Iveco Daily Euro 4. Manual

Figure 289

Fuel pipes

542011

Fuel filter “Filtrauto”

The fuel filter consists of an internal filtering-paper cartridge
(13) and is equipped with a water separator.
The maximum water storage capacity of the filter is 150 cm

The water sensor detects the presence of water in the filter
starting from an existing volume of 70 cm

This sensor is located in the lower part of the filter.
The temperature, water and clogging (if any) sensors are
interfaced with the electronic circuit (11) located inside in the
upper portion of the assembly.
When the diesel fuel temperature is lower than a limit value,
the electric resistor will come into operation by properly
heating the diesel fuel before the latter is conveyed to the
high-pressure pump.
Clogging sensor (if any) features:
- differential working pressure: 0.7 to 0.85 bar
Tightening torques

5. Cover

±5 Nm

12. Air/water drain screw 1

±0.2 Nm

NTC and heating features
- rated voltage

13.5 V

- max. permitted voltage 30 V
- rated output

250 W at 185 l/h, T = - 10˚C

- temperature range

-30 to 120˚C

112721

1. High-pressure pump supply pipe quick-coupling fitting —

2. Supply pipe quick-coupling fitting — 3. — Fuel filter

mounting.

112218

Figure 290

1. Body - 2. Gasket - 3. Cover bottom - 4. Drain screw gasket - 5. Customer reference - 6. Diesel oil outlet - 7. Diesel oil inlet -

8. Air drain screw - 9. Supplier code - 10. Air bleeding or water draining screw - 11. Lower bottom - 12. Inner pipe - 13.

Filtering paper - 14. Upper bottom - 15. Heating earth - 16. NTC1 - 17. NTC2 - 18. Clogging sensor (if foreseen) - 19. Water

sensor - 20. Heating - 21. Feed - 22. GND

NOTE

Due to the very high pressure existing within this hydraulic system, the following precautions shall be taken for safety
reasons:
- avoid connecting the high-pressure pipe fittings by means of makeshift fasteners: tighten them to the specified

torque;

- avoid disconnecting the high-pressure pipes when the engine is running (DO NOT make any attempt at draining:

this is absolutely useless and dangerous

To ensure correct operation of the system, it is essential that the low-pressure circuit is intact. Therefore, any modification
or attempt at tampering shall be avoided, and corrective actions shall be taken immediately in case of leaks.
In the event that fuel pipes (1-2-3) are disconnected from support (1), make sure, when reattaching the pipes, that their
respective fittings are fully clean.
Such precautions shall be taken to avoid detective sealing, with resulting fuel leaks.

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Figure 291

Pump with 3 radial pumping elements controlled via a gear by
the timing belt; it needs no timing.
The pump is lubricated and cooled by the fuel.

The high-pressure pump cannot be overhauled;
therefore, the fastening screws shall not be removed
or tampered with. The only operation that can be
carried out is the replacement of the drive gear and
pressure regulator.

NOTE

1. Low-pressure feed line - 2. Shaft with cam - 3. 3-lobe element - 4. Pressure regulator - 5. High-pressure line non-return valve -

6. Delivery line - 7. Low/high-pressure line non-return valve.

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775010

High-pressure pump CPH1

Figure 292

1. Solenoid — 2. Magnetic core — 3. Shutter cylinder —

4. Fuel inlet — 5. Fuel outlet.

When the engine control unit governs the pressure regulator
(via PWM signal), the solenoid (1) is energized that, in its turn,
generates the movement of the magnetic core (2). The shift
of the core causes the shutter cylinder (3) to move axially,
choking the flow of fuel.

75574

75575

1. Solenoid — 2. Magnetic core — 3. Pre-load spring —

4. Shutter cylinder.

When the solenoid (1) is not energized, the magnetic core is
pushed into the rest position by the pre-load spring (3). In this
condition, the shutter cylinder (4) is in such a position as to
offer the fuel the greatest section of passage.

Figure 293

Accurately clean high pressure pump.
Take off screws (2) and unthread pressure regulator (3) from
high pressure pump.

Figure 294

Figure 295

Accurately clean the seat (

→) of pressure regulator and the

connection surface (

→) of the regulator.

88408

Mount new seal rings (1 and 2) on pressure regulator (3) and
lubricate the rings with vaseline.

771034

Pressure control valve

The fuel pressure regulator is mounted on the low-pressure
circuit of the CP3 pump. The pressure regulator modulates
the amount of fuel sent to the high-pressure circuit according
to the commands received directly from the engine control
unit. The pressure regulator is mainly composed of the
following components:
-

connector

casing

solenoid

pre-load spring

shutter cylinder.

When there is no signal, the pressure regulator is normally
open, therefore with the pump providing maximum delivery.
The engine control unit, via the PWM (Pulse Width
Modulation) signal, modulates the change in fuel flow rate in
the high-pressure circuit by partially closing or opening the
sections of passage of the fuel in the low-pressure circuit.
Operation

Replacing pressure regulator

For cleaning, do not use a tool which could damage
the surfaces and pay attention that impurities are
not introduced into channels.

NOTE

Figure 296

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Figure 297

Mount pressure regulator (1) on high pressure pump (2).

Screw up screws (1) and tighten them at 6

÷ 7 Nm (0.6 ÷ 0.7

kgm) torque.

Figure 298

Mounting operation must be performed keeping
the regulator perpendicular to connection plane
without angling it, in order not to damage seal rings
(1-2, Figure 296).

NOTE

Where pressure regulator is replaced on the engine
mounted on the vehicle, it is needed, after
replacement, to check that there are no fuel leaks
after an engine working period.

NOTE

774510

Hydraulic accumulator (rail)

Figure 299

The hydraulic accumulator is mounted on aspiration side
cylinder head.
Its task is to damp pressure oscillations caused:

the operation of the high-pressure pump;

the opening of the electro-injectors.

Fuel pressure sensor (2) is fitted on hydraulic accumulator (1).

Small valves (throttle valves) or control bushes (3), with

∅ =

0.85 mm, have been fitted to the fuel delivery couplings, which
control the fuel pressure waves generated by the
high-pressure pump. Their function is to protect the electric
injectors by reducing their wear in time.
Fuel pressure sensor (2) may affect the accuracy of the injector
minimum flow rate correction, since the minimum flow rate
depends both on the injection time and the actual pressure of
the hydraulic accumulator.
In case of replacement, the EDC control unit 16 correction
coefficients (ZFC) shall be set to zero.
The correction coefficients can be set to zero by means of the
IVECO MODUS - E.A.SY. - IT 2000 diagnosis instruments, by
programming the control unit again and performing the sensor
replacement procedure, in accordance with the instructions
given by the diagnosis instruments.

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Content .. 37 38 39 40 ..

Iveco Daily Euro 4. Manual - part 39