Iveco EuroCargo (12 to 26 t). Manual — part 5
62241
Figure 3
From the engine right side:
- Move the gear control lever (1) leftwards.
- Loosen clamps (14) and remove the after-cooler tubing
(15).
- Loosen the tightener (16) and undermine the belt.
- Unscrew relevant fastening screws, remove the
conditioner (17) compressor and place it on the
condenser, tightly fastened to prevent it form dropping.
- Remove the exhaust brake throttle valve (9) guard (12).
- Disconnect the tubing (10) , unscrew the exhaust pipe
fastening screws (7) and remove the throttle valve (9).
- Unscrew the elastic support (silent block) fastening nut
that fixes the exhaust pipe (8) to the frame and remove
it.
- Disconnect air tubing (4).
- Loosen clamps from the radiator and the thermostat
and remove the cooling fluid tubing (18).
!
During the refitting, do not invert the tubing (18)
position, because it will interfere with the fan.
- Disconnect the tubing (2) from the clamp that fixes it to
the head and free it from the check clamps.
- Disconnect the tubing (3) from the clamp placed as
shown (
→).
- Loosen the clamp and disconnect the cooling fluid tubing
(11).
- Disconnect the alternator, starter and ground cable
electrical connections.
- Remove the clamp (5) that fixes the harness to the
engine support bracket and disconnect all those
connections coming from the harness.
- Place the lifting arm (99360595) to the engine and
tension it with a proper lifting device.
- Unscrew fastening nuts (7 and 14, Figure 2) and (6 and
13, Figure 3); then, lift the engine moving it at the same
time towards the rear part and remove it from the
compartment.
!
Depending on the kind of vehicle cab, the cab rear
traverse might be removed, too.
E
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12-26 t
6
ENGINE
Base - February 2003
- There are no oil drippings between cover and head
cylinders, oil pan and base, heat exchanger oil filter and
its seatings and between the different lubrication circuits;
- There are no fuel leakages from fuel tubings;
- There are no air losses from pneumatic tubings;
- The warning lights on the instrument panels and the
devices disconnected during the engine removal work
correctly.
- There are no water drippings from the connecting
manifolds of the engine cooling tubing and the cab
heating, and in case fasten by blocking collars further;
Refitting
Invert the operations requested for removal and observe the
following directions:
- Take great care during the engine assembling;
- Check
cooling
fluid
and
air-conveyor
coupling
conditions and in case they are damaged, replace them
immediately;
- Check engine and speed gear unit elastic supports; in
case they are damaged, replace them immediately;
- Check if the exhaust pipe parts or its fastening elements
are damaged or about to be damaged and replace them;
- Fasten screws or nuts to the prescribed torque;
- Check accurately
that the connections of the low
pressure fuel tubings to its unions are correct, as
specified in the notes concerning “main service
operations to be performed on engine fitted on vehicle”.
- Fill the cooling system with the cooling fluid and carry out
the bleeding as described in the relevant chapters;
- Fill the hydraulic steering circuit and carry out the
bleeding as described in the relevant chapter;
!
Check that hydraulic steering oil and the cooling fluid
do not contain filth before using them; if they do,
filter with appropriate net filters; in case of filling-ups,
see
the
table
REFUELING
in
the
section
“GENERAL”.
- Check the engine and speed gear oil level; in case of
filling-ups, see the table REFUELING in the section
“GENERAL”.
Tests and checks
Start the engine, leave it in motion at running rate
little more than the minimal and wait that the cooling
fluid temperature reaches the rate for the
thermostat to be opened , then check that:
Engine cooling filling system
General rules
Figure 4
70469
- These operations shall be carried out when the engine
is cool.
- The cap (1) is sealed and shall never be tampered by the
user.
To empty or fill it use only the cap (2).
- To avoid air locks in the system, the fluid shall be poured
very slowly (about 8 l per minute).
- The antifreeze contained in the cooling fluid shall not
exceed 50%.
Figure 5
79450
- Open the heating fluid tap knob (1) completely.
- Remove the cap (2, Figure 4) and refuel as described
before until the expansion cup is full.
O
1
2
3
4
E
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12-26 t
ENGINE
7
Base - February 2003
70471
Figure 6
The bleeding shall be performed as follows:
- Insert in the bleeding screw (1) its proper small tube (1)
to drain the fuel in the appropriate container;
- Loosen the screw (1).
Check the fuel level in the tank and in case increase it.
Lift the vehicle from the front part, start the engine and let
it rotate at its minimum for some time.
Check that there are no oil drippings from the hydraulic
circuit and check its level in the tank.
Turn the steering wheel slowly in both directions to let out
the air contained in the hydraulic system.
Check again the oil level in the tank and increase it, if
necessary.
Air bleeding
- Start air bleeding from the cooling system immediately
after filling operations.
- Start the engine at the minimum speed for at least 5
minutes.
- Fill the fluid up after this time.
- Close the cap 2, Figure 4, accurately and take the engine
at high revolutions to simplify fluid cooling until the
thermostat opens.
- Note: Screen the radiator with a cardboard between it
and the intercooler to quicken the operation.
- Take the fluid temperature to 90
°C ∼ (to be sure that
the thermostat will open) checking the on board
thermometer.
- When the fluid reaches the right temperature, keep the
engine at max. revolutions possible to let the air out
completely.
- Check that in the expansion cup there are no more air
bubbles or foam.
- The max complete deareation time is
∼ 15 minutes from
the thermostat opening.
Important warnings
- From the moment the cap (2, Figure 4) is closed and the
engine heating starts, do not remove the cap until the
engine is completely cooled.
Consequently, in case of filling, wait until the engine is
cool.
This will avoid two consequences:
-
Scalds to the operator;
-
Engine damages, since the system can be pressurized
only with a cool engine heating.
542011
Air bleeding from fuel system
- Start priming pump hand control (2) until fuel goes out
from the bleeding screw (1) without air;
- Close the screw (1);
- Operate on the hand control until the priming pump (2)
starts idle working;
- Start the engine and let it rotate at its minimum for some
minutes to eliminate air residuals.
!
Fire danger: always close the bleeding screw to avoid
fuel leakages.
501430
Air bleeding from hydraulic
power steering system
E
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C
ARGO
T
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12-26 t
8
ENGINE
Base - February 2003
70472
70131
70473
70133
Figure 7
Figure 8
Figure 9
Figure 10
Place the vehicle in safety conditions.
Disconnect battery terminals, lift the radiator cowling,
overturn the cab and operate as follows:
- Disconnect oil tubings (5 and 6) from the tappet cover
(7) and remove it;
- Remove ignition harness clamps (1);
- Disconnect
ignition
harness
(1)
from
injector
connectors, overpressure and temperature/pressure
sensors (4);
- Remove tubings (9) from the hydraulic accumulator (3)
and fuel manifolds for injectors.
Remove nuts (7) and disconnect electrical cables from
injectors (8).
Remove screws (1) and injector harness support (2) with the
gasket.
Remove screws (5) and air temperature/pressure sensor (6).
Remove nuts (3) and fuel manifolds (4).
Refitting
!
During unlocking of the fitting (3) fastening pipe (9)
to rail (3), avoid flow limiters (8) rotation with an
appropriate wrench.
Loosen fastening tappet register nuts (1) and unscrew
registers.
Remove screws (2), rocker unit (3) consisting of support (6),
rockers (4) and shafts (5) and remove bonds (7) from the
valves.
70338
Figure 11
Assemble a new ring (2) lubricated with vaseline and a new
washer (3) on the injector (1).
Remove injector fastening screws and with the tool
99342101 (1) remove also the injectors (2) from cylinder
heads.
!
The disassembled fuel manifolds (4) shall never be
used again but replaced with new ones.
E
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C
ARGO
T
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12-26 t
ENGINE
9
Base - February 2003
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