Iveco Daily Euro 4. Manual — part 43
Remove nuts (4), then place remote-control switch/fuse
holder (3) aside.
Disconnect pipe (18) from the heat exchanger and the
turboblower.
Disconnect pipe (34) from the heat exchanger and the
throttle valve assembly.
Disconnect or remove the coolant pipes:
- (15), from the thermostat;
- (16), from the engine oil heat exchanger;
- (19), from pipe (18);
- (20), from radiator (17).
Properly obstruct the turboblower air outlet to
avoid casual penetration of foreign bodies into the
turboblower and, therefore, damage to the latter.
NOTE
108629
Properly obstruct the turboblower air outlet to
avoid casual penetration of foreign bodies into the
turboblower and, therefore, damage to the latter.
NOTE
Figure 2
Remove screws (13) securing radiator (17) to the supports.
Disconnect electric connection (12).
Release remote-control switch supporting bracket (14) from
the left side.
Remove radiator/heat exchanger assembly (17) together with
the condenser-drying filter and pipes (if any).
Remove oil filling cap (1) and remove sound-proofing cover
(5).
Loosen the straps, then disconnect coolant vent pipes (2)
from expansion tank (8).
Disconnect tank (8) pressure sensor (7) electric connection.
Remove tank (8) fastening nuts (10), then remove the tank
from the wall.
Disconnect electric connection (9) of the level sensor placed
under tank (8).
Loosen the straps, then disconnect coolant pipe (6) located
below tank (8).
Disconnect electric connection (11) from the throttle valve
assembly actuator.
Disconnect expansion tank (8) pipe (28) and cab heater pipe
(29) from water pump pipe (25).
Loosen the straps, then disconnect coolant vent pipes (33)
from EGR valve (31) and (27) from the cylinder head.
Loosen the strap, then disconnect coolant pipe (32) and
vacuum pipe (30) from EGR valve (31).
Loosen the strap, then disconnect pipe (26) from air pipe (22).
Disconnect electric connection (24) from air flow meter (23).
Loosen the straps, then disconnect air pipe (22) complete
with air flow meter (23) from the turboblower and air filter
(21).
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Disconnect vacuum pipe (2) from variable geometry
turboblower actuator (1) (if any).
Cut the straps securing the cables to the engine, then
disconnect the electric connections from the VGT solenoid
valve (13, if any), alternator (15), oil level sensor (16).
Remove the screw and take ground cable (9) off.
Remove the nuts, then take cables off starting motor (7).
Disconnect servo brake vacuum pipe (8) from pipe union
(12).
Disconnect delivery pipe (5) and return pipe (6) from the
low-pressure fuel pipes.
Place a container under the power steering pump to recover
the system oil, then detach oil return and delivery pipes (11
and 10).
Loosen the fastening strap, then remove power steering tank
(4) from the support.
Apply tool 99360543 (3) onto the engine brackets to take the
engine off its compartment and secure it to the hoist.
108630
Figure 3
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Act from under the vehicle to disconnect jointed heads (17)
from:
- lever shift control cables (16);
- selection cable (max. pull-out load: 250 N - max. pull-in load:
60 N);
- engagement cable (max. pull-out load: 100 N - max. pull-in
load: 80 N).
Use a suitable screwdriver to open out flexible cable fins (18)
so that the pawls are disengaged from the support.
Undo fastening screws (22), move clutch control cylinder (23)
together with its bracket and properly secure it to the chassis.
Remove the sealing from ring (1), then unscrew the same and
disconnect the speed indicator control cable.
Disconnect electric connection (4) or (28 - for vehicles
equipped with automatic transmission) from the reversing
light switch.
When removing the gearbox unit from the engine, remove
the fastening screws and detach the starting motor.
Remove the fastening screws and take the gearbox unit off the
engine.
The power unit shall be removed from the engine
compartment with the greatest care, so as not avoid
damaging the parts left on the vehicle, especially the
steering box oil pipes.
NOTE
As regards the vehicles equipped with automatic
transmission, carefully carry out the operations
described in the charter of the ”Gearbox unit” section.
NOTE
Disconnect exhaust pipe (8) from the turboblower outlet
pipe.
Vehicles equipped with D.P.F. catalyst: remove the fastening
screws, then take exhaust pipe (8) supporting bracket (10) off
gearbox unit (9).
Disconnect vacuum pipe (25) from VGT actuator (24 - only
176 HP engines).
Put a supporting jack under the gearbox unit.
Remove the bracket supporting the gearbox to the rear
crosspiece by acting on the four screws (5).
Undo fastening screws (10), then remove gearbox unit
supporting
crosspiece
(11)
complete
with
its
gearbox/supporting bracket.
Remove nuts (15) securing elastic supports (14) to the chassis.
Remove bolts (3) securing propeller shaft (2) to the gearbox
unit; if necessary, remove screws (6) securing elastic support
(7) to the chassis and properly secure propeller shaft to the
chassis.
Remove the jack from under the gearbox.
Lift the power unit and remove it from the engine
compartment.
Vehicles equipped with automatic transmission:
disconnect gearbox-chassis cable connector (27)
from control unit.
NOTE
108631
Figure 4
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Refitting
To refit the engine assembly, carry out the operations
described for removal in reverse order, following these
instructions:
- Before refitting the gearbox to the engine, it is necessary
to remove the pressure plate bearing from the
diaphragm spring by opening out the retaining circlip.
Fit the pressure plate bearing on the sleeve of the drive
input shaft cover, connecting it to the clutch release
lever. Spread the gearbox input shaft with Molikote
molybdenum disulphide grease.
As regards the 6 S 400 O.D. gearbox units, proceed as
follows.
Engage a gear to let the main shaft turn, rotating the
propeller shaft connecting flange. Push the gearbox fully
in so that the pressure plate bearing couples with the
diaphragm spring correctly.
As regards the 6 S 400 O.D. gearbox units, follow the
procedures described in the specific chapter.
- Pay special attention to the operations needed to install
the engine assembly in the engine bay.
- Check the conditions of the coolant pipes or sleeves and
of the air ducts. Replace them if they show any sign of
deterioration.
- Check the flexible mountings of the assemblies: engine
and gearbox. Replace them if they show any sign of
deterioration.
- Check that the exhaust pipe members have not
deteriorated and are not about to deteriorate. If this is
so, replace them along with the flexible parts for securing
them.
- Tighten the screws or nuts to the required torque.
- Meticulously check the state of the vacuum pipe. It must
show no sign of cracking, cutting, scoring or of being
crushed. Replace it if there is any doubt at all about its
soundness. When mounting it, make sure the pipe does
not come into contact with sharp metal parts or corners
or with any particularly hot parts. In addition, after
assembly, the pipe must have no bends or constrictions,
its radius of curvature should be broad and it must be
secured to the vacuum pump fitting with a suitable
clamp.
- Make sure that fuel pipes rapid engagement fittings are
accurately clean, and result to have been fully inserted
and not going to be disconnected after their being
connected to relating engagement unions.
- Fill the cooling system with coolant.
- Fill the hydraulic power steering circuit and bleed the air
as described under the relevant heading.
- Check the level of oil in the engine and gearbox.
- Recharge the air-conditioning system (if any), as
described in the relevant chapter in the “Bodywork and
chassis” section.
- Check, if necessary, the headlamp orientation.
- No water leaks from the connecting sleeves of the
engine cooling and cab heating circuit pipes; tighten the
collars if necessary.
- No oil leaks from between the cover and cylinder head,
oil sump and crankcase, oil filter and its seat, heat
exchanger and crankcase or from between the various
pipes of the lubricating circuit.
- No fuel leaks from injection pump and injector lines.
Tighten fittings if necessary.
- Check the indicator and warning lights on the instrument
panel and the devices disconnected on removing the
engine all work properly.
Check the level of oil in the tank and top it up if necessary.
Lift the vehicle at the front, start up the engine and let it idle
for some time.
Check there is no oil leakage from the hydraulic circuit and
check the level in the tank.
Slowly turn the steering wheel in both directions of steering
so that the air in the hydraulic system comes out.
Check the level of oil in the tank again and top up if necessary.
Checks and tests
Start up the engine, leave it running just a little faster
than idling speed and wait for the coolant
temperature to reach the value for opening the
thermostat, then check that:
When positioning the engine in the engine bay,
take special care not to damage the top pipe of the
power steering and the soundproof-heatproof
cladding of the engine bay.
Once positioned, meticulously check that the top
pipe of the power steering is sound.
Before using it again, check that the power steering
oil and coolant contain no impurities. If they do,
filter with suitable mesh filters. For any topping up,
refer to the REPLENISHING FLUIDS table in the
“GENERAL” section.
NOTE
501430
Power steering system air
bleed
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