Iveco Daily. Manual — part 76
REMARKS:
1) references for which no letters or numbers are given are reserved for other injection pump
designs;
2) for a correct adjustment of injection pumps on the electric bench, conform to the manual
IVECO Technical Publications and Training No. XXXXXXXXX;
3) measurements taken on injection pumps equipped with ”KSB” must be performed with the
same at rest;
4) (*) LDA adjusting point: act on spring pre-loading ring;
5) after every variation of LDA pressure, act on the control lever;
6) for adjusting the starting point (ARF valve) add a 12.0 mm spacer to the third delivery stop.
6b)
“MODIFICATION POINT 6” FOR POTENTIOMETER SETTING POINT, PLACE A 12mm
SHIM BETWEEN THE THROTTLE LEVER AND THE THIRD STOP.
I V E C O
E N G I N E E R I N G
No. 500338906
Edit. 1
I N J E C T I O N R O T A R Y P U M P T E S T V A L U E S
Sheet 4/4
NOTES: BOSCH SHEET ED. 5 DTD. 24.06.98
C . I . D .
DATE
26-06-98
FEEDING
286
D
AILY
Base - May 2004
F1A ENGINE
287
D
AILY
Base - May 2004
F1A engine
Page
MAIN OPERATIONS ON ENGINE MOUNTED
ON VEHICLE
291
. . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL-REFITTING
293
. . . . . . . . . . . . .
- Removal
293
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
297
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checks and tests
297
. . . . . . . . . . . . . . . . . . . . . . .
- Power steering system air bleed
297
. . . . . . . . . . . .
REPLACING BELTS
298
. . . . . . . . . . . . . . . . . . . . . . .
- Replacing air-conditioning compressor drive belt
(version with belt tensioner)
298
. . . . . . . . . . . . . .
- Disassembly
298
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly and adjusting belt tension
298
. . . . . . . . .
- Replacing air-conditioning compressor drive belt
(version with elastic belt)
298
. . . . . . . . . . . . . . . . .
- Disassembly
298
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly
298
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Power steering pump-alternator belt replacement 298
- Disassembly
298
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly
298
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing timing drive belt
299
. . . . . . . . . . . . . . . .
- Disassembly
299
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly
300
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING ELECTRO-INJECTORS
301
. . . . . . . . . .
- Disassembly
301
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly
301
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD REMOVAL AND REFITTING
302
- Removal
302
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
304
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING HIGH-PRESSURE PUMP CP3
305
. . . . .
- Removal
305
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
305
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING WATER PUMP
305
. . . . . . . . . . . . . . . .
- Removal
305
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revi - February 2005
F1A ENGINE
D
AILY
288
Base - May 2004
305
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMISSIONS
306
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE IDENTIFICATION CODE
308
. . . . . . . . . . .
CHARACTERISTIC CURVES
308/1
. . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS
310
. . . . . . . . . . . . . . .
ASSEMBLY DATA — CLEARANCES
313
. . . . . . . . . .
TOOLS
318
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPERIMENTAL TOOLS
323
. . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
334
. . . . . . . . . . . . . . . . . . .
OVERHAULING ENGINE F1A
339
. . . . . . . . . . . . . .
DISASSEMBLING THE ENGINE AT THE BENCH
339
REPAIRS
348
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK
348
. . . . . . . . . . . . . . . . . . . . . . .
- Checks and measurements
348
. . . . . . . . . . . . . . . .
- Checking head mating surface on cylinder block
349
CRANKSHAFT
349
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring main journals and crank pins
349
. . . . . .
- Checking crankshaft
350
. . . . . . . . . . . . . . . . . . . . .
- Replacing timing control gear
352
. . . . . . . . . . . . . .
ENGINE ASSEMBLY
352
. . . . . . . . . . . . . . . . . . . . . .
- Assembling main bearings
352
. . . . . . . . . . . . . . . . .
- Measuring main journal assembly clearance
352
. . .
- Checking crankshaft end float
353
. . . . . . . . . . . . . .
- Assembling rear seal
354
. . . . . . . . . . . . . . . . . . . . .
- Replacing bearing supporting gearbox input shaft
355
ENGINE FLYWHEEL
355
. . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD — PISTON ASSEMBLY
355
. . .
- Pistons
356
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring piston diameter
356
. . . . . . . . . . . . . . . .
- Piston pins
357
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Conditions for correct pin-piston coupling
357
. . . .
- Piston rings
357
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting rods
358
. . . . . . . . . . . . . . . . . . . . . . . .
- Bushes
359
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Checking connecting rods
359
. . . . . . . . . . . . . . . .
- Checking torsion
359
. . . . . . . . . . . . . . . . . . . . . . .
- Checking bending
359
. . . . . . . . . . . . . . . . . . . . . . .
- Assembling connecting rod-piston assembly
359
. . .
- Checking for connecting rod — piston distortion
360
- Assembling piston rings
360
. . . . . . . . . . . . . . . . . .
- Assembling connecting rod — piston assemblies
in cylinder barrels
360
. . . . . . . . . . . . . . . . . . . . . . .
- Measuring crankpin assembly clearance
361
. . . . . .
- Checking piston protrusion
361
. . . . . . . . . . . . . . .
CYLINDER HEAD
362
. . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly
362
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing valves
362
. . . . . . . . . . . . . . . . . . . . . . . .
- Checking cylinder head seal
363
. . . . . . . . . . . . . . .
- Checking cylinder head mating surface
363
. . . . . . .
VALVES
363
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing deposits, refacing and checking valves
363
- Checking clearance between valve stem and
valve guide and centring valves
364
. . . . . . . . . . . . .
VALVE GUIDES
364
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing valve guides
364
. . . . . . . . . . . . . . . . . . .
- Boring valve guides
364
. . . . . . . . . . . . . . . . . . . . . .
VALVE SEATS
365
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regrinding - replacing valve seats
365
. . . . . . . . . . .
VALVE SPRINGS
366
. . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS — TAPPETS
366
. . . . . . . . . . . . . . . .
- Checks
367
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING CYLINDER HEADS
367
. . . . . . . . . . .
- Overhead
368
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Overhead removal
368
. . . . . . . . . . . . . . . . . . . . . .
TIMING SYSTEM
369
. . . . . . . . . . . . . . . . . . . . . . . . .
- Description
369
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft
370
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checks
370
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and pin alignment
370
. . . . . . . . .
Revi - February 2005
F1A ENGINE
289
D
AILY
Base - May 2004
- Assembling overhead
371
. . . . . . . . . . . . . . . . . . . .
- Assembling front seal ring
372
. . . . . . . . . . . . . . . . .
- Refitting cylinder head
375
. . . . . . . . . . . . . . . . . . .
- Adjusting air-conditioner —
compressor drive belt tension
378
. . . . . . . . . . . . .
- Timing speed sensor
382
. . . . . . . . . . . . . . . . . . . . .
- Engine speed sensor
382
. . . . . . . . . . . . . . . . . . . . .
LUBRICATION
383
. . . . . . . . . . . . . . . . . . . . . . . . . .
- General
383
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL VACUUM PUMP ASSEMBLY (GPOD)
385
. . . . .
- Oil pump
385
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Characteristic data
385
. . . . . . . . . . . . . . . . . . . . . .
- Vacuum pump
385
. . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pressure control valve
386
. . . . . . . . . . . . . . . .
- Oil filter
386
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Modine heat exchanger
386
. . . . . . . . . . . . . . . . . .
- Oil vapour recirculation system
387
. . . . . . . . . . . .
- Description
387
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING
388
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Description
388
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation
388
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electromagnetic pulley
389
. . . . . . . . . . . . . . . . . . .
- Water pump
389
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostat
389
. . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBOCHARGING
390
. . . . . . . . . . . . . . . . . . . . . .
- Description
390
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Turbocharger
391
. . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRS
392
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pressure relief valve
392
. . . . . . . . . . . . . . . . . . . . .
- Checking and adjusting pressure relief valve
392
. . .
- Replacing pressure relief valve
392
. . . . . . . . . . . . .
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
393
- EGR system operation
393
. . . . . . . . . . . . . . . . . . .
Page
- Operating principles
393
. . . . . . . . . . . . . . . . . . . . .
- Air flow meter
394
. . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SUPPLY
395
. . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH-PRESSURE ELECTRONIC
INJECTION SYSTEM (MS 6.3 - EDC 16)
395
. . . .
- General
395
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM OPERATION
397
. . . . . . . . . . . . . . . . . . . .
- Self-diagnosis — BLINK CODE
397
. . . . . . . . . . . . .
- Immobilizer recognition
397
. . . . . . . . . . . . . . . . . .
- Checking fuel temperature
397
. . . . . . . . . . . . . . . .
- Checking engine coolant temperature
397
. . . . . . .
- Checking quantity of fuel injected
397
. . . . . . . . . . .
- Checking idling adjustment
397
. . . . . . . . . . . . . . . .
- Fuel cut-off in release phase
397
. . . . . . . . . . . . . . .
- Checking cylinder balancing on idling
397
. . . . . . . .
- Checking regular engine rotation (anti-sawing)
397
.
- Checking smokiness at exhaust on acceleration
397
- Checking exhaust gas recirculation
(E.G.R. if present)
397
. . . . . . . . . . . . . . . . . . . . . . .
- Checking top speed limit
397
. . . . . . . . . . . . . . . . .
- Checking regular rotation on acceleration
397
. . . .
- Checking glow plug control unit
397
. . . . . . . . . . . .
- Checking activation of air-conditioning system
397
.
- Checking fuel pump
397
. . . . . . . . . . . . . . . . . . . . .
- Checking diesel warming
398
. . . . . . . . . . . . . . . . .
- Checking cylinder position
398
. . . . . . . . . . . . . . . .
- Checking pilot and main injection timing
398
. . . . .
- Checking injection pressure closed cycle
398
. . . . .
- Fuel supply
398
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Correcting flow rate according
to water temperature
398
. . . . . . . . . . . . . . . . . . . .
- Correcting flow rate to avoid noise,
smoke or overloading
398
. . . . . . . . . . . . . . . . . . . .
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