Iveco daily euro 4, Repair Manual

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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.
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Before doing any work on the engine, perform the engine/vehicle fault diagnosis with specific IVECO diagnosis
equipment and print out the results.
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Replacement of the MS6.3 or EDC 16control unit must be authorized by the Help Desk. Replacing operation
requires reprogramming as described in specific section.
- Following components in feed system cannot be overhauled but have to be replaced: pressure relief valve, if present,
fuel pressure sensor, hydraulic accumulator, complete CP3 high pressure feed pump, pressure control valve, electric
injectors.
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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.
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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.
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Take care over the direction of assembly for all electrical connections.
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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.
Replacing one or more electrical injectors requires central unit programming as described in specific section.
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.. Replacing the sensor requires central unit programming as described in
specific section.
F1C ENGINE
161
D
AILY
E
URO
4
Print 603.93.651 Base - March 2006