Iveco Daily F1A Engine Troubleshooting and Repair Manual



Iveco Daily F1A Engine Service Manual PDF

This Iveco Daily F1A Engine Troubleshooting and Repair Manual is intended to aid in determining the cause of engine-related problems and to provide recommended repair procedures. The manual is divided into sections by system. Each section provides general information, specifications, diagrams, and service tools, where applicable. The specific repair procedures are referenced in the Troubleshooting Symptom Charts.

MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE ENGINE REMOVAL-REFITTING

  • Removal
  • Refitting
  • Checks and tests
  • Power steering system air bleed

REPLACING BELTS

  • Assembly
  • Disassembly
  • Replacing timing drive belt
  • Assembly
  • Disassembly
  • Power steering pump-alternator belt replacement
  • Assembly
  • Disassembly
  • Replacing air-conditioning compressor drive belt (version with elastic belt)
  • Assembly and adjusting belt tension
  • Disassembly
  • Replacing air-conditioning compressor drive belt (version with belt tensioner)

REPLACING ELECTRO-INJECTORS

  • Disassembly
  • Assembly

CYLINDER HEAD REMOVAL AND REFITTING

  • Removal
  • Refitting

REPLACING HIGH-PRESSURE PUMP CP3

  • Removal
  • Refitting

REPLACING WATER PUMP

  • Removal
  • Refitting

EMISSIONS
ENGINE IDENTIFICATION CODE
CHARACTERISTIC CURVES
GENERAL SPECIFICATIONS
ASSEMBLY DATA — CLEARANCES
TOOLS
EXPERIMENTAL TOOLS
TIGHTENING TORQUE
OVERHAULING ENGINE F1A
DISASSEMBLING THE ENGINE AT THE BENCH
REPAIRS
CYLINDER BLOCK

  • Checks and measurements
  • Checking head mating surface on cylinder block

CRANKSHAFT

  • Measuring main journals and crank pins
  • Checking crankshaft
  • Replacing timing control gear

ENGINE ASSEMBLY

  • Assembling main bearings
  • Measuring main journal assembly clearance
  • Checking crankshaft end float
  • Assembling rear seal
  • Replacing bearing supporting gearbox input shaft

ENGINE FLYWHEEL CONNECTING ROD — PISTON ASSEMBLY

  • Pistons
  • Measuring piston diameter
  • Piston pins
  • Conditions for correct pin-piston coupling
  • Piston rings
  • Connecting rods
  • Bushes
  • Checking connecting rods
  • Checking torsion
  • Checking bending
  • Assembling connecting rod-piston assembly
  • Checking for connecting rod — piston distortion
  • Assembling piston rings
  • Assembling connecting rod — piston assemblies in cylinder barrels
  • Measuring crankpin assembly clearance
  • Checking piston protrusion

CYLINDER HEAD

  • Disassembly
  • Removing valves
  • Checking cylinder head seal
  • Checking cylinder head mating surface

VALVES

  • Removing deposits, refacing and checking valves
  • Checking clearance between valve stem and valve guide and centring valves

VALVE GUIDES

  • Replacing valve guides
  • Boring valve guides

VALVE SEATS

  • Regrinding – replacing valve seats

VALVE SPRINGS ROCKER ARMS — TAPPETS

  • Checks

ASSEMBLING CYLINDER HEADS

  • Overhead
  • Overhead removal

TIMING SYSTEM

  • Description
  • Camshaft
  • Checks
  • Checking cam lift and pin alignment
  • Assembling overhead
  • Assembling front seal ring
  • Refitting cylinder head
  • Adjusting air-conditioner — compressor drive belt tension
  • Timing speed sensor
  • Engine speed sensor

LUBRICATION

  • General

OIL VACUUM PUMP ASSEMBLY (GPOD)

  • Oil pump
  • Characteristic data
  • Vacuum pump
  • Oil pressure control valve
  • Oil filter
  • Modine heat exchanger
  • Oil vapour recirculation system
  • Description

COOLING

  • Description
  • Operation
  • Electromagnetic pulley
  • Water pump
  • Thermostat

TURBOCHARGING

  • Description
  • Turbocharger

REPAIRS

  • Pressure relief valve
  • Checking and adjusting pressure relief valve
  • Replacing pressure relief valve

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

  • EGR system operation
  • Operating principles
  • Air flow meter

FUEL SUPPLY

HIGH-PRESSURE ELECTRONIC

INJECTION SYSTEM (MS 6.3 – EDC 16)

  • General

SYSTEM OPERATION

  • Self-diagnosis — BLINK CODE
  • Immobilizer recognition
  • Checking fuel temperature
  • Checking engine coolant temperature
  • Checking quantity of fuel injected
  • Checking idling adjustment
  • Fuel cut-off in release phase
  • Checking cylinder balancing on idling
  • Checking regular engine rotation (anti-sawing)
  • Checking smokiness at exhaust on acceleration
  • Checking exhaust gas recirculation (E.G.R. if present)
  • Checking top speed limit
  • Checking regular rotation on acceleration
  • Checking glow plug control unit
  • Checking activation of air-conditioning system
  • Checking fuel pump
  • Checking diesel warming
  • Checking cylinder position
  • Checking pilot and main injection timing
  • Checking injection pressure closed cycle
  • Fuel supply
  • Correcting flow rate according to water temperature
  • Correcting flow rate to avoid noise, smoke or overloading
  • De-rating
  • Injection timing electronic test
  • Speed governor
  • Engine starting
  • Cold starting
  • Warm starting
  • Run up
  • After run
  • Cut-off
  • Cylinder balancing
  • Synchronization search

OPERATION HYDRAULIC SYSTEM

  • Fuel pump
  • Specifications
  • Fuel filter
  • Tightening torques
  • Fuel pipes
  • High-pressure pump
  • High-pressure pump internal structure
  • Working principle
  • Pressure control valve
  • Replacing pressure regulator

MECHANICAL SUPPLY PUMP

  • Hydraulic accumulator (rail)
  • Overpressure valve (for forged hydraulic accumulator)

ELECTRO-INJECTORS

  • – Operation

ELECTRIC/ELECTRONIC COMPONENTS

  • Electronic control unit MS6.3 or EDC 16
  • Glow plug electronic control unit
  • Glow plugs

SENSORS

  • Engine speed sensor
  • Camshaft timing sensor
  • Air temperature and pressure sensor
  • Fuel temperature sensor
  • Fuel pressure sensor
  • Atmospheric pressure sensor
  • Engine coolant temperature sensor
  • Throttle pedal position sensor
  • Clutch pedal position sensor
  • Brake pedal position sensor
  • Vehicle speed sensor

GUIDE TO TROUBLESHOOTING

Language: English
File: PDF
Size: 13.5 Mb
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