Iveco Daily Euro 4. Manual — part 45
102217
Fit a new centrifugal filter (1).
Fit a new snap ring (2).
Fit cover (3), and then tighten screws (4) to the specified
torque.
Position connecting joint (1) into gear (4).
Fit vacuum pump oil pump assembly (2) by placing
a new gasket in between.
Tighten screws (3) to the specified torque.
Re-attachment is carried out by reversing the order
of detachment operations. In particular, tighten the
screws and nuts to the specified torque values.
After re-attachment has been completed, fill the
engine cooling system, start the engine and check for
cooling fluid leaks.
Refitting
503010 REPLACING THE VACUUM PUMP
OIL PUMP ASSEMBLY (GPOD)
Removal
102218
Remove screws (3), and then take off vacuum pump oil pump
assembly (2).
Remove connecting joint (1) from gear (4).
Both centrifugal filter (1) and cover (3) seal ring
must be replaced every time they are dismounted.
Re-attachment is carried out by reversing the order of
detachment operations. In particular, tighten the screws and
nuts to the specified torque values.
After re-attachment has been completed, fill the engine
cooling system, check the engine oil level (top up, if
necessary), start the engine and check for cooling fluid leaks.
Remove the front cover, as described in the “Replacing the
drive shaft seal ring and the front cover gasket” chapter.
NOTE
3
2
1
4
Figure 17
Figure 18
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102219
Stop flywheel (1) rotation by means of tool 99360306 (4).
Remove screws (2), and then take off engine flywheel (1).
540640 REPLACING THE DRIVE SHAFT
REAR SEAL RING
Removal
102222
Fit engine flywheel (1), then tighten screws (4).
Apply tool 99360351 (3) to the base in order to stop engine
flywheel (1) rotation.
Tighten engine flywheel (1) fastening screws (4) in two
separate steps:
- step 1: tighten to 30 Nm by means of a torque wrench;
- step 2: tighten to 90
° angle lock.
102220
Apply tool 99340060 (2) to rear seal ring (1), then take the
latter out of the engine base.
Refitting
102221
Thoroughly clean the seal ring seat.
Lubricate the drive shaft rear shank with engine oil.
Apply part (2) of tool 99346259 to the drive shaft rear shank,
then secure it with screws (5) and couple the new seal ring
(3) with the same.
Place part (1) onto part (2), screw down nut (4) until seal ring
(3) is fully assembled to the base.
This operation involves:
- detaching/re-attaching the drive shafts (see
relevant section 505620);
- detaching/re-attaching the gear shift (see
relevant section 530210;
- detaching/re-attaching the clutch (see relevant
section 505210).
Angle lock is performed by means of tool
99395216 (2).
Disassemble tool 99360351 (3).Then fit the clutch, gear shift
and drive shaft back into position, as described in the relevant
sections.
NOTE
Figure 19
Figure 20
Figure 21
Figure 22
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102223
Thoroughly clean the electric injector seat, taking care not to
introduce foreign bodies into the cylinder liners.
Fit a new gasket (18) onto electric injector (16), and then fit
the latter into the overhead.
Re-attachment is carried out by reversing the order of
detachment operations. In particular, comply with the
following instructions:
- fuel pipes must be replaced with new parts every time they
are disassembled;
- tighten the nuts, screws and fittings to the specified torque
values;
- to tighten the fuel pipe fittings, use a wrench of the
99317915 series as well as torque wrench 99389829.
Disconnect the following electric connections: (4), from the
pressure sensor, and (2), from the level sensors, both of them
located on expansion tank (1).
Remove nuts (3) securing expansion tank (1) to the wall,
then put the expansion tank aside.
Remove plug (6), and then take off sound-proofing cover (5).
Disconnect electric connections (7) from electric injectors
(16) and (9) from fuel pressure sensor (8).
Press clips (15) in the direction shown by the arrow, then
disconnect fuel recovery pipe (14) fittings from electric
injectors (16).
Disconnect fuel pipes (11) from electric injectors (16) and
hydraulic accumulator (10).
Remove screws (12) and brackets (13) securing electric
injectors (16) to the cylinder head.
Use tool 99342153 (17) to take electric injectors (16) off the
overhead.
Refitting
Removal
Figure 23
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REPLACING ELECTRO-INJECTORS
108636
Remove bracket (11) securing the low-pressure pipe
assembly to the inlet manifold.
Remove screw (6), then take coolant pipe (8) fastening strap
(5) off the cylinder head.
Remove air conveyor (3) from the overhead, from
turboblower (4).
Disconnect oil pipe (7) from the connection on the cylinder
head.
Remove nuts (2), then remove turboblower (4) from
exhaust manifold.
Removal
Properly plug the turbocharger air outlet/inlet, to
prevent
foreign
bodies
from
penetrating
accidentally into the turbocharger (and, therefore,
damaging the same).
Remove the fan from the electro-magnetic joint.
Take off the air-conditioning compressor drive belt (if any)
as well as the water pump-alternator drive belt, as described
in the relevant chapters.
Remove the front cover, as described in the “Replacing the
seal ring and the front cover gasket” chapter”.
Proceed as follows, by operating as described in the “Power
unit detachment/re-attachment” chapter:
- drain the cooling fluid;
- remove the front cross-member;
- remove the expansion tank.
Cut the straps securing the cables to the engine, then
disconnect the electric connections below:
- (12) thermostat;
- (17) preheating plugs;
- (20) pressure sensor;
- (21) electric injectors;
- (1) electromagnetic joint;
- (22) phase sensor;
- (9) pressure regulator;
- (15) air temperature sensor;
- (23) throttle valve assembly actuator.
Remove the electric injectors as described in the respective
charter. Remove screw (14), then take fuel pipe (16) off
high-pressure pump (10) and hydraulic accumulator (18).
Remove the fastening screws, then take off hydraulic
accumulator (18).
Use tool 99360076 to remove oil filter (3) from the heat
exchanger.
NOTE
Figure 24
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540610
REMOVAL/REFITTING THE CYLINDER HEAD
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