Iveco Daily. Manual — part 101
75246
75245
75514
Figure 218
Figure 219
Figure 220
Fit the cooling fan (1) back onto the electromagnetic
coupling. Fit the arm 99360549 onto the engine lifting hooks.
Hook the arm onto the hoist and remove the engine from
the rotary stand (3). Take out the brackets 99361028 (2).
Complete engine assembly.
Fit on the left and right engine mountings (3) and tighten the
fixing screws to the prescribed torque.
Connect the oil pipe (2) to the turbocharger (1) and to the
crankcase and tighten the fixing screws and the coupling of
the oil pipe (2) to the prescribed torque.
If applicable, mount the following parts:
- Engine cable, connecting its electrical connections to the
thermostat temperature sensor, timing sensor, engine
speed sensor, pressure regulator, rail pressure sensor
and intake manifold air pressure/temperature sensor.
- Hydraulic accumulator guard.
- Top soundproofing cover.
- Add the prescribed grade and quantity of lubricating oil
to the engine.
The sensor gap is:
- 1
±0.5 mm, between the camshaft pulley (2) and timing
sensor (1).
- 1 mm, between the phonic wheel (4) and speed sensor
(3).
764264
Timing speed sensor
764266
Engine speed sensor
Cross-section A-A
F1A ENGINE
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Base - May 2004
Figure 221
5450
LUBRICATION
General
The engine is lubricated by forced circulation performed by the
following parts:
- An oil gear pump is incorporated in an assembly that also
includes the vacuum pump (GPOD).
- A pressure control valve incorporated in the crankcase.
- A Modine-type heat exchanger with built-in safety valve.
- A double filtration oil filter with built-in safety valve.
Operation (see Figure 221)
Engine oil is drawn up from the sump by the oil pump (3)
via the suction strainer (2) and delivered under pressure to
the heat exchanger (5) where it is cooled.
The oil continues through the oil filter (6) and goes to
lubricate the relevant parts through ducts or pipes.
At the end of the lubrication cycle, the oil returns to the
sump by gravity. The oil filter can be excluded by the safety
valve built into it if it gets clogged. The heat exchanger is
also excluded by a safety valve if it gets clogged.
In addition, the lubrication oil supplies the hydraulic
automatic tightener (7) of the camshaft drive (8).
75515
Oil under pressure
Oil in freefall
Coolant
Breather on pressure control valve
F1A ENGINE
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D
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Base - May 2004
F1A ENGINE
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Base - May 2004
DIAGRAM OF GPOD ASSEMBLY ON ENGINE
1. Vacuum pump — 2. Oil pump — 3. Crankshaft —
A. Vacuum pump oil supply hole.
Clearance between the crankshaft gear teeth and the oil
pump drive gear 0.003
÷ 0.2 mm.
The assembly must not be overhauled; in the event of
defective operation, it must be replaced.
75517
Figure 222
Figure 223
OIL VACUUM PUMP ASSEMBLY (GPOD)
The oil pump (3) is a gear pump driven directly by the
crankshaft.
75516
503010
Oil pump
Characteristic data
transmission ratio
1.15
displacement
16.2 cm
3
pumping diameter
49.5 mm
number of teeth
7
height
11
oil pump minimum speed
862 rpm
oil pump max. speed
4485 rpm
oil pump over-revs
5247 rpm
oil pump forced over-revs
6279 rpm
speed
2500 rpm
torque
2.1 Nm
power draw (calc.)
550 W
Vacuum pump
The vacuum pump (2, Figure 223), with radial blades, is also
incorporated in the GPOD (1, Figure 223). It is driven directly
by the oil pump.
transmission ratio
3.25
displacement
86 cm
3
volume to drain
4.5 litres
volume to drain with EGR
9 litres
chamber diameter
65 mm
rotor diameter
50 mm
cam
7.5 mm
number of blades
3
height
34 mm
vacuum pump minimum speed
994 rpm
vacuum pump max. speed
5168 rpm
vacuum pump over-revs
6046 rpm
vacuum pump forced over-revs
7235 rpm
theoretical flow rate at minimum (air)
85.5 l/min
actual flow rate at minimum (air) —
at atmospheric pressure
46 l/min
Theoretical speed at max. speed — (air) 444.4 l/min
Actual flow rate at max. speed — (air)
at atmospheric pressure
60 l/min
measured power draw (maximum)
speed
2500 rpm
torque
2.1 Nm
power draw (calc.)
550 W
F1A ENGINE
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Base - May 2004
Oil temperature: 100
°C — closed recirculation —
max. outlet pressure 5 bars
engine speed rpm
(oil pump speed — rpm)
capacity (l/min)
750 (862)
12
3900 (4485)
68
Oil temperature: 100
°C — engine speed 750 rpm
(pump speed 994 rpm)
tank
(litres)
vacuum
(bar)
0.5
0.8
4.5
4.5
12.5
5.6
time (sec)
6.0
16.0
9
(
)
9.0
24.0
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