Iveco Daily. Manual — part 78
75817
Figure 2
- Take the cap (2) off the expansion tank (4).
- Unscrew the coolant plug (16), under the radiator (17),
and drain the cooling system.
- Disconnect the pipe (25) from the coalescence filter (26)
and from the air intake pipe (14).
- Disconnect the pipes (12) and (13) from the heat
exchanger, intake manifold and turbocharger.
- Unscrew the air filter bracket fasteners (20) to help
extract the air intake pipe (21) from the duct (18) on the
radiator assembly.
- Disconnect the pipe (22) from the duct (19) and (23)
from the engine.
- Disconnect the tube (3) from the expansion tank (4).
- Unscrew the screws (11) to remove the radiator
assembly (17) together with the heat exchanger.
- Disconnect the coolant pipes (8) and (24) from the rigid
three-way pipe (27), freeing them from any clamps (7).
- Disconnect the heater delivery pipe (1).
- Unscrew the fasteners (6) to remove the expansion tank
(4), disconnecting the level sensor’s electrical connection.
- Take the soundproofing cover (5) off the cylinder head
after removing the oil filler cap.
- Disconnect the coolant pipes (9 and 10).
Close the turbocharger air outlet appropriately to
prevent foreign bodies accidentally getting inside
and damaging it.
NOTE
Vehicles with an air-conditioner in the cab should
have the electrical connection (15) disconnected
from the drier filter.
NOTE
In case of vehicles equipped with cabin internal
conditioner, proceed as follows:
- vehicles equipped with drying filter separated
from the condenser:
put the radiator (complete with the condenser
and
drying
filter)
back
in
the
engine
compartment, taking care not to subject the
conditioning system pipes to tension;
- vehicles equipped with drying filter built into the
condenser:
blow gas off the air-conditioning system, as
described in the relevant chapter in the
“Bodywork
and
chassis”
section,
then
disconnect the pipes from the condenser and
seal both the pipes and their respective fittings
on the condenser to prevent moisture and
impurities from penetrating into the system.
NOTE
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75820
Figure 3
Place a container under the power steering pump to recover
the oil from the system. Then disconnect the oil inlet and
outlet pipes (16 and 17).
- Disconnect the pipes (7) recovering diesel from the
high-pressure-pump.
- Disconnect the pipe (8) delivering diesel to the
high-pressure-pump.
- Disconnect the vacuum pipe (23) from the vacuum
pump.
- Disconnect the air intake duct (19).
- Free the wiring harness of the engine (15) from the
clamps (
←) on the timing cover, disconnect the
connections of the alternator (21) and from the sensors
on the thermostat (22), from the electromagnetic
coupling of the fan hub (20) and move the wiring to one
side so it will not interfere with the disassembly of the
engine.
- Disconnect the wiring (2) from the water temperature
and timing sensors, from the injectors, intake air
temperature sensor and rail pressure sensor. Move the
wiring to one side.
- Disconnect the high-pressure pump electrical connection
(10).
- Disconnect the engine speed sensor (9).
- Disconnect the engine earth cable (6).
- Disconnect the positive cable from the starter motor (5).
The remaining electrical connections of the engine cable are
disconnected from the associated electrical components after
removing the engine.
- Disconnect the oil fillpipe by undoing the fastenings (1).
- Undoing the fastenings (18), remove the fan from the
electromagnetic coupling (20).
- Attach tool 99360544 (4) to the brackets on the engine
to extract it from the engine bay and put it slightly under
traction.
Close the turbocharger air outlet appropriately to
prevent foreign bodies accidentally getting inside.
NOTE
In case of vehicles equipped with conditioner,
proceed as follows:
- as regards the vehicles equipped with drying
filter separated from the condenser, remove
compressor (11) by proceeding as follows:
-
loosen the belt stretcher by acting on
screw (13), then remove belt (14);
-
act
on
fasteners
(12)
to
remove
compressor (11), then put the latter back
into
the
compartment
without
disconnecting the pipes of the system itself;
- as regards the vehicles equipped with drying
filter built into the condenser, disconnect the
pipes from the compressor, then seal the pipes
and their respective fittings on the compressor
to prevent moisture and impurities from
penetrating into the system.
NOTE
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ENGINE F1A
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Revi - February 2005
- Disconnect the screws (16 and 20) securing the brackets
(17 and 19) and disconnect the ”bowdens” (18 and 21)
from the gearbox.
- Unscrew the fixing screws (22), move the clutch control
cylinder (23), with its bracket, and fasten it to the chassis
frame appropriately.
- Remove the sealing from the ring nut (1), unscrew it and
disconnect the speedometer control cable.
- Disconnect the electrical connection (4) from the
reversing light switch.
Figure 4
If it is necessary to detach the gearbox from the engine, take
out the fixing screws and remove the starter motor.
Take out the fixing screws and detach the gearbox from the
engine.
The power unit must be removed from the engine
compartment with the greatest care, to avoid
damaging the remaining parts on the vehicle, in
particular the steering box oil pipes.
NOTE
As far as automatic transmission is concerned,
strictly adhere to the operations described in the
relevant chapter in the “Gearbox” section.
NOTE
- Disconnect the exhaust pipe (9) from the turbocharger
outlet pipe.
- Put a jack under the gearbox to support it.
- Disconnect the bracket supporting the gearbox on the
rear crosspiece by undoing the four screws (5).
- Unscrew the fixing screws (6) and remove the crosspiece
(7) supporting the gearbox complete with the
gearbox/support bracket.
- Remove nuts (14) securing elastic supports (13) to the
chassis.
- Remove bolts (3) securing drive shaft (2) to the gearbox;
remove, if necessary, screws (24) securing elastic support
(25) to the chassis, then properly secure the drive shaft
to the chassis.
- Take the jack out from under the gearbox.
- Lift the engine assembly and take it out of the engine bay.
As regards automatic transmission, disconnect
gearbox-chassis cable connector (27) from the
control unit.
NOTE
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ENGINE F1A
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- 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.
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.
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.
- 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 the quick-coupling fittings of the fuel pipes are
thoroughly clean and, after connection to the relevant
high-pressure pump unions or fuel filter mount, are fully
inserted and do not come loose.
- 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.
- Adjust the tension of the drive belt of the compressor
for the air-conditioner as described in “Replacing Belts”
(if present).
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.
501430
Power steering system air
bleed
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
F1A ENGINE
297
D
AILY
Base - May 2004
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