Iveco Daily Euro 4. Manual — part 30
75495
75497
85844a
Figure 213
Figure 214
Figure 215
Figure 216
Thoroughly clean the hydraulic tappets (2), lubricate them and
fit them in the cylinder head (3), positioning the rocker arms (1)
on the valves correctly.
Fit on the gasket (5).
Insert the two tools SP. 2264 (4) into the electro-injector seats
for subsequent centring of the overhead on the cylinder head.
Mount the overhead (1) together with the tools 99360614
(3) for the timing and tighten the fixing screws (2) to the
prescribed torque.
Take out the tools SP. 2264 (4).
Mount the fixed tightener (1) and tighten the fixing screw (2)
to the prescribed torque.
Mount the automatic tightener (4) without fully tightening
the fixing screw (3), max. closing torque 5 Nm.
Turn the automatic tightener (1) clockwise, positioning it as
shown in frame A.
Turn the timing belt (10) as shown in the figure observing the
precautions below.
Do not bend the timing belt. Arrows indicating the direction
of assembly of the timing belt on the engine are shown on
the back of the belt. The arrows must correspond to the
direction of rotation of the belt and the notches must
coincide with those on the pulley (7) and the gear (12).
X = Direction of movement of the tightener —
Y = Direction of rotation of the key.
108328
If the engine has run for a period equivalent to
≥
25,000 km, the toothed belt must be replaced with
a fresh one, no matter what its state of wear.
NOTE
Only for the intake valve distributing shaft with
full-section tapered shank.
If required to fit the timing belt (10) on the pulley
(7), remove tool 99360608 (8) and turn the pulley
(7) clockwise by no more than half a pulley tooth.
NOTE
Camshaft drive
On completing assembly, adjust the toothed pulley (7) to put
the section X of the belt under tension and tighten the screw
(9) to a torque of 90 Nm
Keeping the screw (2) stationary and using a suitable wrench
on the hexagon of the plate (3) of the tightener, turn it
anticlockwise to cover the reference hole (5) located on the
fixed portion of the tightener (see frame B).
In the above conditions, tighten the fixing screw (2) to a
torque of 36
± 4 Nm.
Tighten screw (9) to the torque values below:
-
screw (9) securing pulley (7) to the distributing shaft with
full-section tapered shank: 90 Nm;
-
screw (9) securing pulley (7) to the distributing shaft with
hollow-section cylindrical shank: 130 Nm.
Remove the tools 99360614 (6) and 99360615 (11) for the
timing.
Turn the engine in its direction of rotation by 8 turns to be
able to put the tools (6) and (11) back in to do the timing.
In these conditions, the notches of the timing belt (10) must
coincide with those of the pulley (7) and the gear (12).
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Figure 217
Figure 218
Figure 219
Figure 220
Remove the tools (6 and 11, Figure 216).
Screw the plug (1) into the oil-vacuum pump mounting (2)
and the plugs on the holes of the overhead.
Mount the timing cover (1) and tighten the screws (2) to the
prescribed torque.
Mount the damper pulley (3) and tighten the screws (4) to
the prescribed torque.
Mount the oil level sensor (1).
Fit on the power steering (2) pump mounting (4) and tighten
the fixing screws (3) to the prescribed torque.
Position the alternator (2) on the mounting (5) and secure
it with the bottom screws (3 and 4) and the bolt.
Figure 221
Fit on the mounting (1) together with the electromagnetic
coupling (4) and tighten the fixing screws (2 and 3) to the
prescribed torque.
See frame C: Figure 216, holding the tightener plate (3)
stationary with the wrench inserted in its hexagon, loosen the
fixing screw (2). Keeping the fixing screw (2) stationary, turn
the plate (3) clockwise until its reference mark (4) coincides
with the reference hole (5) of the fixed portion of the
tightener. In the above conditions, tighten the screw (2) to a
torque of 36
±4 Nm.
Rotate the engine by two turns in its direction of rotation until
the point of tool 99360615 (1) engagement into the drive
shaft is reached. When this point is exceeded, the drive shaft
shall be rotated by two more turns. Verify, under the above
conditions, that reference hole (5) is found within index (4)
as represented in box C; otherwise, the aforesaid operations
shall be repeated.
After assembly, the belt (10) tension measured using tool
99395849 must be as follows in the following points: X
1
=
212
± 12 Hz -X
1
= 178
± 10 Hz.
Do not turn the engine in the opposite direction;
if, on turning the engine, you pass the point for
inserting the tools (6) and (11), turn the engine
clockwise by another two turns.
NOTE
108166
108165
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Figure 222
Figure 223
Figure 224
Figure 225
Using a wrench on the automatic tightener (2), mount the
drive belt (1), taking care to position its ribs correctly in the
respective races of the pulleys.
Screw down pressure sensor (2) onto hydraulic accumulator
(1) and tighten it to 70 + 5 Nm.
75501
Mount the fixed tightener (2) and tighten the fixing screw (1).
Mount the automatic tightener (3) and tighten the screw (4)
to the prescribed torque.
Fit the flexible belt (3) equipped with tool 99360191 (2) on
the pulley (4) and apply the tool on the pulley (1).
Fit the drive ring (5) on the flexible belt (3) and fasten the ring
on the compressor support.
Turn the drive shaft clockwise until the belt fits perfectly on
the pulley (1).
Figure 226
108326
108327
75503
Fit a new seal (3) on the electro-injector (1) and mount this
in the overhead (2).
Figure 227
90155
Mount the brackets (3) fastening the electro-injectors (1)
and screw down the screws (2) without locking them.
Mount the hydraulic accumulator (4) and tighten the fixing
screws to the prescribed torque.
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Figure 228
Connect the fuel pipes (2) to the electro-injectors (1) and to
the hydraulic accumulator (3).
Tighten the screws (4) fixing the electro-injector brackets to
the prescribed torque.
Mount the glow plugs (1) and, using the box-type wrench SP.
2275 (2) and torque wrench 99389819 (3), tighten them to
a torque of 8
÷ 10 Nm.
Mount the intake manifold (1) with a new gasket and, using
a torque wrench, tighten the fixing screws (2) to the
prescribed torque.
Fit air pressure/temperature sensor (3) into place, then
tighten the fastening screw to the prescribed torque.
Using the wrench (4) of the 99317915 series and the torque
wrench 99389829 (3), tighten the fuel pipe fittings (1) and (2)
to the prescribed torque.
Figure 229
Figure 230
Whenever they get removed, the fuel pipes must
be replaced with new ones.
NOTE
Figure 231
108329
108330
108331
108332
Figure 232
Fit throttle valve assembly (1), together with a new gasket,
onto inlet manifold (3).
Screw down screws (2), then tighten them to the prescribed
torque.
Fit pipe (5), together with a new gasket, onto throttle valve
assembly (1).
Screw down fastening nuts (4) by a few turns, so that pipe
(5) can still be moved.
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