Technical Fiat Ducato X250 2008 with Iveco F1AE0481N engine repair manual.

[MillyMilano]

I have a snapped injector retaining bolt (M8 x 80) and all methods have failed in its removal including stud extractors and welding a new nut on the end. I now need to remove the cylinder head, or possibly the cam cover to get this stud out. I can’t find a manual that uses the above engine. I have looked in the download section but can’t find anything. I have bought an eBay repair manual, but the engine section is brief and does not have the right engine.

any help much appreciated.

simon.

 

[HughJampton]

I acquired from somewhere a translation of an independent X/250 maintenance manual that has a reasonable amount on cylinder head work for both the 2.3 and 3.0 engines.

I've just uploaded it to the download section, but it will need to be accepted by a mod before it appears. Check back later.

It may be of some help.

 

[MillyMilano]

That’s great thanks, it looks like the M8 bolt passes through the cam cover and bolts into the cylinder head. On the three that came out they were corroded around the non threaded portion that passes through the cam cover. This channel is open to the elements and on my engine has spent a fair amount of time submerged as it is below the level of the drain hole. Terrible design! Or designed never to be subjected to water!

 

[Anthony489]

Hi Simon

There are specialist companies who have developed tooling for both injector clamp bolt and injector removal. I suggest you look for one of these firms before removing the cylinder head. They may offer a mobile service.

As you say, it is a poor design and is made worse by the water ingress problem. Hence the growth of these specialists. I think the same design has been used for most of the F1A type engines.

 

[MillyMilano]

Hi Simon

There are specialist companies who have developed tooling for both injector clamp bolt and injector removal. I suggest you look for one of these firms before removing the cylinder head. They may offer a mobile service.

As you say, it is a poor design and is made worse by the water ingress problem. Hence the growth of these specialists. I think the same design has been used for most of the F1A type engines.

Hey Anthony,

living in Northern Scotland is bad for mobile services!

it looks like I just need to remove the cam cover, after taking off the cam belt. This should free the stuck bolt as I suspect the threads are ok but the shaft is corroded into the cam cover. I have ordered a top end gasket set and new injector bolts from AUTODO. When I loosen the cam cover it may well break the corrosion and allow the bolt to come loose, or if it is corroded bad it may make removing the cam cover difficult.

thanks for the comment.

simon.

 

[FreeSpirit]

Hi Here is an Iveco Daily Service manual that covers the F1AE0481 engine series but not specifically the N model, which is obviously modified for Ducatos, it is around 200 Mb in size, the F1AE0481 engine starts on Page 272.
Cheers

 

[FreeSpirit]

Not sure what happened to the attached file for above post it seems to have vanished ??
If you want a link to the PDF, PM me & I will respond, Maybe too large for the server, the old forum would tell you what the max file size was.
Cheers

 

[MillyMilano]

Not sure what happened to the attached file for above post it seems to have vanished ??
If you want a link to the PDF, PM me & I will respond, Maybe too large for the server, the old forum would tell you what the max file size was.
Cheers

That’s great thanks for helping, might need to get the file into the document download section. Will message you

 

[Sasa5664]

Хеј Антони,

живот у северној Шкотској је лош за мобилне услуге!

изгледа да само треба да скинем поклопац брега, након што скинем ремен. Ово би требало да ослободи заглављени вијак јер сумњам да су навоји у реду, али осовина је кородирала у поклопац гребена. Од АУТОДО-а сам наручио комплет заптивки и нове завртње за убризгавање. Када олабавим поклопац гребена, то би могло да прекине корозију и дозволи да се завртањ олабави, или ако је јако кородиран, то може отежати уклањање поклопца брега.

хвала на коментару

 

[Sasa5664]

И kad sklonis poklopac sa bregastim neće ići bas lako da se odvije.Pokusaj sa kratkim grejanjem sa brendom u više navrata i hladi sa vazduhom .Budi strpljiv i uspeces sigurno sam nemoj žuriti.Pozdrav.

 

[FreeSpirit]

Sorry, you need to use English, can't read "Serbian" ??
Cheers

 

[ben]

Maybe too large for the server,

Max size is 400mb, but there was an issue with the upload mechanism. I resolved that a few weeks ago

Best to upload these kinda things to the Downloads section though so they're easier to find

 

[MillyMilano]

Well, the engine is fixed. I welded 3 nuts onto the broken bolt and no luck, just twisted the bolt shaft and snapped below the weld again.

I then had the Motorhome recovered to Precision Engines in Elgin, Scotland.

They also tried welding and again the bolt just snapped flush with the cam box. Two injectors were stuck, and a hydraulic injector remover was used to get them out.

So the cam box came off, with the radiator and cam belt. With the cam box off the bolt again snapped off but now flush with the head. It then was drilled out and re tapped. This bolt was corroded deep into the head.

The engine was then reassembled with new gaskets cam belt coolant and 4 x new Bosch injectors. The Moho was Road tested for 24 miles over 3 days by then and handed back yesterday.

This took 2 weeks to sort. I am glad that this is done now as this would have been a nightmare to sort on holiday.

Precision Engines charged 16 hours of labour at £60 an hour. This worked out the same labour that Fiat charged for Cam belt water pump and service!!

Total cost including VAT was £2300.

Need to get some miles on her now!

What do you think?

 

[camionpilot]

Painfull ..!!!