Iveco Daily. Manual — part 143
Revi - February 2005
490
F1C ENGINE
D
AILY
Base - May 2004
- Refitting
492/13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING ELECTRO-INJECTORS
492/14
. . . . . . . . . .
- Removal
492/14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
492/14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DETACHING/RE-ATTACHING
THE CYLINDER HEAD
492/15
. . . . . . . . . . . . . . . . .
- Removal
492/15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
492/17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE VIEWS
493
. . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE IDENTIFICATION CODE
496
. . . . . . . . . . .
CHARACTERISTIC CURVES
500
. . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS
502
. . . . . . . . . . . . . . .
ASSEMBLY DATA — CLEARANCES
505
. . . . . . . . . .
TOOLS
510
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPERIMENTAL TOOLS
516
. . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
523
. . . . . . . . . . . . . . . . . . .
OVERHAULING ENGINE F1C 526
. . . . . . . . . . . .
DISASSEMBLING THE ENGINE AT THE BENCH
526
REPAIRS
536
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK
536
. . . . . . . . . . . . . . . . . . . . . . .
- Checks and measurements
536
. . . . . . . . . . . . . . . .
- Checking head mating surface on cylinder block
537
CRANKSHAFT
537
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring main journals and crank pins
537
. . . . . .
- Checking crankshaft
538
. . . . . . . . . . . . . . . . . . . . .
- Replacing timing control gear
540
. . . . . . . . . . . . . .
ENGINE ASSEMBLY
540
. . . . . . . . . . . . . . . . . . . . . .
- Assembling main bearings
540
. . . . . . . . . . . . . . . . .
- Measuring main journal assembly clearance
540
. . .
- Checking crankshaft end float
541
. . . . . . . . . . . . . .
- Assembling rear seal
542
. . . . . . . . . . . . . . . . . . . . .
ENGINE FLYWHEEL
543
. . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD — PISTON ASSEMBLY
543
. . .
- Replacing bearing supporting gearbox input shaft
543
- Pistons
544
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring piston diameter
544
. . . . . . . . . . . . . . . .
Page
- Piston pins
545
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Conditions for correct pin-piston coupling
545
. . . .
- Piston rings
545
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting rods
546
. . . . . . . . . . . . . . . . . . . . . . . .
- Bushing
546
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking connecting rods
546
. . . . . . . . . . . . . . . .
- Checking torsion
547
. . . . . . . . . . . . . . . . . . . . . . .
- Checking bending
547
. . . . . . . . . . . . . . . . . . . . . . .
- Assembling connecting rod-piston assembly
547
. . .
- Checking for connecting rod — piston distortion
548
- Assembling piston rings
548
. . . . . . . . . . . . . . . . . .
- Assembling connecting rod — piston assemblies
in cylinder barrels
548
. . . . . . . . . . . . . . . . . . . . . . .
- Measuring crankpin assembly clearance
548
. . . . . .
- Checking piston protrusion
549
. . . . . . . . . . . . . . .
CYLINDER HEAD
550
. . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly
550
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembling valves
550
. . . . . . . . . . . . . . . . . . . . .
- Checking cylinder head seal
551
. . . . . . . . . . . . . . .
- Checking cylinder head mating surface
551
. . . . . . .
VALVES
551
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing deposits, refacing and checking valves
551
- Checking clearance between valve stem
and valve guide and centring valves
552
. . . . . . . . .
VALVE GUIDES
552
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing valve guides
552
. . . . . . . . . . . . . . . . . . .
- Boring valve guides
552
. . . . . . . . . . . . . . . . . . . . . .
VALVE SEATS
553
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regrinding - replacing valve seats
553
. . . . . . . . . . .
VALVE SPRINGS
554
. . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS — TAPPETS
554
. . . . . . . . . . . . . . . .
- Checks
555
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING CYLINDER HEADS
555
. . . . . . . . . . .
- Overhead
556
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Overhead removal
556
. . . . . . . . . . . . . . . . . . . . . .
Revi - February 2005
F1C ENGINE
491
D
AILY
Base - May 2004
TIMING SYSTEM
557
. . . . . . . . . . . . . . . . . . . . . . . . .
- Description
557
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft
558
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checks
558
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and pin alignment
558
. . . . . . . . .
- Assembling overhead
559
. . . . . . . . . . . . . . . . . . . .
AUXILIARY ORGAN CONTROLS
559
. . . . . . . . . . .
- Cylinder head refitting
561
. . . . . . . . . . . . . . . . . . .
TIMING SYSTEM CONTROL
562
. . . . . . . . . . . . . . .
- Replacement of alternator free wheel
567
. . . . . . .
- Timing speed sensor
572
. . . . . . . . . . . . . . . . . . . . .
- Engine speed sensor
572
. . . . . . . . . . . . . . . . . . . . .
LUBRICATION
573
. . . . . . . . . . . . . . . . . . . . . . . . . .
- General
573
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP/DEPRESSOR UNIT
575
. . . . . . . . . . . . . .
- Oil pump
575
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Characteristic data
575
. . . . . . . . . . . . . . . . . . . . . .
- Vacuum pump
576
. . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pressure adjusting valve
576
. . . . . . . . . . . . . . .
- Disassembly
576
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly
577
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil filter
577
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Heat exchanger
577
. . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly
577
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly
577
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil vapour recirculation (Blow-by)
579
. . . . . . . . . .
- Operation
579
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING
580
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Description
580
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation
580
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electromagnetic pulley
581
. . . . . . . . . . . . . . . . . . .
- Water pump
581
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostat
581
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
TURBOCHARGING
582
. . . . . . . . . . . . . . . . . . . . . .
- Description
582
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Turbocharger
type MITSUBISHI TD 4 HL-13T - 6
583
. . . . . . . . .
REPAIRS
584
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pressure relief valve
584
. . . . . . . . . . . . . . . . . . . . .
- Checking and adjusting pressure relief valve
584
. . .
- Changing the pressure relief valve
584
. . . . . . . . . .
- GARRET GT 2256 T variable
geometry turbosupercharger
585
. . . . . . . . . . . . . .
- General
585
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation at low engine rpm
585
. . . . . . . . . . . . . .
- Operation at high engine rpm
585
. . . . . . . . . . . . .
- Proportional solenoid valve controlling
turbocharger actuator
586
. . . . . . . . . . . . . . . . . . .
- Actuator
586
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRS
587
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking and adjusting the actuator
587
. . . . . . . . .
FUEL SUPPLY
589
. . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH-PRESSURE ELECTRONIC
INJECTION SYSTEM (EDC 16)
589
. . . . . . . . . . .
- General
589
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM OPERATION
591
. . . . . . . . . . . . . . . . . . . .
- Self-diagnosis — BLINK CODE
591
. . . . . . . . . . . . .
- Immobilizer recognition
591
. . . . . . . . . . . . . . . . . .
- Checking fuel temperature
591
. . . . . . . . . . . . . . . .
- Checking engine coolant temperature
591
. . . . . . .
- Checking quantity of fuel injected
591
. . . . . . . . . . .
- Checking idling adjustment
591
. . . . . . . . . . . . . . . .
- Fuel cut-off in release phase
591
. . . . . . . . . . . . . . .
- Checking cylinder balancing on idling
591
. . . . . . . .
- Checking regular engine rotation (anti-sawing)
591
.
- Checking smokiness at exhaust on acceleration
591
Revi - February 2005
492
F1C ENGINE
D
AILY
Base - May 2004
- Checking exhaust gas recirculation
(E.G.R. if present)
591
. . . . . . . . . . . . . . . . . . . . . . .
- Checking top speed limit
591
. . . . . . . . . . . . . . . . .
- Checking regular rotation on acceleration
591
. . . .
- Checking glow plug control unit
591
. . . . . . . . . . . .
- Checking activation of air-conditioning system
591
.
- Checking fuel pump
591
. . . . . . . . . . . . . . . . . . . . .
- Checking diesel warming
592
. . . . . . . . . . . . . . . . .
- Checking cylinder position
592
. . . . . . . . . . . . . . . .
- Checking pilot and main injection timing
592
. . . . .
- Checking injection pressure closed cycle
592
. . . . .
- Fuel supply
592
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Correcting flow rate according
to water temperature
592
. . . . . . . . . . . . . . . . . . . .
- Correcting flow rate to avoid noise,
smoke or overloading
592
. . . . . . . . . . . . . . . . . . . .
- De-rating
592
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injection timing electronic test
592
. . . . . . . . . . . . .
- Speed governor
592
. . . . . . . . . . . . . . . . . . . . . . . .
- Engine starting
592
. . . . . . . . . . . . . . . . . . . . . . . . .
- Cold starting
593
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Warm starting
593
. . . . . . . . . . . . . . . . . . . . . . . . .
- Run up
593
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- After run
593
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cut-off
593
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cylinder balancing
593
. . . . . . . . . . . . . . . . . . . . . .
- Synchronization search
593
. . . . . . . . . . . . . . . . . . .
OPERATION
595
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEM
595
. . . . . . . . . . . . . . . . . . . . .
- Fuel pipes
595
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fuel pump
596
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Specifications
596
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Fuel filter
597
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Tightening torques
597
. . . . . . . . . . . . . . . . . . . . . .
- High-pressure pump
598
. . . . . . . . . . . . . . . . . . . . .
Page
- High-pressure pump internal structure
600
. . . . . . .
- Working principle
601
. . . . . . . . . . . . . . . . . . . . . . .
- Pressure regulator
604
. . . . . . . . . . . . . . . . . . . . . .
- Replacing pressure regulator
604
. . . . . . . . . . . . . . .
MECHANICAL SUPPLY PUMP
605
. . . . . . . . . . . . . .
- Hydraulic accumulator (rail)
606
. . . . . . . . . . . . . . .
ELECTRO-INJECTORS
606
. . . . . . . . . . . . . . . . . . . .
- Operation
606
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC/ELECTRONIC COMPONENTS
607
. . . . .
- Electronic control unit EDC 16
607
. . . . . . . . . . . .
- Glow plug electronic control unit
607
. . . . . . . . . . .
- Glow plugs
607
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSORS
607
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Engine speed sensor
607
. . . . . . . . . . . . . . . . . . . . .
- Camshaft timing sensor
607
. . . . . . . . . . . . . . . . . .
- Air temperature and pressure sensor
608
. . . . . . . .
- Fuel temperature sensor
608
. . . . . . . . . . . . . . . . .
- Fuel pressure sensor
608
. . . . . . . . . . . . . . . . . . . . .
- Atmospheric pressure sensor
608
. . . . . . . . . . . . . .
- Engine coolant temperature sensor
608
. . . . . . . . .
- Throttle pedal position sensor
608
. . . . . . . . . . . . .
- Clutch pedal position sensor
608
. . . . . . . . . . . . . .
- Brake pedal position sensor
608
. . . . . . . . . . . . . . .
- Vehicle speed sensor
608
. . . . . . . . . . . . . . . . . . . .
ACTUATORS
608
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- PWM (Pulse Width Modulation) controls
608
. . . .
TROUBLESHOOTING GUIDE
609
. . . . . . . . . . . . . .
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
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..
F1C ENGINE
492/1
D
AILY
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