . . . . . . . .
- Synchronization search
399
. . . . . . . . . . . . . . . . . . .
OPERATION
401
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEM
403
. . . . . . . . . . . . . . . . . . . . .
- Fuel pump
403
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Specifications
403
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Fuel filter
404
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Tightening torques
404
. . . . . . . . . . . . . . . . . . . . . .
- Fuel pipes
404
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- High-pressure pump
405
. . . . . . . . . . . . . . . . . . . . .
- High-pressure pump internal structure
407
. . . . . . .
- Working principle
408
. . . . . . . . . . . . . . . . . . . . . . .
- Pressure control valve
411
. . . . . . . . . . . . . . . . . . .
- Replacing pressure regulator.
411
. . . . . . . . . . . . . .
MECHANICAL SUPPLY PUMP
412
. . . . . . . . . . . . . .
- Hydraulic accumulator (rail)
413
. . . . . . . . . . . . . . .
- Overpressure valve
(for forged hydraulic accumulator)
413
. . . . . . . . . .
ELECTRO-INJECTORS
413
. . . . . . . . . . . . . . . . . . . .
- Operation
414
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC/ELECTRONIC COMPONENTS
414
. . . . .
- Electronic control unit MS6.3 or EDC 16
414
. . . . .
- Glow plug electronic control unit
415
. . . . . . . . . . .
- Glow plugs
415
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSORS
415
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Engine speed sensor
415
. . . . . . . . . . . . . . . . . . . . .
- Camshaft timing sensor
415
. . . . . . . . . . . . . . . . . .
- Air temperature and pressure sensor
415
. . . . . . . .
- Fuel temperature sensor
415
. . . . . . . . . . . . . . . . .
- Fuel pressure sensor
415
. . . . . . . . . . . . . . . . . . . . .
- Atmospheric pressure sensor
415
. . . . . . . . . . . . . .
- Engine coolant temperature sensor
416
. . . . . . . . .
- Throttle pedal position sensor
416
. . . . . . . . . . . . .
- Clutch pedal position sensor
416
. . . . . . . . . . . . . .
- Brake pedal position sensor
416
. . . . . . . . . . . . . . .
- Vehicle speed sensor
416
. . . . . . . . . . . . . . . . . . . .
ACTUATORS
416
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- PWM (Pulse Width Modulation) controls
416
. . . .
GUIDE TO TROUBLESHOOTING
417
. . . . . . . . . . .
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.
- Following components in feed system cannot be overhauled but have to be replaced: pressure relief valve, if present,
fuel pressure sensor, hydraulic accumulator, complete CP1 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.
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
Pressure sensor, as well as pressure relief valve (if present) can be successively mounted 5 times. Thereafter, they need
to be replaced. They must be lubricated with a thin layer of oil before being mounted.
Pressure relief valve, if present, must also be lubricated before being mounted and its gasket must compulsorily be
replaced.
Toothed timing drive belt
If the engine has run for a period equivalent to over 25,000 km, the toothed timing drive belt must be replaced with
a fresh one, no matter what its state of wear, whenever it gets removed or any work is done on its automatic tightener.
F1A ENGINE
291
D
AILY
Base - May 2004
72446
F1A ENGINE
D
AILY
292
Base - May 2004
540110
ENGINE REMOVAL-REFITTING
75818
Figure 1
Removal
Set the vehicle over the pit or on the lift.
Lift up the bonnet (2), unscrew the screws (1) securing it and
take it off. Remove the prop (3).
Disconnect the negative cable (4) and the positive cable (6)
from the battery (5) and detach this from the engine bay.
Unhook the cable (11) from the bonnet opening control
devices.
Disconnect the electrical connections (12) of the front
headlamps.
Unscrew the nuts (7) and screws (8), then remove the front
cross member (10) with the light clusters.
Unscrew the screws (10, 12 and 14) and remove the bottom
side guards (11 and 13).
Underneath the vehicle (see Figure 4):
- Unscrew the screws (
⇒) and remove the central guard
(12).
ENGINE F1A
293
D
AILY
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст