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Iveco Cursor Series C78 C10 C13 Engine Workshop Service Repair Manual – PDF DOWNLOAD
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Iveco Cursor Series C78 C10 C13 Engine Workshop Service Repair Manual
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Description
Iveco Cursor Series C78 C10 C13 Engine Workshop Service Repair Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:478
DOWNLOADABLE:YES
FILE TYPE:PDF
IVECO CURSOR SERIES C78 C10 C13 ENGINE WORKSHOP SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Iveco Cursor Series C78 C10 C13 Engine Workshop Service Repair Manual
- This publication describes the characteristics, data and correct methods for repair operations on each component of the vehicle. If the instructions provided are followed and the specified equipment is used, correct repair operations in the programmed time will be ensured, safeguarding against possible accidents. Before starting to performwhatever type of repair, ensure that all accident prevention equipment is available and efficient. All protections specified by safety regulations, i.e.: goggles, helmet, gloves, boot, etc. must be checked and worn.
- All machining, lifting and conveying equipment should be inspected before use. The data contained in this publication was correct at the time of going to press but due to possible modifications made by the Manufacturer for reasons of a technical or commercial nature or for adaptation to the legal requirements of the different countries, some changes may have occurred. No part of this publication, including the pictures, may be reproduced in any form or by any means.
External spiral winding
The filtering elements are closely wound by a spiral so that each fold is firmly anchored to the spiral with respect to the others. This produces a uniform use of the element even in the worst conditions such as cold starting with fluids with a high viscosity and peaks of flow. In addition, it ensures uniform distribution of the flow over the entire length of the filtering element, with consequent optimization of the loss of load and of its working life.
Mount upstream
To optimize flow distribution and the rigidity of the filtering element, this has an exclusivemount composed of a strongmesh made of nylon and an extremely strong synthetic material.
Filtering element
Composed of inert inorganic fibres bound with an exclusive resin to a structure with graded holes, the element is manufactured exclusively to precise procedures and strict quality control.
TABLE OF CONTENTS:
Iveco Cursor Series C78 C10 C13 Engine Workshop Service Repair Manual
CURSOR ENGINES F2B - F3A - F3B......................................................................................... 0 CURSOR ENGINES..................................................................................................... 3 SPECIAL REMARKS.................................................................................................... 5 Graph and symbols.............................................................................................. 6 Part 1 - F2B CURSOR ENGINES........................................................................................ 7 UPDATING....................................................................................................... 9 SECTION 1 - General Specifications............................................................................. 11 CORRESPONDENCE BETWEEN IVECO CODE AND IVECO MOTORS COMMERCIAL CODE......................................... 13 LUBRICATION................................................................................................ 18 Oil pump............................................................................................... 19 Overpressure valve..................................................................................... 19 Oil pressure control valve (on the base unit).......................................................... 20 Filter support and heat exchanger...................................................................... 20 By-pass valve inside the filter support/heat exchanger assembly........................................ 21 Thermostatic valve..................................................................................... 21 Engine oil filters..................................................................................... 21 COOLING.................................................................................................... 22 Description............................................................................................ 22 Operation.............................................................................................. 22 Water pump............................................................................................. 23 Thermostat............................................................................................. 23 TURBOCHARGING.............................................................................................. 24 TURBOCHARGER............................................................................................... 24 TURBOCHARGING.............................................................................................. 25 Turbocharger HOLSET HY55V.............................................................................. 25 SECTION 2 - Fuel............................................................................................... 27 FUEL FEED.................................................................................................. 29 FEED SCHEME WITH PUMP MOUNTED LATERALLY.................................................................... 29 FEED SCHEME WITH PUMP MOUNTED FRONTALLY.................................................................... 30 Overpressure valve..................................................................................... 31 Feed pump.............................................................................................. 31 Injector-pump.......................................................................................... 32 Injector Phases........................................................................................ 33 SECTION 3 - Vehicle application................................................................................ 35 CLEARANCE DATA............................................................................................. 37 PART ONE - MECHANICAL COMPONENTS........................................................................... 39 DISMANTLING THE ENGINE ON THE BENCH.................................................................... 41 ASSEMBLING THE ENGINE ON THE BENCH..................................................................... 48 Diagram showing the underblock fixing screws tightening order...................................... 50 Fitting the connecting rod-piston assembly into the cylinder liners................................ 51 Mounting cylinder head............................................................................. 52 Fitting engine flywheel............................................................................ 54 Fitting camshaft................................................................................... 55 Fitting pump-injectors............................................................................. 56 Fitting rocker-arm shaft assembly.................................................................. 56 Camshaft timing.................................................................................... 57 Phonic wheel timing................................................................................ 59 Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors.... 60 ENGINE COMPLETION...................................................................................... 61 PART TWO - ELECTRICAL EQUIPMENT............................................................................ 63 Components on the engine F2B........................................................................... 65 BLOCK DIAGRAM.......................................................................................... 66 EDC MS 6.2 electronic control unit................................................................. 67 EDC control unit PIN-OUT - Connector “A” (Engine).................................................. 68 EDC control unit PIN-OUT - Connector “B” (Frame area).............................................. 69 Pump injector (78247).............................................................................. 70 Engine coolant temperature sensor (85153).......................................................... 71 Fuel temperature sensor (47042).................................................................... 72 Flywheel pulse transmitter (48035)................................................................. 73 Distribution pulse transmitter (48042)............................................................. 74 Overfeed pressure transmitter (85154).............................................................. 75 Air temperature transmitter on manifold (85155).................................................... 76 Pre-post reheat resistor (61121)................................................................... 77 EDC SYSTEM FUNCTIONS................................................................................... 78 PART THREE - TROUBLESHOOTING............................................................................... 81 PREFACE................................................................................................ 83 PART FOUR - MAINTENANCE PLANNING........................................................................... 91 MAINTENANCE............................................................................................ 93 Maintenance services scheme........................................................................ 93 CHECKS AND/OR MAINTENANCEWORK.......................................................................... 94 OFF-PLANE OPERATIONS................................................................................... 95 SECTION 4 - General overhaul................................................................................... 97 GENERAL CHARACTERISTICS.................................................................................... 99 ASSEMBLY CLEARANCE DATA....................................................................................101 REPAIR OPERATIONS..........................................................................................107 CYLINDER BLOCK.............................................................................................107 Checks and measurements................................................................................107 CYLINDER LINERS............................................................................................108 Removal of cylinder liners.............................................................................109 Fitting and checking protrusion........................................................................109 CRANKSHAFT.................................................................................................110 Measuring main journals and crank pins.................................................................111 Preliminary measurement of main and big end bearing shell selection data...............................112 Selecting the main and big end bearing shells..........................................................113 Defining the class of diameter of themain journals and crankpins (Journals with nominal diameter)......114 Selection of main half-bearings (nominal diameter pins)................................................115 Selection of main half-bearings (rectified pins).......................................................116 Selecting the big end bearing shells (journals with nominal diameter)..................................117 Selection of connecting rod half-bearings (rectified pins).............................................118 Replacing the timing control gear and the oil pump.....................................................119 Checking main journal installation clearance...........................................................119 Checking crankshaft end float..........................................................................120 PISTON-CONNECTING ROD ASSEMBLY.............................................................................121 Removal................................................................................................121 Measuring the diameter of the pistons..................................................................122 Conditions for correct gudgeon pin-piston coupling.....................................................122 Piston rings...........................................................................................123 CONNECTING ROD.............................................................................................124 Checking connecting rod alignment......................................................................125 Mounting the connecting rod - piston assembly..........................................................125 Mounting the piston rings..............................................................................125 Fitting the connecting rod-piston assembly into the piston liners......................................126 Piston protrusion check................................................................................126 Checking assembly clearance of big end pins............................................................127 CYLINDER HEAD..............................................................................................127 Valve removal..........................................................................................127 Checking the planarity of the head on the cylinder block...............................................127 VALVE......................................................................................................127 Removing deposits and checking the valves..............................................................127 VALVE GUIDES...............................................................................................128 Replacing of valve guides..............................................................................129 Replacing - Reaming the valve seats....................................................................129 REPLACING INJECTOR HOLDER CASES............................................................................129 Removal................................................................................................129 Checking protrusion of injectors.......................................................................131 TIMING GEAR................................................................................................132 Camshaft drive.........................................................................................132 Intermediate gear pin..................................................................................132 Idler gear.............................................................................................132 Twin idler gear........................................................................................132 Replacing the bushings.................................................................................132 Check of cam lift and timing system shaft pins alignment...............................................133 Bushes.................................................................................................134 Replacing camshaft bushes using beater 99360487........................................................135 Removing bushes........................................................................................135 Assembling bushes......................................................................................135 VALVE SPRINGS..............................................................................................136 Fitting the valves and oil seal ring...................................................................136 ROCKER SHAFT...............................................................................................137 Shaft..................................................................................................137 Rocker.................................................................................................137 TIGHTENING TORQUES.........................................................................................138 Underblock fixing screws tightening sequence...........................................................141 Diagram of cylinder head fixing screws tightening sequence.............................................142 Diagram of rocker shaft fixing screws tightening sequence..............................................142 Diagram of exhaust manifold fixing screws tightening sequence..........................................142 Diagram of turbocharger fixing screws and nuts tightening sequence.....................................143 Diagram of heat exchanger fixing screws tightening sequence............................................143 Diagram of engine oil sump fixing screws tightening sequence...........................................143 Diagram of rocker arm cap fixing screws tightening sequence............................................144 SECTION 5 - Tools..............................................................................................145 TOOLS......................................................................................................147 Appendix.......................................................................................................157 SAFETY PRESCRIPTIONS.......................................................................................159 Part 2 - F3A CURSOR ENGINES........................................................................................161 UPDATING.......................................................................................................163 SECTION 1 - General Specifications.............................................................................165 CORRESPONDENCE BETWEEN IVECO CODE AND IVECO MOTORS COMMERCIAL CODE.........................................167 VIEWS OF ENGINE............................................................................................169 LUBRICATION................................................................................................172 Oil pump...............................................................................................173 Overpressure valve.....................................................................................173 Oil pressure control valve.............................................................................174 Heat exchanger for engine versions with double filter..................................................174 Heat exchanger for engine versions with single filter..................................................175 By-pass valve..........................................................................................176 Thermostatic valve.....................................................................................176 Engine oil filters.....................................................................................176 COOLING....................................................................................................177 Description............................................................................................177 Operation..............................................................................................177 Water pump.............................................................................................178 Thermostat.............................................................................................178 TURBOCHARGING..............................................................................................179 Turbocharger HOLSET HY55V..............................................................................179 SECTION 2 - Fuel...............................................................................................181 FEEDING....................................................................................................183 FUEL SUPPLY DIAGRAM........................................................................................184 Fuel pump..............................................................................................185 Injector-pump..........................................................................................185 Injector Phases........................................................................................186 SECTION 3 - Vehicle application................................................................................189 CLEARANCE DATA.............................................................................................191 PART ONE - MECHANICAL COMPONENTS...........................................................................193 DISMANTLING THE ENGINE ON THE BENCH....................................................................195 ASSEMBLING THE ENGINE ON THE BENCH.....................................................................202 Diagram of tightening sequence of crankcase base fixing screws.....................................204 Fitting connecting rod - piston assemblies in cylinder liners......................................205 Mounting cylinder head.............................................................................206 Fitting engine flywheel............................................................................208 Fitting camshaft...................................................................................209 Fitting pump-injectors.............................................................................210 Fitting rocker-arm shaft assembly..................................................................210 Phonic wheel timing................................................................................213 Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors....214 COMPLETING ENGINE ASSEMBLY.............................................................................215 PART TWO - ELECTRICAL EQUIPMENT............................................................................217 Components on the engine F3A...........................................................................219 BLOCK DIAGRAM..........................................................................................220 EDC MS 6.2 electronic control unit.................................................................221 EDC control unit PIN-OUT - Connector “A” (Engine)..................................................222 EDC control unit PIN-OUT - Connector “B” (Frame area)..............................................223 Pump injector (78247)..............................................................................224 Engine coolant temperature sensor (85153)..........................................................225 Fuel temperature sensor (47042)....................................................................226 Flywheel pulse transmitter (48035).................................................................227 Distribution pulse transmitter (48042).............................................................228 Overfeed pressure transmitter (85154)..............................................................229 Air temperature transmitter on manifold (85155)....................................................230 Pre-post reheat resistor (61121)...................................................................231 EDC SYSTEM FUNCTIONS...................................................................................232 PART THREE - TROUBLESHOOTING...............................................................................235 PREFACE................................................................................................237 PART FOUR - MAINTENANCE PLANNING...........................................................................245 MAINTENANCE............................................................................................247 Maintenance services scheme........................................................................247 CHECKS AND/OR MAINTENANCEWORK..........................................................................248 OFF-PLANE OPERATIONS...................................................................................249 SECTION 4 - General overhaul...................................................................................251 GENERAL CHARACTERISTICS....................................................................................253 ASSEMBLY CLEARANCE DATA....................................................................................255 REPAIR OPERATIONS..........................................................................................261 CYLINDER BLOCK.............................................................................................261 Checks and measurements................................................................................261 CYLINDER LINERS............................................................................................262 Removing cylinder liners...............................................................................263 Fitting and checking protrusion........................................................................263 CRANKSHAFT.................................................................................................264 Measuring the main journals and crankpins..............................................................265 Preliminary measurement of main and big end bearing shell selection data...............................266 Selecting the main and big end bearing shells..........................................................267 Defining the class of diameter of themain journals and crankpins (Journals with nominal diameter)......268 Selecting the main bearing shells (Journals with nominal diameter).....................................269 Selecting the main bearing shells (ground journals)....................................................270 Selecting the big end bearing shells (journals with nominal diameter)..................................271 Selecting big end bearing shells (ground journals).....................................................272 Replacing the timing gear and oil pump.................................................................273 Checking main journal assembly clearance...............................................................273 Checking crankshaft end float..........................................................................274 PISTON CONNECTING ROD ASSEMBLY.............................................................................275 Removal................................................................................................275 Measuring the diameter of the pistons..................................................................276 Conditions for correct gudgeon pin-piston coupling.....................................................276 Piston rings...........................................................................................277 CONNECTING RODS............................................................................................278 Bushings...............................................................................................279 Checking connecting rods...............................................................................279 Mounting the connecting rod — piston assembly..........................................................280 Mounting the piston rings..............................................................................280 Fitting the big end bearing shells.....................................................................280 Fitting connecting rod - piston assemblies in the cylinder liners......................................281 Checking piston protrusion.............................................................................281 Checking crankpin assembly clearance...................................................................282 CYLINDER HEAD..............................................................................................282 Removing valves........................................................................................282 Checking the planarity of the head on the cylinder block...............................................282 Valves.................................................................................................282 Removing deposits and checking the valves..............................................................282 Valve seats............................................................................................283 Checking clearance between valve-stem and associated valve guide.......................................284 Replacing valve guides.................................................................................284 Replacing injector cases...............................................................................284 Checking injector protrusion...........................................................................286 TIMING GEAR................................................................................................287 Camshaft drive.........................................................................................287 Idler gear and pin.....................................................................................287 Twin intermediate gear and pin.........................................................................287 Replacing the bushings.................................................................................287 Check of cam lift and timing system shaft pins alignment...............................................288 Camshaft...............................................................................................289 Bushings...............................................................................................289 Replacing camshaft bushings with drift 99360499........................................................290 Dismounting the bushings...............................................................................290 Mounting the bushings..................................................................................290 Valve springs..........................................................................................291 Fitting valves and oil seal............................................................................292 ROCKER SHAFT...............................................................................................292 Shaft..................................................................................................293 Rocker arms............................................................................................293 TIGHTENING TORQUE..........................................................................................294 Diagrams of tightening sequence for screws fixing crankcase base.......................................297 Diagram of cylinder head fixing screws tightening sequence.............................................298 Diagram of exhaust manifold fixing screws tightening sequence..........................................298 Diagram of turbocharger fixing screws and nuts tightening sequence.....................................298 Diagram of tightening sequence for heat exchanger screws...............................................299 Diagram of tightening sequence for engine oil sump screws..............................................299 Diagram of tightening sequence for screws fixing rocker cover..........................................299 SECTION 5 - Tools..............................................................................................301 TOOLS......................................................................................................303 Appendix.......................................................................................................313 SAFETY PRESCRIPTIONS.......................................................................................315 Part 3 - F3B CURSOR ENGINES........................................................................................317 UPDATING.......................................................................................................319 SECTION 1 - General Specifications.............................................................................321 CORRESPONDENCE BETWEEN IVECO CODE AND IVECO MOTORS COMMERCIAL CODE.........................................323 VIEWS OF ENGINE............................................................................................325 LUBRICATION................................................................................................328 Oil pump...............................................................................................329 Overpressure valve.....................................................................................329 Additional oil pump....................................................................................329 Oil pressure control valve.............................................................................330 Heat exchanger.........................................................................................330 By-pass valve..........................................................................................331 Thermostatic valve.....................................................................................331 Engine oil filters.....................................................................................331 COOLING....................................................................................................332 Description............................................................................................332 Operation..............................................................................................332 Water pump.............................................................................................333 Thermostat.............................................................................................333 TURBOCHARGING..............................................................................................334 Turbocharger HOLSET HX 50W.............................................................................335 Turbocharger HOLSET HY 55 V............................................................................336 SECTION 2 - Fuel...............................................................................................339 FEEDING....................................................................................................341 Scheme with pump mounted laterally.....................................................................341 Scheme with pump mounted frontally.....................................................................342 Overpressure valve.....................................................................................343 Feed pump..............................................................................................343 Injector-pump..........................................................................................344 Injector Phases........................................................................................345 SECTION 3 -Vehicle application.................................................................................347 CLEARANCE DATA.............................................................................................349 PART ONE - MECHANICAL COMPONENTS...........................................................................351 STRIPPING THE ENGINE ON THE BENCH......................................................................353 ASSEMBLING THE ENGINE ON THE BENCH.....................................................................361 Diagram of tightening sequence of crankcase base fixing screws.....................................363 Fitting connecting rod - piston assemblies in cylinder liners......................................364 Mounting cylinder head.............................................................................365 Fitting engine flywheel box........................................................................366 Fitting engine flywheel............................................................................367 Fitting camshaft...................................................................................368 Fitting pump-injectors.............................................................................369 Fitting rocker-arm shaft assembly..................................................................369 Timing of timing system shaft......................................................................370 Phonic wheel timing................................................................................372 Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors....373 COMPLETING ENGINE ASSEMBLY.............................................................................374 PART TWO - ELECTRICAL EQUIPMENT............................................................................377 Components on the engine F3B...........................................................................379 BLOCK DIAGRAM..........................................................................................380 EDC MS 6.2 electronic control unit.................................................................381 EDC control unit PIN-OUT - Connector “A” (Engine)..................................................382 EDC control unit PIN-OUT - Connector “B” (Frame area)..............................................383 Pump injector (78247)..............................................................................384 Engine coolant temperature sensor (85153)..........................................................386 Fuel temperature sensor (47042)....................................................................387 Flywheel pulse transmitter (48035).................................................................388 Distribution pulse sensor (48042)..................................................................389 Overfeed pressure sensor (85154)...................................................................390 Air temperature sensor on manifold (85155).........................................................391 Pre/post-heating resistance (61121)................................................................392 EDC SYSTEM FUNCTIONS...................................................................................393 PART THREE - TROUBLESHOOTING...............................................................................397 PREFACE................................................................................................399 PART FOUR - MAINTENANCE PLANNING...........................................................................407 MAINTENANCE............................................................................................409 Maintenance services scheme........................................................................409 CHECKS AND/OR MAINTENANCEWORK..........................................................................410 OFF-PLANE OPERATIONS...................................................................................411 SECTION 4 - General overhaul...................................................................................413 GENERAL CHARACTERISTICS....................................................................................415 ASSEMBLY CLEARANCE DATA....................................................................................417 ENGINE OVERHAUL............................................................................................423 CYLINDER BLOCK.............................................................................................423 Checks and measurements................................................................................423 Cylinder liners........................................................................................424 Removing cylinder liners...............................................................................425 Assembly and checking protrusion.......................................................................425 Crankshaft.............................................................................................426 Measuring the main journals and crankpins..............................................................427 Preliminary measurement of main and big end bearing shell selection data...............................428 Selecting the main bearing and big end bearing shells..................................................429 Defining the class of diameter of themain journals and crankpins (Journals with nominal diameter)......430 Selecting the main bearing shells (Journals with nominal diameter).....................................431 Selecting the main bearing shells (ground journals)....................................................432 Selecting the big end bearing shells journals with nominal diameter)...................................433 Selecting big end bearing shells (ground journals).....................................................434 Replacing the timing control gear and the oil pump.....................................................435 Checking main journal installation clearance...........................................................435 Checking crankshaft end float..........................................................................436 PISTON CONNECTING ROD ASSEMBLY.............................................................................437 Removal................................................................................................437 Measuring the diameter of the pistons..................................................................438 Conditions for correct gudgeon pin-piston coupling.....................................................438 Piston rings...........................................................................................439 Connecting rod.........................................................................................440 Connecting rods bushings...............................................................................441 Checking connecting rods...............................................................................441 Mounting the connecting rod — piston assembly..........................................................442 Mounting the piston rings..............................................................................442 Fitting the big end bearing shells.....................................................................442 Fitting connecting rod - piston assemblies in the cylinder liners......................................443 Checking piston protrusion.............................................................................443 Checking crankpin assembly clearance...................................................................444 CYLINDER HEAD..............................................................................................444 Dismounting the valves.................................................................................444 Checking head bearing surface on cylinder block........................................................444 Decarbonizing and checking valves......................................................................445 Valve seats............................................................................................445 Replacing of valve guides..............................................................................446 Replacing - Reaming the valve seats....................................................................446 Removing injector holder cases.........................................................................446 Assembly...............................................................................................447 Checking injector protrusion...........................................................................448 CAMSHAFT...................................................................................................449 Checking cam lift and pin alignment....................................................................449 Timing system bushings.................................................................................450 Replacing camshaft bushes using beater 99360499........................................................451 Removal................................................................................................451 Assembly...............................................................................................451 VALVE SPRINGS..............................................................................................452 Fitting the valves and oil seal ring...................................................................452 ROCKER SHAFT...............................................................................................453 Shaft..................................................................................................453 Rocker.................................................................................................453 TIMING GEAR................................................................................................454 Camshaft drive.........................................................................................454 Idler gear and pin.....................................................................................454 Twin intermediate gear and pin.........................................................................454 Replacing the bushings.................................................................................454 TIGHTENING TORQUE..........................................................................................455 Diagram of tightening sequence of crankcase base fixing screws.........................................458 Diagram of tightening sequence of exhaust manifold fixing screws.......................................459 Diagram of tightening sequence of exhaust manifold fixing screws.......................................459 Diagram of tightening sequence of screws and nuts fixing turbocharger on exhaust manifold..............459 Diagram of tightening sequence of heat exchanger fixing screws.........................................460 Diagram of tightening sequence of engine oil sump fixing screws........................................460 Diagram of tightening sequence for screws fixing rocker cover..........................................460 Diagram of tightening sequence of screws fixing gearbox to crankcase...................................461 SECTION 5 - Tools..............................................................................................463 TOOLS......................................................................................................465 Appendix.......................................................................................................475 SAFETY PRESCRIPTIONS.......................................................................................477
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
