Iveco Daily Euro 4. Manual — part 27
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Check the valve seats. On finding any slight scoring or burns,
regrind them with an appropriate tool according to the
angles given in Figure 165.
Having to replace them, with the same tool and taking care
not to affect the cylinder head, remove as much material
from the valve seats as possible until, with a punch, it is
possible to extract them from the cylinder head.
Heat the cylinder head to 80
÷ 100°C and, using a suitable
drift, fit in it the new valve seats, previously chilled in liquid
nitrogen.
Using a specific tool, regrind the valve seats according to the
angles given in Figure 165.
Using the milling cutter 99394038 (1), clean the injector seat
of any deposits.
Mount the valves, block the seat of the electro-injectors and
glow plugs; using a suitable tool, check the seal of the
valves/seats.
Using a dial gauge (1), check that, from the plane of the
cylinder head, the valve recessing (2) and the protrusion of
the injector (3) and of the glow plug have the prescribed
value:
-
Valve recessing: 0.5
÷ 0.8 mm.
-
Injector protrusion: 2.77
÷ 3.23 mm.
-
Glow plug protrusion: 3.78 mm.
540661
VALVE SEATS
Recutting and replacing valve seats
Figure 165
Figure 166
Figure 167
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Figure 168
Figure 169
Figure 170
Figure 171
Before assembly, check the flexibility of the valve springs with
the tool 99305047. Compare the load and elastic
deformation data with those of the new springs given in the
following figures.
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
COMPLETE ROCKER ARM ASSEMBLY
The rocker arm assembly is composed of the rocker arm (1),
hydraulic tappet (3), made integral with each other by the clip
(2).
540665
VALVE SPRINGS
ROCKER ARMS — TAPPETS
CROSS-SECTION OF THE HYDRAULIC TAPPET
A = 32.44
±0.3, end of stroke
B = 31.30, working position
C = 29.75
±0.25, start of stroke
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Under a load of
mm
kg
H 54
Free
H1 45
P 243
±12
H2 35
P1 533
±24
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Figure 172
Figure 173
Figure 174
Checks
The sliding surface of the tappets must have no scoring/dents;
replace them if they do.
Using a micrometer, measure the diameter of the tappets
and, using a bore meter, measure the diameter of the seats
in the cylinder head; the difference in the measurements will
give the assembly clearance.
Lubricate the stem of the valves (1) and insert them into the
associated valve guides (4) according to the position marked
during removal. Using tool SP.2264 (2), mount the oil seals
(3) on the valve guides (4).
MAIN DATA HYDRAULIC TAPPETS — SEATS
Position the springs (8) and plates (7) on the cylinder head
(5).
Fit the part (4) of tool 99360260 onto the cylinder head (5)
and secure it with the screws (3).
Fit the part (2) of tool 99360260 onto part (4), screw down
the nut (1) so that by compressing the springs (8) it is possible
to insert the retaining cotters (6); then unscrew the nut (1)
checking that the cotters (6) have settled in correctly.
Repeat these operations on the remaining valves.
ASSEMBLING CYLINDER HEADS
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Figure 175
Figure 176
Figure 177
Figure 178
Figure 179
Fit the thermostat casing (2) with a new seal and tighten the
fixing screws (3) to the prescribed torque.
Fit temperature sensor (1) into place and tighten it to the
prescribed torque.
Mount the temperature sensors (1 and 2) and, using the
wrench SP.2263 (3), tighten them to the prescribed torque.
Position the overhead (2) together with the pins 99360614
(1) on the mounting SP. 2271.
Stop rotation the toothed pulley.
Take out the screw (4) with the washer (5) beneath fastening
the toothed pulley (3).
Only engines with intake distributing shaft con tapered shank.
Using the extractor 99340028 (2) extract the toothed pulley
(1) driving the camshaft.
Using four self-tapping screws (2), apply the tool SP. 2325 (3)
to the seal (1) and with the extractor (5 and 6) remove the
seal (1) from the overhead (4).
Remove the circlip (1) and take off the cover (2) together
with the seal (3).
540650
Overhead
Overhead removal
The screws (2) must be screwed down so they get
positioned at the dimension shown in the figure.
NOTE
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