Iveco Daily. Manual — part 71
Mark (
⇒) the position of assembly of the injection pump (3)
on the auxiliary member assembly (1).
Take out the fixing nuts (2) and remove the injection pump
(3) from the auxiliary member assembly (1).
Take out the nuts (4) and disconnect the electric cable (5)
from the glow plugs (6).
Unscrew and remove the injectors (1).
Take out the screws (2) and remove the guard (3).
52210
52212
52211
52213
52214
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Lift the clips (1) and remove the side soundproofing guard
(2).
Take out the nuts (3) and remove the top soundproofing
guard (4).
Remove the fuel pipes (1) from the injection pump (3) and
from the injectors (2).
Remove the fuel recovery pipes (4) from the injectors (2).
Remove the tappet cover (6) with its relative gasket.
Take out the screw (2) and remove the fillpipe (1) from the
auxiliary member assembly (5).
Take out the screw (3) and extract the oil dipstick pipe (4)
from the crankcase base.
6
To remove the lower fixing nut on the crankcase
side, use wrench 99352114 (4).
NOTE
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Remove the fixed tightener mounting (2) and the guard (3)
beneath.
Remove the screws fixing the thermostat box (1).
Block rotation of the electromagnetic pulley.
Unscrew the nut (6) securing the hub (4) clockwise.
Remove the hub (4) and the washer (5).
50658
50660
52215
50661
52216
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Using the right wrench on the tightener (2), slacken the
tension of the belt (1) and remove it.
Using tool 99360306 (3) applied as illustrated in the figure,
block crankshaft rotation and loosen the screws fixing (1) the
flywheel (2).
Remove the screw fixing the pulley (1) to the crankshaft.
Remove the pulley (1) from the crankshaft and the spacer,
if any.
Loosen the screws fixing the gears (1 - 7).
Insert a special wrench between (5) the push rod (3) and the
cylinder (4) of the tightener.
Take out the nut (2).
Remove the bottom cover (6).
Remove the cogged belt (8).
The hub fastening nut (6) has a left-hand thread.
NOTE
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52217
52218
62083
Figure 39
Figure 40
Figure 41
Remove the key (1) and washer (3) from the water pump
shaft (2).
Remove the pulley (10) from the water pump shaft (2).
Take out the nuts (8) and extract the electromagnetic
coupling (9).
Remove the mounting (5) complete with alternator (4) from
the crankcase and from the water pump (2), complete with
thermostat box (7).
Remove the adjustable tightener (6).
Remove the front cover (11) of the crankshaft.
Remove the screws (2) fixing the cylinder head (1) and
remove this with the gasket from the crankcase.
MAIN DATA OF MONDIAL PISTONS FEDERAL MOGUL, PINS AND RINGS OF THE 8140.63... ENGINE
* This dimension is measured on the diameter of 91.4 mm.
PISTONS - PINS - SNAP RINGS
30’
Check piston protrusion as described in the
relevant paragraph to verify the possibility of
crankcase flattening in case it is deformed.
NOTE
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IGNITIO
N
SEQUE
NCE
1-3-4-2
Figure 42
Figure 43
On the crown of the piston, reference (1) indicates the type
of engine (7), class selection (A) and supplier (X)*; reference
(2) has an adhesive label (on the piston supplied as a spare)
with the code number for optical reading of the type of
engine and class selection; reference (3); piston crown cavity.
Figure 44
62385
Fit piston (1) to connecting rod (2) so as piston assembly
reference and connecting rod numbers (3) can be seen as
shown in the figure.
DIAGRAM OPENING-CLOSING VALVE
62084
Figure 45
Assembling connecting rod-piston assembly
Fitting connecting rods-pistons
Set shaft on centres and check, with a centesimal dial gauge
placed on central support, that alignment error is no greater
than 0.04 mm, otherwise replace shaft. Also check cams (1)
lift: it should be 10.5 mm; if different values are found replace
the shaft.
560610
CYLINDER HEADS
541210
CAMSHAFT
541211
Checking cam lift and journal align-
ment
61795
* X = Federal MOGUL
Y = MONDIAL PISTON
IGNITION
SEQUENCE
1-3-4-2
45069
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