Iveco F1A Repair Manual

DAILY	F1A ENGINE 287

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

Print 603.93.281

Base - May 2004

288 F1A ENGINE	DAILY

	Page
Print 603.93.281/A
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	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

Base - May 2004

Revi - February 2005

	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

Print 603.93.281/A

DAILY	F1A ENGINE 289

	Page
- 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

Print 603.93.281/A	Base - May 2004
	Revi - February 2005

290 F1A ENGINE	DAILY

	Page
- De-rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	398
- Injection timing electronic test . . . . . . . . . . . . .	398
- Speed governor . . . . . . . . . . . . . . . . . . . . . . . .	398
- Engine starting . . . . . . . . . . . . . . . . . . . . . . . . .	398
- Cold starting . . . . . . . . . . . . . . . . . . . . . . . . . . .	399
- Warm starting . . . . . . . . . . . . . . . . . . . . . . . . .	399
- Run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	399
- After run . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	399
- Cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	399
- Cylinder balancing . . . . . . . . . . . . . . . . . . . . . .	399
- Synchronization search . . . . . . . . . . . . . . . . . . .	399
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .	401
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . .	403
- Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .	403
- Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .	403
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	404
- Tightening torques . . . . . . . . . . . . . . . . . . . . . .	404
- Fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	404
- High-pressure pump . . . . . . . . . . . . . . . . . . . . .	405
- High-pressure pump internal structure . . . . . . .	407
- Working principle . . . . . . . . . . . . . . . . . . . . . . .	408
- Pressure control valve . . . . . . . . . . . . . . . . . . .	411
- Replacing pressure regulator. . . . . . . . . . . . . . .	411
MECHANICAL SUPPLY PUMP . . . . . . . . . . . . . .	412
- Hydraulic accumulator (rail) . . . . . . . . . . . . . . .	413
- Overpressure valve
(for forged hydraulic accumulator) . . . . . . . . . .	413
ELECTRO-INJECTORS . . . . . . . . . . . . . . . . . . . .	413
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .	414
ELECTRIC/ELECTRONIC COMPONENTS . . . . .	414
- Electronic control unit MS6.3 or EDC 16 . . . . .	414
- Glow plug electronic control unit . . . . . . . . . . .	415
- Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . .	415
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	415

	Page
- Engine speed sensor . . . . . . . . . . . . . . . . . . . . .	415
- Camshaft timing sensor . . . . . . . . . . . . . . . . . .	415
- Air temperature and pressure sensor . . . . . . . .	415
- Fuel temperature sensor . . . . . . . . . . . . . . . . .	415
- Fuel pressure sensor . . . . . . . . . . . . . . . . . . . . .	415
- Atmospheric pressure sensor . . . . . . . . . . . . . .	415
- Engine coolant temperature sensor . . . . . . . . .	416
- Throttle pedal position sensor . . . . . . . . . . . . .	416
- Clutch pedal position sensor . . . . . . . . . . . . . .	416
- Brake pedal position sensor . . . . . . . . . . . . . . .	416
- Vehicle speed sensor . . . . . . . . . . . . . . . . . . . .	416
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . .	416
- PWM (Pulse Width Modulation) controls . . . .	416
GUIDE TO TROUBLESHOOTING . . . . . . . . . . .	417

Base - May 2004	Print 603.93.281/A
Revi - February 2005

DAILY	F1A ENGINE 291

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

Pressure sensor, as well as pressure relief valve (if present) can be successively mounted 5 times. Thereafter, they need to be replaced. They must be lubricated with a thin layer of oil before being mounted.

Pressure relief valve, if present, must also be lubricated before being mounted and its gasket must compulsorily be replaced.

Toothed timing drive belt

If the engine has run for a period equivalent to over 25,000 km, the toothed timing drive belt must be replaced with a fresh one, no matter what its state of wear, whenever it gets removed or any work is done on its automatic tightener.

Print 603.93.281

Base - May 2004

292 F1A ENGINE

DAILY

72446

Base - May 2004

Print 603.93.281

DAILY

ENGINE F1A 293

Print 603.93.281

540110 ENGINE REMOVAL-REFITTING

Removal	Figure 1

Set the vehicle over the pit or on the lift.

Lift up the bonnet (2), unscrew the screws (1) securing it and take it off. Remove the prop (3).

Disconnect the negative cable (4) and the positive cable (6) from the battery (5) and detach this from the engine bay.

Unhook the cable (11) from the bonnet opening control devices.

Disconnect the electrical connections (12) of the front headlamps.

Unscrew the nuts (7) and screws (8), then remove the front cross member (10) with the light clusters.

Unscrew the screws (10, 12 and 14) and remove the bottom side guards (11 and 13).

Underneath the vehicle (see Figure 4):

- Unscrew the screws ( ) and remove the central guard (12).

75818

Print 603.93.281

Base - May 2004

294 ENGINE F1A	DAILY
- Take the cap (2) off the expansion tank (4).	Figure 2
- Unscrew the coolant plug (16), under the radiator (17),
and drain the cooling system.
- Disconnect the pipe (25) from the coalescence filter (26)
and from the air intake pipe (14).
- Disconnect the pipes (12) and (13) from the heat
exchanger, intake manifold and turbocharger.

NOTE Close the turbocharger air outlet appropriately to prevent foreign bodies accidentally getting inside and damaging it.

- Disconnect the coolant pipes (9 and 10).

NOTE Vehicles with an air-conditioner in the cab should have the electrical connection (15) disconnected from the drier filter.

- Unscrew the air filter bracket fasteners (20) to help extract the air intake pipe (21) from the duct (18) on the radiator assembly.

- Disconnect the pipe (22) from the duct (19) and (23) from the engine.

- Disconnect the tube (3) from the expansion tank (4).

- Unscrew the screws (11) to remove the radiator assembly (17) together with the heat exchanger.

NOTE In case of vehicles equipped with cabin internal conditioner, proceed as follows:

- vehicles equipped with drying filter separated from the condenser:

put the radiator (complete with the condenser and drying filter) back in the engine compartment, taking care not to subject the conditioning system pipes to tension;

- vehicles equipped with drying filter built into the condenser:

blow gas off the air-conditioning system, as described in the relevant chapter in the “Bodywork and chassis” section, then disconnect the pipes from the condenser and seal both the pipes and their respective fittings on the condenser to prevent moisture and impurities from penetrating into the system.

-Disconnect the coolant pipes (8) and (24) from the rigid three-way pipe (27), freeing them from any clamps (7).

-Disconnect the heater delivery pipe (1).

-Unscrew the fasteners (6) to remove the expansion tank

(4), disconnecting the level sensor’s electrical connection.

- Take the soundproofing cover (5) off the cylinder head

75817

after removing the oil filler cap.

Base - May 2004	Print 603.93.281/A
Revi - February 2005

DAILY	ENGINE F1A 295

Place a container under the power steering pump to recover Figure 3 the oil from the system. Then disconnect the oil inlet and

outlet pipes (16 and 17).

- Disconnect the pipes (7) recovering diesel from the high-pressure-pump.

- Disconnect the pipe (8) delivering diesel to the high-pressure-pump.

- Disconnect the vacuum pipe (23) from the vacuum pump.

- Disconnect the air intake duct (19).

NOTE Close the turbocharger air outlet appropriately to prevent foreign bodies accidentally getting inside.

- Free the wiring harness of the engine (15) from the clamps (←) on the timing cover, disconnect the connections of the alternator (21) and from the sensors on the thermostat (22), from the electromagnetic coupling of the fan hub (20) and move the wiring to one side so it will not interfere with the disassembly of the engine.

- Disconnect the wiring (2) from the water temperature and timing sensors, from the injectors, intake air temperature sensor and rail pressure sensor. Move the wiring to one side.

- Disconnect the high-pressure pump electrical connection (10).

- Disconnect the engine speed sensor (9).

- Disconnect the engine earth cable (6).

- Disconnect the positive cable from the starter motor (5).

The remaining electrical connections of the engine cable are disconnected from the associated electrical components after removing the engine.

- Disconnect the oil fillpipe by undoing the fastenings (1).

- Undoing the fastenings (18), remove the fan from the electromagnetic coupling (20).

- Attach tool 99360544 (4) to the brackets on the engine to extract it from the engine bay and put it slightly under traction.

NOTE In case of vehicles equipped with conditioner,

proceed as follows:

- as regards the vehicles equipped with drying

filter separated from the condenser, remove compressor (11) by proceeding as follows:

- loosen the belt stretcher by acting on screw (13), then remove belt (14);

- act on fasteners (12) to remove compressor (11), then put the latter back into the compartment without

disconnecting the pipes of the system itself; - as regards the vehicles equipped with drying

filter built into the condenser, disconnect the pipes from the compressor, then seal the pipes

and their respective fittings on the compressor to prevent moisture and impurities from

penetrating into the system.

75820

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	Revi - February 2005

296 ENGINE F1A	DAILY

- Disconnect the screws (16 and 20) securing the brackets Figure 4 (17 and 19) and disconnect the ”bowdens” (18 and 21)

from the gearbox.

- Unscrew the fixing screws (22), move the clutch control cylinder (23), with its bracket, and fasten it to the chassis frame appropriately.

- Remove the sealing from the ring nut (1), unscrew it and disconnect the speedometer control cable.

-Disconnect the electrical connection (4) from the reversing light switch.

NOTE As regards automatic transmission, disconnect gearbox-chassis cable connector (27) from the control unit.

- Disconnect the exhaust pipe (9) from the turbocharger outlet pipe.

- Put a jack under the gearbox to support it.

- Disconnect the bracket supporting the gearbox on the rear crosspiece by undoing the four screws (5).

- Unscrew the fixing screws (6) and remove the crosspiece

(7) supporting the gearbox complete with the gearbox/support bracket.

- Remove nuts (14) securing elastic supports (13) to the chassis.

- Remove bolts (3) securing drive shaft (2) to the gearbox; remove, if necessary, screws (24) securing elastic support (25) to the chassis, then properly secure the drive shaft to the chassis.

- Take the jack out from under the gearbox.

- Lift the engine assembly and take it out of the engine bay.

NOTE The power unit must be removed from the engine compartment with the greatest care, to avoid damaging the remaining parts on the vehicle, in particular the steering box oil pipes.

If it is necessary to detach the gearbox from the engine, take out the fixing screws and remove the starter motor.

Take out the fixing screws and detach the gearbox from the engine.

NOTE As far as automatic transmission is concerned, strictly adhere to the operations described in the relevant chapter in the “Gearbox” section.

102184

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Revi - February 2005

DAILY	F1A ENGINE 297

Refitting

To refit the engine assembly, carry out the operations described for removal in reverse order, following these instructions:

-Before refitting the gearbox to the engine, it is necessary to remove the pressure plate bearing from the diaphragm spring by opening out the retaining circlip.

Fit the pressure plate bearing on the sleeve of the drive input shaft cover, connecting it to the clutch release lever. Spread the gearbox input shaft with Molikote molybdenum disulphide grease.

Engage a gear to let the main shaft turn, rotating the propeller shaft connecting flange. Push the gearbox fully in so that the pressure plate bearing couples with the diaphragm spring correctly.

-Pay special attention to the operations needed to install the engine assembly in the engine bay.

-Check the conditions of the coolant pipes or sleeves and of the air ducts. Replace them if they show any sign of deterioration.

-Check the flexible mountings of the assemblies: engine and gearbox. Replace them if they show any sign of deterioration.

-Check that the exhaust pipe members have not deteriorated and are not about to deteriorate. If this is so, replace them along with the flexible parts for securing them.

-Tighten the screws or nuts to the required torque.

-Meticulously check the state of the vacuum pipe. It must show no sign of cracking, cutting, scoring or of being crushed. Replace it if there is any doubt at all about its soundness. When mounting it, make sure the pipe does not come into contact with sharp metal parts or corners or with any particularly hot parts. In addition, after assembly, the pipe must have no bends or constrictions, its radius of curvature should be broad and it must be secured to the vacuum pump fitting with a suitable clamp.

-Make sure the quick-coupling fittings of the fuel pipes are thoroughly clean and, after connection to the relevant high-pressure pump unions or fuel filter mount, are fully inserted and do not come loose.

-Fill the cooling system with coolant.

-Fill the hydraulic power steering circuit and bleed the air as described under the relevant heading.

-Check the level of oil in the engine and gearbox.

-Adjust the tension of the drive belt of the compressor for the air-conditioner as described in “Replacing Belts” (if present).

NOTE When positioning the engine in the engine bay, take special care not to damage the top pipe of the power steering and the soundproof-heatproof cladding of the engine bay.

Once positioned, meticulously check that the top pipe of the power steering is sound.

Before using it again, check that the power steering oil and coolant contain no impurities. If they do, filter with suitable mesh filters. For any topping up, refer to the REPLENISHING FLUIDS table in the “GENERAL” section.

Checks and tests

Start up the engine, leave it running just a little faster than idling speed and wait for the coolant temperature to reach the value for opening the thermostat, then check that:

-No water leaks from the connecting sleeves of the engine cooling and cab heating circuit pipes; tighten the collars if necessary.

-No oil leaks from between the cover and cylinder head, oil sump and crankcase, oil filter and its seat, heat exchanger and crankcase or from between the various pipes of the lubricating circuit.

-No fuel leaks from injection pump and injector lines. Tighten fittings if necessary.

-Check the indicator and warning lights on the instrument panel and the devices disconnected on removing the engine all work properly.

501430 Power steering system air bleed

Check the level of oil in the tank and top it up if necessary. Lift the vehicle at the front, start up the engine and let it idle for some time.

Check there is no oil leakage from the hydraulic circuit and check the level in the tank.

Slowly turn the steering wheel in both directions of steering so that the air in the hydraulic system comes out.

Check the level of oil in the tank again and top up if necessary.

Print 603.93.281

Base - May 2004

298 F1A ENGINE	DAILY

REPLACING BELTS

543910 Replacing air-conditioning compressor drive belt (version with belt tensioner)

Disassembly

Figure 5

75247

Set the vehicle on a lift or over a pit. From underneath the vehicle, detach the middle soundproofing guard.

Loosen the screw (2) fixing the tightener (1) and remove the belt (4) driving the air-conditioner compressor (3).

Assembly and adjusting belt tension

Figure 6

75502

Mount the drive belt, taking care to position its ribs properly in the respective races of the pulleys.

With the tool SP.2341 (2) inserted in the holes of the tightener (1) and a torque wrench (3), turn the tightener (1) with a torque of 8.2-10 Nm; in this condition, tighten the screw (4) to a torque of 25 Nm.

Turn the engine in its direction of rotation to have the belt

(5) make two full turns.

Using tool 99395849, measure the tension of the belt (5) in the section A, which must be 204 ± 10 Hz, corresponding to a load of 1010 ± 10 N on the tightener.

Fit the middle soundproofing guard back on.

543910 Replacing air-conditioning compressor drive belt (version with elastic belt)

Disassembly

Figure 7

90155

Take elastic belt (3) off pulleys (1 and 4).

Assembly

Fit the flexible belt (3) equipped with tool 99360191

(2) on the pulley (4) and apply the tool on the pulley (1).

Fit the drive ring (5) on the flexible belt (3) and fasten the ring on the compressor support.

Turn the drive shaft clockwise until the belt fits perfectly on the pulley (1).

543910 Power steering pump-alternator belt replacement

Disassembly

Figure 8

75248

Disassemble the compressor drive belt, if there is one, as described under the relevant heading.

Slacken off the tension of the belt (1) using a specific wrench on the automatic tightener (2) and remove the belt.

Assembly

Mount the drive belt (1) taking care to position its ribs correctly in the respective races of the pulleys. Release the automatic tightener (2). Turn the crankshaft by one turn to settle the belt.

Mount the compressor drive belt, if there is one, and adjust the tension as described under the relevant heading.

Fit the middle soundproofing guard back on.

Base - May 2004

Print 603.93.281

DAILY	ENGINE F1A 299

541257 Replacing timing drive belt

Figure 9

Disassembly

Following the procedures described for removing the engine, take out the radiator assembly without disconnecting the air-conditioning system pipes from the condenser or from the drier filter and put it appropriately aside in the engine bay.

Remove the air-conditioner compressor drive belt (22) (if there is one) and the water pump / alternator drive belt as described under the relevant headings.

Remove the fan (25) from the electromagnetic coupling (6). Disconnect the electrical connection (24) from the electromagnetic coupling (6).

Take out the fixing screws (2) and (3) and remove the mounting together with the electromagnetic coupling (6). Take out the screws and remove the fixed tightener (5) and the automatic tightener (4).

Remove screws (26), then disassemble pulley (27). Remove the wiring from the timing cover (23) and dismantle this.

Take off the cap (13) and remove the soundproofing cover (14).

Disassemble valve gear cover (23). Disconnect the pipes (15) from the pipe (16).

Take out the fixing screws (8) and remove the expansion tank (7); disconnect the electrical connection for the level indicator from the expansion tank and put the tank (8) aside appropriately.

Take out the screws (10) and remove the bracket (11) fixing the soundproofing cover (14).

Remove the plugs (9) from the overhead and the plug (20) from the oil pump — vacuum pump assembly mounting. Turn the crankshaft clockwise so as to be able to insert the pins 99360614 (12) through the holes in the plugs (9) into the relevant holes of the camshafts and pin 99360615 (19) through the hole in the plug (20) into the crankshaft. Loosen the screw (17) securing the automatic tightener (18) and remove the timing belt (21).

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	Revi - February 2005

300 ENGINE F1A	DAILY

Figure 10

Assembly

Insert tool 99360608 (8) into the hole of the toothed pulley

(7) and into the corresponding hole of the overhead to prevent changing the assembly position of the toothed pulley

(7) in the following operations.

Loosen the screw (9) fixing the toothed pulley (7) and, using tool 99340028, drive the pulley (7) out of the camshaft. Turn the automatic tightener (1) clockwise, positioning it as shown in frame A.

Turn the timing belt (10) as shown in the figure observing the precautions below.

Do not bend the timing belt. Arrows indicating the direction of assembly of the timing belt on the engine are shown on the back of the belt. The arrows must correspond to the direction of rotation of the belt and the notches must coincide with those on the pulley (7) and the gear (12).

If required to fit the timing belt (10) on the pulley (7), remove tool 99360608 (8) and turn the pulley (7) clockwise by no more than half a pulley tooth.

On completing assembly, adjust the toothed pulley (7) to put the section X of the belt under tension and tighten the screw

(9) to a torque of 90 Nm.

Keeping the screw (2) stationary and using a suitable wrench on the hexagon of the plate (3) of the tightener, turn it anticlockwise to cover the reference hole (5) located on the fixed portion of the tightener (see frame B).

In the above conditions, tighten the fixing screw (2) to a torque of 36 ± 4 Nm.

Remove the tools 99360614 (6) and 99360615 (11) for the timing.

Turn the engine in its direction of rotation by 8 turns to be able to put the tools (6) and (11) back in to do the timing.

In these conditions, the notches of the timing belt (10) must coincide with those of the pulley (7) and the gear (12).

NOTE Do not turn the engine in the opposite direction; if, on turning the engine, you pass the point for inserting the tools (6) and (11), turn the engine clockwise by another two turns.

See frame C: holding the tightener plate (3) stationary with the wrench inserted in its hexagon, loosen the fixing screw (2). Keeping the fixing screw (2) stationary, turn the plate (3)

clockwise until its reference mark (4) coincides with the reference hole (5) of the fixed portion of the tightener.

In the above conditions, tighten the screw (2) to a torque of 30 ± 4 Nm.

Then complete assembly by carrying out the steps described for disassembly in reverse order.

After assembly, the belt (10) tension measured using tool 99395849 must be as follows in the following points: X, 212

± 12 Hz - X1, 178 ± 10 Hz.

x = direction of movement of the tightener
y = direction of rotation of the wrench	85844

Base - May 2004

Print 603.93.281

DAILY	F1A ENGINE 301

775010 REPLACING ELECTRO-INJECTORS

Figure 11

Disassembly

Partly drain the coolant off from the radiator.

Remove the plug (13, Figure 9) and detach the soundproofing cover (14, Figure 9).

Disconnect the pipes (15, Figure 9) from the pipe (16, Figure 9).

Take out the fixing screws (8, Figure 9) and remove the expansion tank (7, Figure 9). Disconnect the level indicator electrical connection from the expansion tank.

Disconnect the pipe (17, Figure 12) from the coalescence filter (2, Figure 12).

Disconnect the electrical connections (1) from the electro-injectors (10) and (2) from the fuel pressure sensor

(8).

Press the springs (3) in the direction shown by the arrow and disconnect the fittings of the pipe (4) to recover fuel from the electro-injectors (10).

Disconnect the fuel pipes (7) from the electro-injectors (10) and from the hydraulic accumulator (9).

Take out the screws (6) and the brackets (5) fixing the electro-injectors (10) to the cylinder head.

Using tool 99342153 (11) extract the electro-injectors (10) from the overhead.

75564

Assembly

Thoroughly clean the seat of the electro-injectors, taking care no foreign bodies get into the cylinder barrels.

Fit a fresh gasket (12) onto the electro-injector (10) and fit this in the overhead.

Complete assembly by carrying out the operations described for disassembly in reverse order, taking the following precautions:

-With each disassembly, the fuel pipes must be replaced with fresh ones.

-Tighten the nuts, screws and fittings to the prescribed torque.

-To tighten the fittings of the fuel pipes, use the wrench in the 99317915 series and the torque wrench 99389829.

-After assembly, replenish the coolant as described under the relevant heading.

Check assembly of the timing sensor as described under the relevant heading.

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Base - May 2004

302 F1A ENGINE	DAILY

540610 CYLINDER HEAD REMOVAL AND REFITTING

Figure 12

Removal

Remove the timing belt as described under the relevant heading (operation 541257).

Disconnect the coolant pipes (12) and (13) from the pipe (11).

Take out the fixing screws and remove the expansion tank (16), disconnecting the level sensor electrical connection from this.

Remove the pipe (18) for the oil dipstick from the intake manifold.

Disconnect the pipes (1) and (17) from the coalescence filter

(2) and detach this from the overhead.

75567

Disconnect the pipe (3) from the fitting.

Remove the electro-injectors (4) as described in “Replacing electro-injectors” (operation 775010).

Disconnect the electrical connections from: timing sensor (5) and remove this from the overhead, water temperature sensors (6) and (7), air pressure and temperature sensor (10), and glow plugs (15).

Detach the fuel pipe (9) from the hydraulic accumulator (8), from the high-pressure pump and from the intake manifold. Disconnect the fuel return pipe (14) from the pressure relief valve of the hydraulic accumulator (8).

Base - May 2004

Print 603.93.281

DAILY	F1A ENGINE 303

Figure 13

Loosen the clamp and disconnect the sleeve (11) from the air duct (10).

Loosen the collar (2), take out the screw (13) fixing the bracket (12) and detach the air duct (10).

Disconnect the oil vapour recirculation pipe (8) from the air intake sleeve (9) and disconnect this from the turbocharger

(5).

Disconnect the oil pipe (1) from the cylinder head and from the turbocharger (5).

Loosen the clamp (7) and disconnect the oil pipe (6) from the crankcase union.

Take out the screws and disconnect the exhaust pipe (4) from the turbocharger (5).

Take off the nuts (3) and remove the turbocharger (5) with its gasket from the exhaust manifold.

NOTE Close the turbocharger air outlet/inlet appropriately to prevent foreign bodies accidentally getting inside and damaging it.

75568

Take out the screws and remove the overhead together with the pins 99360614.

NOTE The pins 99360614 applied so as not to alter the timing after removing the timing belt must be removed from the overhead only if this is to be removed.

Take off the overhead gasket.

Take out the tappets and carefully put them aside. Using the bushing 99355041, take out the glow plugs.

Take out the screws fixing the cylinder head and detach this from the crankcase.

Remove the cylinder head gasket.

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Base - May 2004

304 F1A ENGINE	DAILY

Refitting

Refitting requires carrying out the operations for removal in reverse order, while taking the following precautions: Check that the timing tools:

-99360614 (6, Figure 10) and 99360608 (8, Figure 10) are inserted in the overhead;

-99360615 (11, Figure 10) is inserted in the crankcase as described in “Replacing timing belt.”

Check that the mating surfaces of the cylinder head and crankcase are clean.

Keep the cylinder head gasket clean.

Position the cylinder head gasket with the lettering ”TOP” facing the cylinder head.

NOTE It is essential to keep the gasket sealed in its package until just before assembly.

Mount the cylinder head. Insert the screws and tighten them, in three successive stages, following the order and method shown in the following figure.

NOTE The angle closure is done with tool 99395216.

Figure 14

A

75494

Diagram of the tightening sequence for the cylinder head fixing screws:

-1st phase: pre-tightening with torque wrench

•screws 1-2-3-4-5-6 to a torque of 100 ±5 Nm;

•screws 7-8-9-10 to a torque of 50 ±2.5 Nm.

-2nd phase: angle closing

•screws 1-2-3-4-5-6 90° ±5°;

•screws 7-8-9-10 60° ±3°.

-3rd phase: angle closing

•screws 1-2-3-4-5-6 90° ±5°;

•screws 7-8-9-10 60° ±3°.

A = flywheel side.

-Tighten the screws and nuts to the prescribed torque.

-The seals and gaskets must not be reused, but replaced with new ones.

NOTE If the engine has run for a period equivalent to = 25,000 km, the toothed timing drive belt must be replaced with a fresh one, no matter what its state of wear.

To tighten the glow plugs, use the bushing 99355041 and torque wrench 99389819.

Base - May 2004

Print 603.93.281

DAILY	F1A ENGINE 305

771010 REPLACING HIGH-PRESSURE PUMP CP3

Removal

Remove the timing drive belt, as described in the relevant chapter (operation 541257).

Disconnect the following items:

-electric connection from the pressure sensor;

-fuel pipes from the high-pressure pump.

Figure 15

75271

Lock rotation of the high-pressure pump gear (1) by applying tool SP. 2263 (2) as illustrated in the figure. Remove the nut

(3)and take out the tool (2).

Figure 16

75272

Using tool 99340035 (2) applied as shown in the figure, extract the gear (1) from the shaft of the high-pressure pump

(3).

Print 603.93.281/A

Figure 17

75273

Take out the screws (1) and remove the high-pressure pump

(2) from the water pump mounting (3).

Refitting

Re-attachment is carried out by reversing the order of detachment operations. In particular, take care of the following: replace the seal rings, gaskets and high-pressure pipe with new parts; tighten the nuts, screws and fittings to the specified torque values.

NOTE If the engine has run for a period equivalent to = 25,000 km, the toothed timing drive belt must be replaced with a fresh one, no matter what its state of wear.

543210 REPLACING WATER PUMP

Removal

Remove the high-pressure pump as described under the relevant heading.

Figure 18

75569

Take out the screw (2) and remove the fixed tightener (1). Take out the screws (3) and remove the water pump mounting (4).

Refitting

Fit two new seals on the water pump and fit it back on the crankcase, carrying out the operations described for removal in reverse order and tightening the screws or nuts to the prescribed torque.

Base - May 2004

Revi - February 2005

306 F1A ENGINE	DAILY

EMISSIONS

Engine F1AE0481A*A (96 HP) — Engine F1AE0481B*A (116 HP)

Figure 19

75570

Gas emissions

The engines conform to the Euro3 standards on gas emissions (measurement on engine bench according to OICA cycle), with the following limits fixed by the ESC and ELR 1999/96-2001/27 standards:

ESC:

-	CO (carbon monoxide)	< 2.1 g/kWh
-	NOx (nitrogen oxide)	< 5.0 g/kWh
-	HC (unburnt hydrocarbons)	< 0.66 g/kWh
-	Particulate	< 0.13 g/kWh
ELR:		0.8 l/m (opacity)
Test fuel: CEC RF03A084 — S ≤ 0.03%

Smokiness

The engines conform to the limits of smokiness required by EEC standards 72/306, updated 97/20 EC: 1.49 l/m with the following exhaust smoke values:

Maximum power (Bosch BSU opacimeter degrees)	1.5
Maximum torque (Bosch BSU opacimeter degrees)	1.5

Noise emissions

Maximum mean noise level, Lpa, of the standard engines measured according to ISO Std. 3745 (microphones at 1 m

from the engine surfaces):
Idling	(800 rpm)	76 dBA
Full power	(3800 rpm)	96 dBA.

Base - May 2004

Print 603.93.281

DAILY	F1A ENGINE 307

Engine F1AE0481B*B (116 HP with EGR)

Figure 20

Gas emissions

The engine conforms to the Euro3 standards on gas emissions (measurement on engine bench according to OICA cycle), with the following limits fixed by the ESC and ELR 1999/96-2001/27 standards:

ESC:

-	CO (carbon monoxide)	< 0.95 g/kWh
-	NOx (nitrogen oxide)	< 0.78 g/kWh
- HC + NOx (unburnt hydrocarbons)		< 0.86 g/kWh
-	Particulate	< 0.1 g/kWh
ELR:		0.8 l/m (opacity)
Test fuel: CEC RF03A084 — S ≤ 0.03%

75571

Smokiness

The engine conforms to the limits of smokiness required by EEC standards 72/306, updated 97/20 EC: 1.49 l/m with the following exhaust smoke values:

Maximum power (Bosch BSU opacimeter degrees)	1.5
Maximum torque (Bosch BSU opacimeter degrees)	2.5

Full load at 1000 rpm (Bosch BSU opacimeter degrees) 3.5

Noise emissions

Maximum mean noise level, Lpa, of the standard engines measured according to ISO Std. 3745 (microphones at 1 m from the engine surfaces):

Idling	(800 rpm)	76 dBA
Full power	(3800 rpm)	96 dBA.

Print 603.93.281

Base - May 2004

308 F1A ENGINE	DAILY

ENGINE IDENTIFICATION CODE

F	1	A	E	0	4	8	1	A	*	A	+
										Emission level
								Type approval power
							Use No.
						Supply / injection
					No. cylinders
				Engine cycle — cylinder position
			Engine

Family development	0= 4-stroke,
	vertical

Engine family

4 = 4 cylind.

6 = 6 cylind.

8 = DI. TCA

1 = Truck

2 = Bus

4 = E.M. mach. & tractors

6 = Nautical

9 = Military

0481	A = 71 kW - (	96	CV)3000-3700 rpm -244 Nm / 1800÷2800 rpm
0481	B = 85 kW - ( 116		CV)3000-3900 rpm -270 Nm / 1800÷2800 rpm
0481	M = 100 kW - (	136	CV)3600-3900 rpm -320 Nm / 1700÷2900 rpm

Base - May 2004

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Revi - February 2005

DAILY	F1A ENGINE 308/1

CHARACTERISTIC CURVES

Print 603.43.671

Figure 20/1

HP

rpm

102408

CHARACTERISTIC CURVES OF ENGINE F1AE 0481A

Max OUTPUT 71 kW

Max TORQUE 240 Nm

96 HP

24.4 kgm

at 3000 ÷ 3700 rpm

at 1800 ÷ 2800 rpm

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Revi - February 2005

308/2 F1A ENGINE	DAILY

Figure 20/2

HP
rpm	102409

CHARACTERISTIC CURVES OF ENGINE F1AE 0481B

Max OUTPUT 85 kW

Max TORQUE 270 Nm

116 HP

27.5 kgm

at 3000 ÷ 3900 rpm

at 1800 ÷ 2800 rpm

Revi - February 2005

Print 603.93.281/A

DAILY	F1A ENGINE 308/3

Figure 20/3

	HP
rpm	102410

CHARACTERISTIC CURVES OF ENGINE F1AE 0481M

Max OUTPUT 100 kW

Max TORQUE 320 Nm

136 HP

32.6 kgm

at 3600 ÷ 3900 rpm

at 1700 ÷ 2900 rpm

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308/4 F1A ENGINE	DAILY

Revi - February 2005

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DAILY	F1A ENGINE 309

Figure 21

SELF-ADHESIVE LABEL

Engine variant

Iveco drawing number

— 9 digits

Engine serial number

— 7 digits

GAN — 9 characters

Electro-injector class

1 or 2 or 3

Iveco drawing number

— 9 digits

75243

Figure 22

CRANKCASE MARKING

75244

			EXAMPLE
A	=	IVECO trademark	IVECO
B	= IVECO name of engine variant **		F1AE0481A * A001
C	=	Engine serial number	1359862
D	= 1st digit, main journal no. 1 (engine front)
E	= Main bearing selection diameters		12345
F	=	Barrel selection diameters	1234
G	= 1st digit, cylinder no. 1 (engine front)

(**) Data obtainable from “XZ” engine ordering number information

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310 F1A ENGINE	DAILY

Print 603.93.281/A

GENERAL SPECIFICATIONS

		Type		F1AE0481 A	F1AE0481 B	F1AE0481 M
		Cycle			Diesel 4 strokes
		Supply			Turbocharged with intercooler
		Injection			Direct
		Number of cylinders			4 in line
		Bore	mm		88
		Stroke	mm		94
+	+	+.. = Total displacement	cm3		2300
	ρ	Compression ratio			18
		Maximum power	kW	71	85	100
			(HP)	(96)	(116)	(136)
			rpm	3000 ÷ 3700	3000 ÷ 3900	3600 ÷ 3900
		Maximum torque	kW	240	270	320
			(HP)	(24.4)	(27.5)	32.6
			rpm	1800 ÷ 2800	1800 ÷ 2800	1700 ÷ 2900
		Slow running of engine			800
		with no load	rpm
		Fast idling speed of			4600
		engine with no load	rpm
		Pressure at T.D.C.	*bar		20 ÷ 26
	bar	Minimum permissible
		pressure at T.D.C.	*bar
					16

(*)The pressure is measured by setting the engine turning with the aid of just the starter motor, with an oil temperature of 40 — 50°C.

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Revi - February 2005

DAILY	F1A ENGINE 311

Type		F1AE0481 A	F1AE0481 B	F1AE0481 M
A
TIMING SYSTEM
Start before T.D.C.	A		14°
end after B.D.C.	B		27°
B
C
Start before T.D.C.	D		54°
end after B.D.C.	C		10°
D
For timing check
X	mm		-
	mm		-
X
Operation
X	mm		-
	mm		-
		High pressure electronic fuel feed system BOSCH MS6.3 to
		chassis number (…) and BOSCH EDC16 from chassis
SUPPLY			number (…).
		Composed of CP3 high-pressure pump, electro-injectors,
		hydraulic accumulator (rail), EDC control unit, pressure and
			temperature sensors

Pump setting

With piston no.1 at T.D.C.

X

Start of delivery

mm

Electro-injectors type

Injection sequence

-

-

BOSCH

1- 3 - 4 - 2

bar

Injection pressure

bar

1600

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	Revi - February 2005

312 F1A ENGINE	DAILY

	Type		F1AE0481 A	F1AE0481 B	F1AE0481 M
	TURBOCHARGING		With intercooler
	Turbocharger type		KKK K03-2072-EDC 5.68		KKK
Turbocharger shaft radial play				-
Turbocharger shaft end float				-
Maximum stroke of pressure relief valve opening		mm		3.5 ±0.5	2.2 ± 0.5
Pressure corresponding to maximum stroke:		bar	1.5 ±0.002		1.4 ± 0.05
	LUBRICATION		forced by gear pump, pressure relief valve, oil filter with
			integral cartridge with total filtering
	Oil pressure with engine hot
bar	(100°C ±5°C):
	at idling speed	bar		≥0.6
	at top speed	bar		4
			by centrifugal pump, thermostat for adjustment, coolant
	COOLING		temperature, fan with electromagnetic coupling, radiator,
				heat exchanger
	Water pump control:			by belt
	Thermostat:			N. I.
	start of opening:			82 ±2ºC
	FLUIDS
	Capacity:
	engine sump
	at minimum level	liters		3
	engine sump	kg		2.65
	at maximum level	litres		4.3
Urania Daily		kg		3.78
Urania LD 5	quantity in circulation
	in cartridge filter and heat
	exchanger	litres
				1.4
		kg		1.23
	quantity of oil for first
	filling	liters		5.7
		kg		5.02

Base - May 2004	Print 603.93.281/A
Revi - February 2005