Iveco Daily. Manual — part 8
- no coolant leaks from coolant hose and cab interior
heating hose connection sleeves. Tighten hose clips, if
necessary;
- no oil leaks from between cover and cylinder head, oil
sump and crankcase, oil filter and housing, heat
exchanger and crankcase or from lubrication circuit lines;
- no fuel leaks from injection pump and injector lines.
Tighten fittings if necessary;
- check that the indicator lights on the instrument panel
and relating to the devices disconnected when the
engine was removed are working properly.
Refitting
To refit the power unit, reverse removal operations and
observe the following indications:
- before refitting gearbox to engine, remove thrust bearin
from diaphragm spring by opening circlip.
Fit thrust bearing on input shaft cover sleeve and
connect it to clutch disengagement lever. Smear input
shaft with Molikote molybdenum disulphate grease.
Engage a speed to rotate main shaft by rotating propeller
shaft flange. Push down the gearbox to properly engage
thrust bearing into diaphragm spring;
- take the utmost care when refitting the power unit into
engine compartment;
- check the conditions of the coolant pipes or sleeves and
of the air conveyors. 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 the quick-coupling fittings of the fuel
pipes are carefully cleaned and that, after their
connection to the relevant unions of the high-pressure
pump or of the fuel filter mounting, they are fully inserted
and do not get disconnected.
- fill the cooling system with coolant.
- bleed the fuel supply system as described in the relative
paragraph (only for engines 8140.63.4... - 8140.43C.4...);
- fill the power steering circuit and bleed the air as
described in the relevant paragraph;
- check the level of oil in the engine and gearbox;
- adjust the tension of the drive belt of the compressor for
the air-conditioner as described in ”Replacing Belts” (if
present).
Checks and tests
Start up engine, leave running at a speed slightly in
excess of idle speed and wait for coolant to heat
sufficiently to open thermostat. Then check the fol-
lowing:
!
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.
Figure 8
FUEL PIPES
1. High-pressure pump fuel pipe fast coupling - 2. Fuel
supply pipe fast coupling 3. Fuel return pipe fast coupling -
4. Fuel filter mount.
If the fuel pipes (1-2-3) get disconnected from the mount (4),
it is necessary, when refitting, to make sure their couplings are
thoroughly clean. This is to prevent getting a bad seal and fuel
leaking out as a result.
75242
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507130
OXICAT - OXYDIZER CATALYST
(Vehicles with 8140.43C -
8140.63 engines)
Description
455182
The oxidizing catalyst (1) is a post-treatment device for ex-
haust gases. It is used to oxidize CO, HC transforming them
into carbon dioxide (CO
2
) and steam (H
2
O).
This catalyst also treats saturated and aromatic hydrocarbons
forming part of the particulate, such as the carbon in the form
of soot, metals, water and sulphur compounds that are ex-
hausted.
The cylindrical-shaped catalyst consists of a ceramic honey-
comb monolith whose cells are platinum-impregnated, a ca-
talyzing substance of oxidation reactions. Its total volumetric
capacity is equal to 600 cm
3
with a density of 400 cells per
square inch.
The exhaust gases passing through the cells heat the catalyst,
converting the pollutants into inert compounds.
The chemical oxidation reaction of CO, HC and of the parti-
culate is efficient with temperatures ranging between
200
°C ÷350°C.
With temperatures higher than 350
°C it starts oxidizing the sul-
phur contained in the diesel oil, generating sulphur dioxide
(SO
2
) and sulphur trioxide (SO
3
), which are the cause of acid
rain.
Correct catalyst sizing enables limiting the temperature, ob-
taining the greatest percentage of conversion of polluting
emissions, while reducing the freezing of sulphur compounds.
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 flywheel 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.
501430
Power steering system air
bleed
Figure 9
Loosen bleed screw (12), operate priming pump lever (13)
until complete bleeding of all the air in the system, tighten
bleed screw.
542011
Bleending the fuel system
(see
Figure 7) 8140.43C - 8140.63 engines
only
If the engine stops for lack of fuel, resulting in air
being introduced into the system (and if the bleed-
ing process described above is no sufficient), it is
necessary to loosen the unions of at least two injec-
tors, rotate the engine and start it.
When the air has been bled off, close the unions
again.
NOTE
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- remove the pipe (19) from the rear cover of the cylinder
head;
- take out the screw securing the engine electric cable
bracket;
- take out the screw (20) securing the pipes (17) to the
cylinder head;
- take out the screw (18) securing the oil vapour
condenser;
- remove the top (23) and side (22) soundproofing;
- disconnect the electrical connections:
(29) from the electro-injectors (26) (8140.43B/R/S
engines only);
- (13) from the engine speed sensor (8140.43B/R/S and
8140.63 engines only);
- from the glow plugs (8140.63 engine only);
- from the fuel pressure sensor (25) (8140.43B/R/S
engines only);
- remove the tappet cover.
8140.43B/R/S engines only
Disconnect fuel recovery pipe (28) from connection (24).
Press clamps (32) and lift connections (31) at the same time,
disconnect connections and pipes (28) from electroinjectors
(26).
Disconnect the fuel pipes (28) from the electro-injectors
(26) and from the hydraulic accumulator. Take out the
screws securing the electro-injector brackets (20).
Remove the electro-injectors (26) from the cylinder head.
Removal
Remove the timing belt as described under the relevant
heading (operation 541257).
Disconnect the electrical connections from the:
- cooling temperature indicator (11);
- ”KSB” temperature switch (8140.63/43C engines only)
and/or thermostart;
- air temperature and pressure sensor (4) (8140.43B/R/S
engine only);
- expansion tank level indicator (14);
- disconnect the coolant pipes (2, 3 and 5);
- remove the expansion tank (15);
- remove the coolant pipes (10) from the water pump and
from the heat exchanger pipe (9);
- take out the screw (1) and the nut securing the bracket
fixing the pipes (10 and 16) to the inlet manifold;
- extract the oil vapour recirculation valve (6) from the
duct (8) (8140.63 engine only);
- remove the exhaust pipes (7) from the turbocharger
(8140.43C - 8140.43B/R/S engines only);
- remove the turbocharger (8140.43B/R/S/43 C engines
only) from the inlet manifold;
62063
Figure 10
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Cylinder head removal and refitting
Before reusing the cylinder head fixing screws, measure their
thread diameter to check it is no less than 11.5 mm at any
point. If this is not so, replace them.
Turn the camshaft so that the valves of cylinder No. 1 are
shut.
Mount the cylinder head. Insert the screws and tighten them,
in three successive stages, following the order and method
shown in the following figure.
Disconnect the pipe (33) from the high-pressure pump and
from the hydraulic accumulator.
8140.43B/R/S engine excluded
Disconnect the fuel pipes from the injection pump and from
the injectors.
Disconnect the fuel recovery pipes from the injectors.
Disconnect the LDA pipe from the inlet manifold (8140.43
C engine only).
Take out the screws (27) and remove the cylinder head with
its gasket.
Refitting
Refitting requires carrying out the operations for removal in
reverse order, while taking the following precautions:
Check that the piston of cylinder No. 1 is at TDC.
Check that the mating surfaces of the cylinder head and
crankcase are clean.
Keep the cylinder head gasket clean.
Position the cylinder head gasket, of the thickness
determined in the ”checking piston protrusion” paragraph,
with the lettering ”HIGH” facing the cylinder head.
Clean spaces between rear cover (4) and cylinder head (3)
from sealant residues and refill with IVECO 1905685 sealant.
Fit seal (2) on tappet cover (1). Smear tappet cover corners
(
⇒) with Silastic 732 RTV (approx. 10g). Refit tappet cover
on cylinder head and tighten fixing nuts (5) to the specified
torque.
Check the speed sensor is mounted as described under the
relevant heading (8140.63 - 8140.43 S engines only).
When fitting the fuel pipes, don’t use the metal clamp with
the flexible plug and fixing screw. Replace them with new
parts (8140.63 - 8140.43C engines only).
Tightening order diagram for cylinder heads fastening screws:
- 1st step: pre-tightening with torque wrench to torque of
60
± 5 Nm;
- 2nd step: return to torque of 60
± 5 Nm;
- 3rd step: closing with 180
° ± 10° angle.
6448
Figure 11
Figure 12
62063
α
It is essential to keep the gasket sealed in its package
until just before assembly.
NOTE
The angle closure is done with tool 99395216.
NOTE
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