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Iveco VECTOR Series User Manual
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APPENDIX
1
VECTOR
8
ENGINES
Print
P2D32V001E
Base
-
April
2006
Appendix
Page
SAFETY
PRESCRIP
TIONS
3
..................
-
Standard
safety
pr
escripti
ons
3
..............
-
Prevention
of
injury
3
.....................
-
During
maintenance
3
.....................
-
Respect
of
the
Environment
4
..............
202
204
Table of Contents
General Specifications
15
Vector Engines
4
General Warnings
5
Table of Contents
15
Section 1 - General Specifications
16
Correspondence between Technical Code and Commercial Code
17
Lubrication
19
Oil Vapour Recirculation - Blow-By Filter
21
Engine Cooling
22
Cooling System Assembly
23
Variant for Applications with Brake Air Compressor
24
Air/Air Intercooler System
25
Air / Water Intercooler System
26
Supercharging
27
Table of Contents
29
High-Pressure Electronic Injection
31
Fuel System (Common Rail)
31
General Information
31
Description of the System
31
Electrical System
31
Operation
33
Fuel System Diagram
36
Main Mechanical Components of the Fuel System
37
Fuel Pre-Filter for G-DRIVE and SPRINKLER Applications
37
Fuel Pre-Filter for DRAGON and GRIFFON Applications
38
Fuel Filter for G-DRIVE and SPRINKLER Applications
39
Fuel Filters for DRAGON and GRIFFON Applications
40
Low Pressure Pump for G-DRIVE, and SPRINKLER Applications
41
Low Pressure Pump for DRAGON Applications
42
High-Pressure Pump
43
High Pressure Pump Operating Principle
44
Rail
49
Electro-Injector
52
Industrial Application
53
General Specifications
55
Clearance Data - 8 Cyl
59
Part One
61
Mechanical Components
61
Engine Overhaul
63
Preface
63
Dismantling
63
Installation of Components for the Application
74
Fitting the Flywheel Cover Housing
74
Fitting the Rear Oil Seal
75
Engine Flywheel
75
Fitting the Engine Flywheel
75
Fitting the Gearbox
77
Jumpers
79
Rocker Arm Assembly
79
Rocker Arm Support Rockers
79
Adjusting Operating Clearance between Valves and Rockers
80
Fitting the Cylinder Head Tappet Covers
82
Fitting the Injectors
82
Rocker Arms
79
Rods
79
Lubrication
83
Oil Pump
84
Completing the Engine
85
Common Rail Assembly Procedure
90
Preparing for Assembly
90
Cleaning and Preparation
90
Assembly Procedure
90
Test Procedure for Checking for Diesel Leaks from the Common Rail System
91
Checks and Inspections
93
Second Part
95
Electrical Equipment
95
Location of Components on the Engine
97
Circuit Diagram of Engine Cable
98
Engine Components
99
ADEM III Engine Control Unit
102
Electronic Control of the Engine Control Unit
105
Third Part - Diagnostics
107
Troubleshooting
109
General Information
109
Troubleshooting with Tool 99368550
110
Connection Procedures
110
Diagnosis Procedures for Vector 8V Engines
111
Diagnosis Environment
112
Engine Parameter Reading
115
Reading Parameter for Save Code
116
Ilc Simulator 99368543 Tool
122
Fourth Part
129
Planned Maintenance
129
Vector 8 Dragon Fvae2884A*B200 Maintenance Plan
131
Vector 8 Genset Fvae2885X*A100 Maintenance Plan
133
Description of Preventive and Routine Maintenance Work
135
Changing Engine Oil Filters
136
Checking/Refilling Engine Oil Filters
136
Changing the Engine Oil
138
Changing Fuel Prefilter and Water Separator Filter
139
Adjusting Rocker Arm Assembly
140
Changing Fuel Filters
143
Changing an Injector
145
Changing Blow-By Filter
147
Changing Primary System Pump
148
Removal
148
Fitting
149
Removing/Refitting Starter Motor
150
Removal
150
Fitting
150
Overhaul and Technical Specifications
151
General Specifications
153
Assembly Clearance Data
154
Engine Overhaul
160
Dismantling the Engine at the Bench
160
Repair Operations
161
Cylinder Unit
161
Checks and Measurements
161
Replacing Cylinder Liners
162
Timing System
164
Camshaft
164
Checking Cam Lift and Pin Alignment
164
Replacing the Camshaft Idle Gear
164
Changing the Bushings
166
Changing the Tappets
166
Fitting Tappets and Camshaft
166
Output Shaft
166
Measuring Journals and Crankpins
166
Checking Main Journal Alignment
168
Crankshaft Balancing Instructions
169
Replacing Water Pump Drive Gear
169
Changing the Oil Pump and Timing System Gear
170
Fitting the Main Bearings
170
Finding Journal Clearance
171
Tightening Sequence
171
Checking Crankshaft Thrust Clearance
172
Camshaft Timing
173
Piston Rod Assembly
178
Pistons
178
Measuring the Piston Diameter
178
Gudgeon Pins
178
Conditions for Correct Mating of Gudgeon Pin and Piston
179
Piston Rings
179
Connecting Rods
180
Check of Connecting Rod Alignment
181
Fitting the Connecting Rod-Piston Assembly
181
Connecting Rod-Piston Mating
181
Fitting the Piston Rings
181
Check of Rod/Piston Alignment
182
Fitting the Rod-Piston Assemblies into the Cylinder Liners
182
Measuring the Mounting Clearance of Big End Pins
183
Fitting the Connecting Rod Caps
183
Check of Piston Protrusion
183
Cylinder Head
184
Hydraulic Leak Test
184
Dismantling Valves
184
Checking the Cylinder Head Support Surface
184
Valve
184
Removing Carbon Deposits, and Checking the Valves
184
Refacing the Valves
185
Checking Valve Centering
185
Checking Clearance between Valve Stem
185
Valve Guides
185
Replacing the Valve Guides
186
Reaming the Valve Guides
186
Replacing and Regrinding the Valve Seats
186
Replacing the Injector-Holder Cases
187
Fitting the Valves
188
Installing the Cylinder Head
188
4
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Iveco VECTOR Series Specifications
General
Brand
Iveco
Model
VECTOR Series
Category
Engine
Language
English
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