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Make/Model Information:

  • Brand:   Iveco
  • Models included:
    • Iveco-Sofim S23ENT-C
    • Iveco-Sofim S30ENT-C

File Information:

  • Type:   Factory Service Manual (FSM)
  • Language:   English (EN)
  • Number of pages:   458
  • File size:  ∼ 33.41 MB
  • File Format:   PDF only
  • SME Watermarks:   None
  • Password lock:   No
  • Edit/copy/modify:   Yes
  • SKU:   ENIV-0038

NOTE:  This list was created by program script and may not accurately represent the text from the source pages.   For full preview please click on 'Download sample':

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Very hot
SOFIM F1 Series
Vehicle application
S23 ENT C
S30 ENT C
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
SECTION 1 - GENERAL SPECIFICATIONS 3 F1A ENGINES
Print P1D32S001GB Base - February 2005
Technical Code Commercial Code
F1AE0481B*A0.. S23 ENT C
F1AE0481B*B0.. S23 ENT C
F1AE0481A*
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Revi - February 2006
SECTION 1 - GENERAL SPECIFICATIONS 3 F1C ENGINES
Print P1D32S001GB Base - February 2005
Technical Code Commercial Code
F1CE0481B*
F1CE0481A*
F1 SERIES
Vehicle application
S23 ENT C
S30 ENT C
Technical and Repair manual
F1A Engines Part 1
F1C Engines Part 2
F1 ENGINES
1 F1 ENGINES
Print P1D32S001GB Base - February 2005
Section
General specifications 1
Fuel 2
Vehicle uses 3
Features and general overhaul 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the F1A engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four sepa-
rate parts:
1. Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
Installation general prescriptions are reported within the ap-
pendix.
The appendix reports general safety prescriptions to be follo-
wed by all operators whether being in-charge of installation or
maintenance, in order to avoid serious injury.
F1A ENGINES
1 F1A ENGINES
Print P1D32S001GB Base - February 2005
SECTION 1 - GENERAL SPECIFICATIONS 1 F1A ENGINES
Print P1D32S001GB Base - February 2005
SECTION 1
General specifications
CORRESPONDENCE BETWEEN TECHNICAL CODE
AND COMMERCIAL CODE 3 . . . .. . . . . . .. .
LUBRICATION 4 . . .. . . . . . .. . . . . . .. . . . . . .. .
- General 4 . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Operation 4 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Oil pump 6 . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Characteristic data 6 . . . .. . . . . . .. . . . . . .. . . .
- Vacuum pump 6 . . . . . . .. . . . . . .. . . . . . .. . . .
- Oil pressure control valve 7 . . . . .. . . . . . .. . . .
- Oil filter 7 . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Modine heat exchanger 7 . . . . . . .. . . . . . .. . . .
- Oil vapour recirculation system 8 .. . . . . . .. . . .
- Description 8 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
COOLING 10 . . . . . . .. . . . . . .. . . . . . .. . . . . . .. .
- Description 10 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Operation 10 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Electromagnetic pulley 12 .. . . . . . .. . . . . . .. . . .
- Water pump 12 .. . . . . . .. . . . . . .. . . . . . .. . . .
- Thermostat 12 . .. . . . . . .. . . . . . .. . . . . . .. . . .
TURBOCHARGING 13 . . . . . .. . . . . . .. . . . . . .. .
- Description 13 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Turbocharger 14 .. . . . . . .. . . . . . .. . . . . . .. . . .
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
(Illustration, if available) 15 . .. . . . . . .. . . . . . .. .
- EGR system operation 15 .. . . . . . .. . . . . . .. . . .
- Operating principles 15 . . .. . . . . . .. . . . . . .. . . .
- Air flow meter 16 . . . . . . .. . . . . . .. . . . . . .. . . .
SECTION 2 - FUEL 1 F1A ENGINES
Print P1D32S001GB Base - February 2005
SECTION 2
OPERATION 3 . . . . .. . . . . . .. . . . . . .. . . . . . .. .
HYDRAULIC SYSTEM 5 . . . . .. . . . . . .. . . . . . .. .
- Fuel pump (if provided) 5 . . . . . . .. . . . . . .. . . .
- Specifications 5 .. . . . . . .. . . . . . .. . . . . . .. . . .
- Fuel filter 6 . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Fuel pipes 6 . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Tightening torques 6 . . . .. . . . . . .. . . . . . .. . . .
- High-pressure pump 7 . . .. . . . . . .. . . . . . .. . . .
- High-pressure pump internal structure 9 . . .. . . .
- Working principle 10 . . . . .. . . . . . .. . . . . . .. . . .
- Pressure control valve 13 .. . . . . . .. . . . . . .. . . .
MECHANICAL SUPPLY PUMP 13 . . . . .. . . . . . .. .
- Hydraulic accumulator (rail) 14 . . . .. . . . . . .. . . .
- Overpressure valve
(for forged hydraulic accumulator) 14 . . . . . .. . . .
ELECTRO-INJECTORS 14 . . . .. . . . . . .. . . . . . .. .
- Operation 15 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
SECTION 3 - VEHICLE USES 1 F1A ENGINES
Print P1D32S001GB Base - February 2005
SECTION 3
Vehicle uses
GENERAL SPECIFICATIONS 3
PART ONE - MECHANICAL COMPONENTS 5
DISASSEMBLING THE ENGINE
AT THE BENCH 7
OVERHAULING ENGINE F1A 7
MOUNTING 14
- Assembling front seal ring 14
- Refitting cylinder head 17
- Adjusting air-conditioner
compressor drive belt tension 21
- Timing speed sensor 25
- Engine speed sensor 25
REPAIRS 26
- Pressure relief valve 26
- Checking and adjusting pressure relief valve 26 ..
- Replacing pressure relief valve 26
- Replacing pressure regulator. 27
PART TWO -
ELECTRICAL EQUIPMENT 29
F1A ENGINE HARNESS 31
- Injection cable F1A 33
- Bosch MS6.3 control unit 35
- Control unit connection to the injection cable on
engine side (housing A) (EDC MS 6.3) 36
- Control unit connection to cab-bonnet cable
(housing B) (EDC MS 6.3) 37
- Bosch EDC16 control unit 38
- EDC 16 control unit connection to the injection
cable onengine side (housing A) 39
- EDC 16 control unit connection to cab-bonnet
cable (housing K) 41
- EDC system main components 43
2 SECTION 3 - VEHICLE USES F1A ENGINES
Base - February 2005 Print P1D32S001GB
- Camshaft sensor 45
- RPM sensor 46
- RPM sensor 47
- Timing sensor 47
- Pressure regulator 48
- Fuel pressure sensor 49
- Air flow meter (without EGR) 51
- Atmospheric pressure sensor 53
- Engine coolant temperature sensor 53
- Fuel temperature sensor 53
- Preheat plug electronic centre 54
- Preheat plugs 54
- Accelerator pedal sensor 55
MAIN COMPONENTS OF POWER
NETWORK 56
- BOSCH KCBI 14V 110A Alternator 56
- EV 12V - 2.3 kW Starter motor 57
SYSTEM OPERATION 58
- Self-diagnosis BLINK CODE 58
- Immobilizer recognition (if present) 58
- Checking fuel temperature 58
- Checking engine coolant temperature 58
- Checking quantity of fuel injected 58
- Checking idling adjustment 58
- Fuel cut-off in release phase 58
- Checking cylinder balancing on idling 58
- Checking regular engine rotation (anti-sawing) 58
- Checking smokiness at exhaust on acceleration 58
- Checking exhaust gas recirculation
(E.G.R. if present) 58
- Checking top speed limit 58
- Checking regular rotation on acceleration 58
- Checking glow plug control unit 58
- Checking activation of air-conditioning system 58
- Checking fuel pump 58
- Checking diesel warming 59
- Checking cylinder position 59
- Checking pilot and main injection timing 59
- Checking injection pressure closed cycle 59
- Fuel supply 59
- Correcting flow rate according
to water temperature 59
- Correcting flow rate to avoid noise,
smoke or overloading 59
- De-rating 59
- Injection timing electronic test 59
- Speed governor 59
- Engine starting 59
- Cold starting 60
- Warm starting 60
- Run up 60
- After run 60
- Cut-off 60
- Cylinder balancing 60
- Synchronization search 60
PART THREE - TROUBLESHOOTING 61
PT-01 PORTABLE TESTER 63
- Main functions 63
- Test parameters 63
BLINK CODE 67
PART FOUR - MAINTENANCE 135
SECTION 4 - FEATURES AND GENERAL OVERHAUL 1 F1A ENGINES
Print P1D32S001GB Base - February 2005
SECTION 4
Features and general overhaul
GENERAL SPECIFICATIONS 3
ASSEMBLY DATA CLEARANCES 5
ENGINE OVERHAUL 9
ENGINE REMOVAL AT THE BENCH 9
REPAIRS 10
CYLINDER BLOCK 10
- Checks and measurements 10
- Checking head mating surface on cylinder block 11
CRANKSHAFT 11
- Measuring main journals and crank pins 11
- Checking crankshaft 12
- Replacing timing control gear 14
ENGINE ASSEMBLY 14
- Assembling main bearings 14
- Measuring main journal assembly clearance 14 ..
- Checking crankshaft end float 15
- Assembling rear seal 16
CONNECTING ROD PISTON ASSEMBLY 17 ..
- Pistons 18
- Measuring piston diameter 18
- Piston pins 19
- Conditions for correct pin-piston coupling 19
- Piston rings 19
- Connecting rods 20
2 SECTION 4 - FEATURES AND GENERAL OVERHAUL F1A ENGINES
Base - February 2005 Print P1D32S001GB
- Bushes 21
- Checking connecting rods 21
- Checking torsion 21
- Checking bending 21
- Assembling connecting rod-piston assembly 21 ..
- Checking for connecting rod piston distortion 22
- Assembling piston rings 22
- Assembling connecting rod piston assemblies in
cylinder barrels 22
- Measuring crankpin assembly clearance 23
- Checking piston protrusion 23
CYLINDER HEAD 24
- Disassembly 24
- Removing valves 24
- Checking cylinder head seal 24
- Checking cylinder head mating surface 25
VALVES 25
- Removing deposits, refacing and checking valves 25
- Checking clearance between valve stem and valve
guide and centring valves 26
VALVE GUIDES 26
- Replacing valve guides 26
- Boring valve guides 26
VALVE SEATS 27
- Regrinding - replacing valve seats 27
VALVE SPRINGS 28
ROCKER ARMS TAPPETS 28
- Checks 29
ASSEMBLING CYLINDER HEADS 29
- Overhead 30
- Overhead removal 30
TIMING SYSTEM 31
- Description 31
- Camshaft 32
- Checks 32
- Checking cam lift and pin alignment 32
- Assembling overhead 33
TIGHTENING TORQUE 35
SECTION 5 - TOOLS 1 F1A ENGINES
Print P1D32S001GB Base - February 2005
SECTION 5
TOOLS 3
EXPERIMENTAL TOOLS 8
APPENDIX 1 F1A ENGINES
Print P1D32S001GB Base - February 2005
Appendix
SAFETY PRESCRIPTIONS 3
Section
General specifications 1
Fuel 2
Vehicle uses 3
Features and general overhaul 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the F1C engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four sepa-
rate parts:
1. Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
Installation general prescriptions are reported within the ap-
pendix.
The appendix reports general safety prescriptions to be follo-
wed by all operators whether being in-charge of installation or
maintenance, in order to avoid serious injury.
F1C ENGINES
1 F1C ENGINES
Print P1D32S001GB Base - February 2005
SECTION 1 - GENERAL SPECIFICATIONS 1 F1C ENGINES
Print P1D32S001GB Base - February 2005
SECTION 1
General specifications
CORRESPONDENCE BETWEEN TECHNICAL CODE
AND COMMERCIAL CODE 3 . . . .. . . . . . .. .
LUBRICATION 4 . . .. . . . . . .. . . . . . .. . . . . . .. .
- General 4 . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Operation 4 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
OIL PUMP/DEPRESSOR UNIT 6 . . . . .. . . . . . .. .
- Oil pump 6 . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Characteristic data 6 . . . .. . . . . . .. . . . . . .. . . .
- Vacuum pump 7 . . . . . . .. . . . . . .. . . . . . .. . . .
- Oil pressure adjusting valve 7 . . . .. . . . . . .. . . .
- Disassembly 7 . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Assembly 8 . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Oil filter 8 . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Heat exchanger 8 . . . . . .. . . . . . .. . . . . . .. . . .
- Disassembly 8 . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Assembly 8 . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Oil vapour recirculation (Blow-by) 10 . . . . . .. . . .
- Operation 10 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
COOLING 12 . . . . . . .. . . . . . .. . . . . . .. . . . . . .. .
- Description 12 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Operation 12 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Electromagnetic pulley (if available) 14 . . . . .. . . .
- Water pump 14 .. . . . . . .. . . . . . .. . . . . . .. . . .
- Thermostat 14 . .. . . . . . .. . . . . . .. . . . . . .. . . .
TURBOCHARGING 15 . . . . . .. . . . . . .. . . . . . .. .
- Description 15 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Turbocharger
type MITSUBISHI TD 4 HL-13T - 6 16 . . . . .. . . .
SECTION 2 - FUEL 1 F1C ENGINES
Print P1D32S001GB Base - February 2005
SECTION 2
OPERATION 3 . . . . .. . . . . . .. . . . . . .. . . . . . .. .
HYDRAULIC SYSTEM 3 . . . . .. . . . . . .. . . . . . .. .
- Fuel pipes 3 . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Fuel pump 5 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Specifications 5 .. . . . . . .. . . . . . .. . . . . . .. . . .
- Fuel filter 6 . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Tightening torques 6 . . . .. . . . . . .. . . . . . .. . . .
- High-pressure pump 7 . . .. . . . . . .. . . . . . .. . . .
- High-pressure pump internal structure 9 . . .. . . .
- Working principle 10 . . . . .. . . . . . .. . . . . . .. . . .
- Pressure control valve 13 .. . . . . . .. . . . . . .. . . .
MECHANICAL SUPPLY PUMP 13 . . . . .. . . . . . .. .
- Hydraulic accumulator (rail) 14 . . . .. . . . . . .. . . .
ELECTRO-INJECTORS 14 . . . .. . . . . . .. . . . . . .. .
- Operation 14 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
ELECTRIC/ELECTRONIC COMPONENTS 15 . .. .
- Electronic control unit EDC 16 15 .. . . . . . .. . . .
- Glow plug electronic control unit 15 . . . . . . .. . . .
- Glow plugs 15 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Engine speed sensor 15 . . .. . . . . . .. . . . . . .. . . .
- Camshaft timing sensor 15 . . . . . . .. . . . . . .. . . .
SECTION 3 - VEHICLE USES 1 F1C ENGINES
Print P1D32S001GB Base - February 2005
SECTION 3
Vehicle uses
GENERAL SPECIFICATIONS 3
PART ONE - MECHANICAL COMPONENTS 5
OVERHAULING ENGINE F1C 7
DISASSEMBLING THE ENGINE
AT THE BENCH 7
ASSEMBLY 15
ENGINE FLYWHEEL 16
AUXILIARY PARTS CONTROL ASSEMBLY 16
- Cylinder head refitting 18
TIMING SYSTEM CONTROL 19
- Oil pump assembly 22
- Water pump assembly 23
- Replacement of alternator free wheel 24
- Steering pump assembly 25
- Assembly of high pressure pump and fuel supply 26
- Timing speed sensor 29
- Engine speed sensor 29
REPAIRS 30
- Pressure relief valve 30
- Checking and adjusting pressure relief valve 30 ..
- Changing the pressure relief valve 30
- GARRET GT 2256 T variable
geometry turbosupercharger 31
- General 31
- Operation at low engine rpm 31
- Operation at high engine rpm 31
- Proportional solenoid valve controlling
turbocharger actuator 32
- Actuator 32
- Checking and adjusting the actuator 33
2 SECTION 3 - VEHICLE USES F1C ENGINES
Base - February 2005 Print P1D32S001GB
PART TWO -
ELECTRICAL EQUIPMENT 35
F1C ENGINE HARNESS 37
- Injection cable F1C 37
- Bosch EDC16 control unit 39
- EDC 16 control unit connection to the
injection cable on engine side (housing A) 40
- EDC 16 control unit connection to
cab-bonnet cable (housing K) 42
- EDC system main components 44
- Driving shaft and camshaft unit 46
- Camshaft revolution sensor 47
- Driving shaft revolution sensor 48
- Pressure regulator 50
- Fuel pressure sensor (Rail) 51
- Injectors 52
- Airflow gauge 53
- Atmospheric pressure sensor 54
- Engine coolant temperature sensor 54
- Fuel temperature sensor 54
- Preheat plug electronic centre 55
- Preheat plugs 55
- Accelerator pedal sensor 56
- Fuel filter 56
MAIN COMPONENTS OF POWER NETWORK 57
- BOSCH KCBI 14V 110A Alternator 57
- EV 12V - 2.3 kW Starter motor 58
SYSTEM OPERATION 59
- Self-diagnosis BLINK CODE 59
- Immobilizer recognition (if present) 59
- Checking fuel temperature 59
- Checking engine coolant temperature 59
- Checking quantity of fuel injected 59
- Checking idling adjustment 59
- Fuel cut-off in release phase 59
- Checking cylinder balancing on idling 59
- Checking regular engine rotation (anti-sawing) 59
- Checking smokiness at exhaust on acceleration 59
- Checking exhaust gas recirculation
(E.G.R. if present) 59
- Checking top speed limit 59
- Checking regular rotation on acceleration 59
- Checking glow plug control unit 59
- Checking activation of air-conditioning system 59
- Checking fuel pump 59
- Checking diesel warming 60
- Checking cylinder position 60
- Checking pilot and main injection timing 60
- Checking injection pressure closed cycle 60
- Fuel supply 60
- Correcting flow rate according
to water temperature 60
- Correcting flow rate to avoid noise,
smoke or overloading 60
- De-rating 60
- Injection timing electronic test 60
- Speed governor 60
- Engine starting 60
- Cold starting 61
- Warm starting 61
- Run up 61
- After run 61
- Cut-off 61
- Cylinder balancing 61
- Synchronization search 61
PART THREE - TROUBLESHOOTING 63
PT-01 PORTABLE TESTER 65
- Main functions 65
- Test parameters 65
PART FOUR - MAINTENANCE PLANNING 113 .
SECTION 4 - FEATURES AND GENERAL OVERHAUL 1 F1C ENGINES
Print P1D32S001GB Base - February 2005
SECTION 4
Features and general overhaul
GENERAL SPECIFICATIONS 3
ASSEMBLY DATA CLEARANCES 5
ENGINE OVERHAUL 9
REPAIRS 11
CYLINDER BLOCK 11
- Checks and measurements 11
- Checking head mating surface on cylinder block 12
CRANKSHAFT 12
- Measuring main journals and crank pins 12
- Checking crankshaft 13
- Replacing timing control gear 15
ENGINE ASSEMBLY 15
- Assembling main bearings 15
- Measuring main journal assembly clearance 15 ..
- Checking crankshaft end float 16
- Assembling rear seal 17
CONNECTING ROD PISTON ASSEMBLY 18 ..
- Pistons 19
- Measuring piston diameter 19
- Piston pins 19
- Conditions for correct pin-piston coupling 19
- Piston rings 20
- Connecting rods 21
- Bushing 21
2 SECTION 4 - FEATURES AND GENERAL OVERHAUL F1C ENGINES
Base - February 2005 Print P1D32S001GB
- Checking connecting rods 21
- Checking torsion 22
- Checking bending 22
- Assembling connecting rod-piston assembly 22 ..
- Checking for connecting rod piston distortion 23
- Assembling piston rings 23
- Assembling connecting rod piston assemblies in
cylinder barrels 23
- Measuring crankpin assembly clearance 23
- Checking piston protrusion 24
CYLINDER HEAD 25
- Disassembly 25
- Disassembling valves 25
- Checking cylinder head seal 26
- Checking cylinder head mating surface 26
VALVES 26
- Removing deposits, refacing and checking valves 26
- Checking clearance between valve stem and valve
guide and centring valves 27
VALVE GUIDES 27
- Replacing valve guide 27
- Boring valve guides 27
VALVE SEATS 28
- Regrinding - replacing valve seats 28
VALVE SPRINGS 29
ROCKER ARMS TAPPETS 29
- Checks 30
ASSEMBLING CYLINDER HEADS 30
- Overhead 31
- Overhead removal 31
TIMING SYSTEM 32
- Description 32
- Camshaft 33
- Checks 33
- Checking cam lift and pin alignment 33
- Assembling overhead 34
TIGHTENING TORQUE 35
SECTION 5 - TOOLS 1 F1C ENGINES
Print P1D32S001GB Base - February 2005
SECTION 5
TOOLS 3
EXPERIMENTAL TOOLS 9
APPENDIX 1 F1C ENGINES
Print P1D32S001GB Base - February 2005
Appendix
SAFETY PRESCRIPTIONS 3


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