Iveco Cursor Euro 4 Engines Technical & Service Repair Manual

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This technical manual PDF download for the Iveco Cursor Euro 4 Engines has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

IVECO C78
IVECO C78 ENT C
IVECO C10
IVECO C10 ENT C
IVECO C13
IVECO C13 ENT C


TABLE OF CONTENTS :

Graph and symbols

Part 1 - F2B CURSOR EURO 4 ENGINES
Part 2 - F3A CURSOR EURO 4 ENGINES
Part 3 - F3B CURSOR EURO 4 ENGINES

UPDATING
SECTION 1 - General specifications
SECTION 2 - Fuel
SECTION 3 - Vehicle application
SECTION 4 - General overhaul
SECTION 5 - Tools
Appendix


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : P1D32C002
Total Pages : 584


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CURSOR SERIES EURO 4
CURSOR EURO 4 ENGINES
SPECIAL REMARKS
Graph and symbols
Part 1 - F2B CURSOR EURO 4 ENGINES
UPDATING
SECTION 1 - General specifications
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
ENGINE SECTIONS
LUBRICATION
Oil pump
Overpressure valve
Oil pressure control valve
Heat exchanger
By-pass valve inside the filter support/heat exchanger assembly
Thermostatic valve
Engine oil filters
Valve integrated in piston cooling nozzle
COOLING
Description
Operation
Water pump
Thermostat
TURBOCHARGING
VGT TURBOCHARGER
Actuator
Solenoid valve for VGT control
DeNOx SYSTEM 2
General remarks
Tank
AdBlue fluid level gauge control
By-pass valve
Pump module
Dosing module
Catalyst
Exhaust gas temperature sensor
Humidity detecting sensor
SECTION 2 - Fuel
FUEL FEED
Overpressure valve
Feed pump
Injector-pump
Injector Phases
Pressure damper
SECTION 3 - Vehicle application
GENERAL FEATURES
PART ONE - MECHANICAL COMPONENTS
DISMANTLING THE ENGINE ON THE BENCH
ASSEMBLING THE ENGINE ON THE BENCH
Diagram showing the underblock fixing screws tightening order
Fitting the connecting rod-piston assembly into the cylinder liners
Mounting cylinder head
Fitting engine flywheel
Fitting camshaft
Fitting pump-injectors
Fitting rocker-arm shaft assembly
Camshaft timing
Phonic wheel timing
Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors
ENGINE COMPLETION
PART TWO - ELECTRICAL EQUIPMENT
Components on the engine F2B
BLOCK DIAGRAM
EDC SYSTEM FUNCTIONS
EDC 7 UC31 electronic control unit
Electric injector connector ”A”
Sensor connector ”C”
Chassis connector ”B”
Pump injector (78247)
Exhaust brake solenoid valve (78050)
Solenoid valve for VGT control
Distribution pulse transmitter (48042)
Engine coolant temperature sensor (85153)
Fuel temperature sensor (47042)
Flywheel pulse transmitter (48035)
Turbine rpm sensor (48043)
Air pressure/temperature sensor (85156)
Oil temperature/pressure sensor (42030 / 47032)
Pre-post reheat resistor (61121)
PART THREE - TROUBLESHOOTING
PREFACE
DTC error codes with EDC7 UC31 central unit
GUIDELINE FOR TROUBLESHOOTING
PART FOUR - MAINTENANCE PLANNING
MAINTENANCE
Maintenance services scheme
MAINTENANCE INTERVALS
On road application
Off road application (quarries-construction sites)
Off road application (on road usage)
CHECKS AND/OR MAINTENANCEWORK
On road application
Off road application
NON-PROGRAMMED/TIMED OPERATIONS
On road application
Off road application (quarries-construction sites)
Off road application (on road usage)
SECTION 4 - General overhaul
GENERAL CHARACTERISTICS
ASSEMBLY CLEARANCE DATA
REPAIR OPERATIONS
CYLINDER BLOCK
Checks and measurements
CYLINDER LINERS
Removal of cylinder liners
Fitting and checking protrusion
CRANKSHAFT
Measuring main journals and crank pins
Preliminary measurement of main and big end bearing shell selection data
Selecting the main and big end bearing shells
Defining the class of diameter of themain journals and crankpins (Journals with nominal diameter)
Selection of main half-bearings (nominal diameter pins)
Selection of main half-bearings (rectified pins)
Selecting the big end bearing shells (journals with nominal diameter)
Selection of connecting rod half-bearings (rectified pins)
Replacing the timing control gear and the oil pump
Checking main journal installation clearance
Checking crankshaft end float
PISTON-CONNECTING ROD ASSEMBLY
Removal
Measuring the diameter of the pistons
Conditions for correct gudgeon pin-piston coupling
Piston rings
CONNECTING ROD
Checking connecting rod alignment
Mounting the connecting rod - piston assembly
Mounting the piston rings
Fitting the connecting rod-piston assembly into the piston liners
Piston protrusion check
Checking assembly clearance of big end pins
CYLINDER HEAD
Dismounting the valves
Checking the planarity of the head on the cylinder block
VALVE
Removing deposits and checking the valves
VALVE GUIDES
Replacing of valve guides
Replacing - Reaming the valve seats
REPLACING INJECTOR HOLDER CASES
Removal
Checking protrusion of injectors
TIMING GEAR
Camshaft drive
Intermediate gear pin
Idler gear
Twin idler gear
Replacing the bushings
Check of cam lift and timing system shaft pins alignment
Bushes
Replacing camshaft bushes using beater 99360487
Removing bushes
Assembling bushes
VALVE SPRINGS
Fitting the valves and oil seal ring
ROCKER SHAFT
Shaft
Rocker
REPAIRING ACTIONS
Variable geometry movement control
Checking the actuator
Checking actuator travel
Cleaning turbine body
TIGHTENING TORQUES
Underblock fixing screws tightening sequence
Diagram of cylinder head fixing screws tightening sequence
Diagram of rocker shaft fixing screws tightening sequence
Diagram of exhaust manifold fixing screws tightening sequence
Diagram of turbocharger fixing screws and nuts tightening sequence
Diagram of heat exchanger fixing screws tightening sequence
Diagram of engine oil sump fixing screws tightening sequence
Diagram of rocker arm cap fixing screws tightening sequence
SECTION 5 - Tools
TOOLS
Appendix
SAFETY PRESCRIPTIONS
Part 2 - F3A CURSOR EURO 4 ENGINES
UPDATING
SECTION 1 - General specifications
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
VIEWS OF THE ENGINE
LUBRICATION
Oil pump
Overpressure valve
Oil pressure control valve
Heat exchanger
By-pass valve
Thermostatic valve
Engine oil filters
Valve integrated in piston cooling nozzle
COOLING
Description
Operation
Water pump
Thermostat
TURBOCHARGING
Turbocharger HOLSET HE531V
Actuator
Solenoid valve for VGT control
DeNOx SYSTEM 2
General remarks
Tank
AdBlue fluid level gauge control
By-pass valve
Pump module
Dosing module
Catalyst
Exhaust gas temperature sensor
Humidity detecting sensor
SECTION 2 - Fuel
FEEDING
Overpressure valve
Feed pump
Injector-pump
Replacing injectors-pump
Pressure damper
SECTION 3 - Vehicle application
GENERAL FEATURES
PART ONE - MECHANICAL COMPONENTS
DISMANTLING THE ENGINE ON THE BENCH
ENGINE ASSEMBLY ON BENCH
Diagram of tightening sequence of crankcase base fixing screws
Fitting connecting rod - piston assemblies in cylinder liners
Mounting cylinder head
Fitting engine flywheel
Fitting camshaft
Fitting pump-injectors
Fitting rocker-arm shaft assembly
Camshaft timing
Phonic wheel timing
Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors
Completing Engine Assembly
PART TWO - ELECTRICAL EQUIPMENT
Components on the engine F3A
BLOCK DIAGRAM
EDC SYSTEM FUNCTIONS
EDC 7 UC31 electronic control unit
Electric injector connector ”A”
Sensor connector ”C”
Chassis connector ”B”
Pump injector (78247)
Exhaust brake solenoid valve (78050)
Solenoid valve for VGT control
Distribution pulse transmitter (48042)
Engine coolant temperature sensor (85153)
Fuel temperature sensor (47042)
Flywheel pulse transmitter (48035)
Turbine rpm sensor (48043)
Air pressure/temperature sensor (85156).
Oil temperature/pressure sensor (42030 / 47032)
Pre-post reheat resistor (61121)
PART THREE - TROUBLESHOOTING
PREFACE
DTC error codes with EDC7 UC31 central unit
GUIDELINE FOR TROUBLESHOOTING
PART FOUR - MAINTENANCE PLANNING
MAINTENANCE
Maintenance services scheme
Maintenance intervals
CHECKS AND/OR MAINTENANCEWORK
NON-PROGRAMMED/TIMED OPERATIONS
SECTION 4 - General overhaul
GENERAL CHARACTERISTICS
ASSEMBLY CLEARANCE DATA
REPAIR OPERATIONS
CYLINDER BLOCK
Checks and measurements
CYLINDER LINERS
Removing cylinder liners
Fitting and checking protrusion
CRANKSHAFT
Measuring the main journals and crankpins
Preliminary measurement of main and big end bearing shell selection data
Selecting the main and big end bearing shells
Defining the class of diameter of themain journals and crankpins (Journals with nominal diameter)
Selecting the main bearing shells (Journals with nominal diameter)
Selecting the main bearing shells (ground journals)
Replacing the timing gear and oil pump
Checking main journal assembly clearance
Checking crankshaft end float
PISTON CONNECTING ROD ASSEMBLY
Removal
Measuring the diameter of the pistons
Conditions for correct gudgeon pin-piston coupling
Piston rings
CONNECTING RODS
Bushings
Checking connecting rods
Mounting the connecting rod — piston assembly
Mounting the piston rings
Fitting the big end bearing shells
Fitting connecting rod - piston assemblies in the cylinder liners
Checking piston protrusion
Checking crankpin assembly clearance
CYLINDER HEAD
Disassembly the valves
Checking head bearing surface on cylinder block
Valves
Removing deposits and checking the valves
Valve seats
Checking clearance between valve-stem and associated valve guide
Valve guides
Replacing injector cases
Checking injector protrusion
TIMING GEAR
Camshaft drive
Idler gear and pin
Twin intermediate gear and pin
Replacing the bushings
Check of cam lift and timing system shaft pins alignment
Camshaft
Bushings
Replacing camshaft bushings with drift 99360499
Dismounting the bushings
Mounting the bushings
Valve springs
ROCKER SHAFT
Shaft
Rocker arms
REPAIR
Variable geometry movement control
Checking the actuator
Checking actuator travel
Cleaning turbine body
TIGHTENING TORQUES
Diagrams of tightening sequence for screws fixing crankcase base
Diagram of cylinder head fixing screws tightening sequence
Diagram of exhaust manifold fixing screws tightening sequence
Diagram of turbocharger fixing screws and nuts tightening sequence
Diagram of tightening sequence for heat exchanger screws
Diagram of tightening sequence for engine oil sump screws
Diagram of tightening sequence for screws fixing rocker cover
F3A ENGINE
Diagram of cylinder head fixing screws tightening sequence
SECTION 5 - Tools
TOOLS
Appendix
SAFETY PRESCRIPTIONS
Part 3 - F3B CURSOR EURO 4 ENGINES
UPDATING
SECTION 1 - General specifications
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
VIEWS OF ENGINE
LUBRICATION
Oil pump
Overpressure valve
Oil pressure control valve
Heat exchanger
By-pass valve
Thermostatic valve
Engine oil filters
Valve integrated in piston cooling nozzle
COOLING
Description
Operation
Water pump
Thermostat
TURBOCHARGING
Turbocharger HOLSET HE 551 V
Actuator
Solenoid valve for VGT control
DeNOx SYSTEM 2
General remarks
Tank
AdBlue fluid level gauge control
By-pass valve
Pump module
Dosing module
Catalyst
Exhaust gas temperature sensor
Humidity detecting sensor
SECTION 2 - Fuel
FEEDING
Overpressure valve
Feed pump
Injector-pump
Pressure damper
SECTION 3 - Vehicle application
CLEARANCE DATA
PART ONE - MECHANICAL COMPONENTS
DISASSEMBLY THE ENGINE ON THE BENCH
ASSEMBLING THE ENGINE ON THE BENCH
Diagram of tightening sequence of crankcase base fixing screws
Fitting connecting rod - piston assemblies in cylinder liners
Mounting cylinder head
Fitting flywheel box
ENGINE FLYWHEEL
Fitting engine flywheel
Fitting camshaft
Fitting pump-injectors
Fitting rocker-arm shaft assembly
Camshaft timing
Phonic wheel timing
Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors
Completing Engine Assembly
PART TWO - ELECTRICAL EQUIPMENT
Components on the engine F3B
BLOCK DIAGRAM
EDC SYSTEM FUNCTIONS
EDC 7 UC31 electronic control unit
Electric injector connector ”A”
Sensor connector ”C”
Chassis connector ”B”
Pump injector (78247)
Exhaust brake solenoid valve (78050)
Solenoid valve for VGT control
Distribution pulse transmitter (48042)
Engine coolant temperature sensor (85153)
Fuel temperature sensor (47042)
Flywheel pulse transmitter (48035)
Turbine rpm sensor (48043)
Air pressure/temperature sensor (85156).
Oil temperature/pressure sensor (42030 / 47032)
Pre-post reheat resistor (61121)
PART THREE - TROUBLESHOOTING
PREFACE
DTC error codes with EDC7 UC31 central unit
GUIDELINE FOR TROUBLESHOOTING
PART FOUR - MAINTENANCE PLANNING
MAINTENANCE
Maintenance services scheme
MAINTENANCE INTERVALS
On road application
Off road application (quarries-construction sites)
Off road application (on road usage)
CHECKS AND/OR MAINTENANCEWORK
On road application
Off road application
NON-PROGRAMMED/TIMED OPERATIONS
On road application
Off road application (quarries-construction sites)
Off road application (on road usage)
SECTION 4 - General overhaul
GENERAL CHARACTERISTICS
ASSEMBLY DATA - CLEARANCE
REPAIRS
CYLINDER BLOCK
Checks and measurements
Cylinder liners
Removing cylinder liners
Assembly and checking protrusion
Crankshaft
Measuring the main journals and crankpins
Preliminary measurement of main and big end bearing shell selection data
Selecting the main bearing and big end bearing shells
Defining the class of diameter of themain journals and crankpins (Journals with nominal diameter)
Selecting the main bearing shells (Journals with nominal diameter)
Selecting the main bearing shells (ground journals)
Selecting the big end bearing shells (journals with nominal diameter)
Replacing the timing gear and oil pump
Checking main journal assembly clearance
Checking crankshaft end float
PISTON CONNECTING ROD ASSEMBLY
Removal
Measuring the diameter of the pistons
Conditions for correct gudgeon pin-piston coupling
Piston rings
Connecting rod
Connecting rods bushings
Checking connecting rods
Mounting the connecting rod — piston assembly
Mounting the piston rings
Fitting the big end bearing shells
Fitting connecting rod - piston assemblies in the cylinder liners
Checking piston protrusion
Checking crankpin assembly clearance
CYLINDER HEAD
Dismounting the valves
Checking head bearing surface on cylinder block
Valves
Valve seats
Checking clearance between valve-stem and associated valve guide
Valve guides
Replacing injector cases
Assembly
Checking injector protrusion
TIMING GEAR
Camshaft drive
Idler gear pin
Idler gear
Twin intermediate gear pin
Twin idler gear
Replacing the bushings
Timing system
Checking cam lift and pin alignment
Bushings
Valve springs
ROCKER SHAFT
Shaft
Rocker arms
REPAIR
Variable geometry movement control
Checking the actuator
Checking actuator travel
Cleaning turbine body
TIGHTENING TORQUE
Diagram of tightening sequence of crankcase base fixing screws
Diagram of tightening sequence of exhaust manifold fixing screws
Diagram of tightening sequence of exhaust manifold fixing screws
Diagram of tightening sequence of screws and nuts fixing turbocharger on exhaust manifold
SECTION 5 - Tools
TOOLS
Appendix
SAFETY PRESCRIPTIONS

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