Iveco Daily. Manual

Figure 242

Fuel pipes

542011

Fuel filter

The fuel filter is composed of a cartridge (8) equipped with a
water separator (9).
The water accumulation capacity (A) of the filter is approx.
100 cm

The water indicator (4) is mounted on the bottom end.
Unscrewing the indicator (4) drains off any water.
Heater support (3) has an integrated temperature sensor.
On heater support (3) there are screwed up sensor (1) to
signal filter clogging and overpressure valve (5).
When the temperature of the diesel is less than 6

°C, an

electric heating element warms it up to at most 15

°C before

sending it to the pressure pump.

When diesel oil temperature is under 6

°C, a resistor heats the

oil up 15

°C maximum before delivering it to high pressure

pump.
Overpressure valve characteristic
opening pressure 1.8

bar

Clogging indicator characteristics
differential working pressure 0.8

bar

Tightening torques

Tightening clogging signalling sensor

±2 Nm

Water indicator

0.8

±1.2 Nm

Tightening overpressure valve

±2 Nm

Threaded insert *

±2 Nm

Fuel filter tightening

±2 Nm

10. Connector

±2 Nm

11. Connector

±2 Nm

12. Bleed screw

12 Nm

Before assembly, apply thread-stop LOCTITE on the
thread.

88613

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

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

quick-coupling fitting — 4. Fuel filter mounting.

If disconnecting the fuel pipes (1-2-3) from the mounting (4),
it is necessary, when refitting, to make sure their fittings are
perfectly clean. This is to avoid an imperfect seal and fuel
getting out.

75585

Figure 243

1. Clogging signalling sensor - 2. Temperature sensor connector - 3. Heater support - 4. Water in signalling sensor -

5. Overpressure valve - 6. Heater connector - 7. Bending insert - 8. Fuel filter - 9. Water separator - 10. Connector -

11. Connector - 12. Purging screw.

+ 0.2
- 0.3

+ 0.05
- 0.1

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Specifications:
Type

with radial pumping elements

Number of pumping elements:3
Total displacement:

0.7 cm

Volumetric efficiency:

> 80% at 1000 bar from 500 to
3000 rpm pump

Operating range:

up to 1350 bar

Input power:

3.2 kW at 1000 bar and
3000 rpm pump

Top speed:

3000 giri/min

Supply:

Diesel at a pressure of 0.5 bar,
with a minimum flow rate of
0.5 l/min more than the flow
rate absorbed by the high
pressure.

1. 3rd pumping element exclusion solenoid valve - 2. Push rod - 3. Inlet plate valve - 4. Cylinder - 5. Pumping element -

6. Pump shaft - 7. Inlet - low pressure (from diesel filter) - 8. Delivery ball valve - 9. Delivery - high pressure (rail) -

10. Delivery - low pressure (recirculation) - 11. Three-lobe cam

50702

Figure 244

775010

High-pressure pump

This is the ”radialjet” type with three radial pistons (total
displacement 0.7 c.c.). It is operated by the timing belt without
any need for timing.
Each pumping assembly is composed of:

—

a piston (5) operated by a cam (2) integral with the shaft
of the pump (6);

—

an inlet plate valve (3);

—

a delivery ball valve (4).

The high-pressure pump must be supplied by the motor pump
at a pressure of at least 0.5 bar.
The maximum delivery pressure reaches 1350 bar.
The delivery pressure is controlled by a pressure adjustment
solenoid valve mounted on the pump.

The high-pressure pump is lubricated and cooled by the diesel
through appropriate channelling.
In addition, the pump is equipped with a 3rd pumping element
exclusion device.

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1. Valve - 2. Ball shutter - 3. Pin - 4. Body - 5. Coil -

6. Pre-loading spring - 7. Anchor

It is mounted on the high-pressure pump and operated by the
electronic control unit. It regulates the supply pressure of the
fuel for the electro-injectors.
The pressure regulator is mainly composed of:

—

a ball shutter (2)

—

a pin (3) controlling the valve (1)

—

a pre-loading spring (6)

—

a coil (5).

With the solenoid de-energized, the delivery pressure
depends on the pre-load of the spring.
Pressure modulation is obtained by supplying the solenoid coil
in PWM (Pulse Width Modulation) and closing the regulation
loop by feedback from the pressure sensor, the PWM signal
has a carrier of 1000 Hz and the duty cycle can be varied via
software from 1% to 95%.

Replacing pressure regulator.
Accurately clean high pressure pump and operate as follows.

50703

Figure 245

88411

Figure 246

Accurately clean the seat (

⇒) of pressure regulator and the

connection surface (

⇒) of the regulator.

88412

Figure 247

3rd pumping element exclusion device

The 3rd pumping element exclusion device is composed of a
solenoid valve (1, Figure 244) that by means of the push rod
(2, Figure 244) keeps the inlet valve (3, Figure 244) open
during the delivery phase of the 3rd pumping element (5,
Figure 244). It is activated by the electronic control unit when
the engine, running above 4200 rpm, does not increase the
power. The fuel thus discharged (approx. 1/3 of the delivery),
before being put into the recirculation circuit, increases the
efficiency of the high-pressure pump.

771034

Pressure regulator

Take off screws (2) and unthread pressure regulator (3) from
high pressure pump (1).

Figure 248

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

88413

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

NOTE

ENGINES 8140.43R/B/S/N

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88414

Figure 249

88411

Figure 250

These ensure engine operation protecting the vehicle against
the risk of fire in the event of fuel leakage: internal
(electro-injector jet jammed open) or external (pipe fittings,
loose or damaged electro-injectors under high pressure).
Under regular conditions, piston (1) is kept in open position
by spring (2) and fuel pressure that, due to section difference
between piston (1) internal and external surface operates
highly on the latter one. When there is high pressure loss at
limiter outlets, inlet pressure prevails and overcoming spring
(2) reaction moves piston (1), closing fuel outlet U.

52176

Figure 251

The hydraulic accumulator is mounted on the cylinder head
on the opposite side to the intake.
With its volume of approximately 29 cm

dampens the

pressure ripples of the fuel due to:

—

the operation of the high-pressure pump

—

the opening of the electro-injectors.

The flow limiters (2) are mounted on the top of the hydraulic
accumulator (1).
The fuel pressure sensor (4) and pressure relief valve (5) are
mounted on the bottom.

774512

Flow limiters

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

Figure 252

774510

Hydraulic accumulator (rail)

Screw up screws (1) and tighten them at 6

÷ 7 Nm (0,6 ÷ 0,7

kgm) torque.

88415

Mounting operation must be performed keeping
the regulator perpendicular to connection plane
without angling it, in order not to damage seal rings
(2 and 3, Figure 248).

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

For engine 8140.43S only.
Since engine No. 3089322, a rail with the same
configuration but without flow limiters and pressure
relief valve has been mounted. Component
description given in the following pages stands valid
for engines up to this serial No.

NOTE

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Iveco Daily. Manual - part 34