Iveco Daily. Manual — part 10
Remove the air manifold (10) from the inlet manifold without
disconnecting the electric cables and the fuel pipe.
Put the air manifold (10) appropriately to one side in the
engine bay. Take out the side soundproofing cover (if any)
and the top cover (11). Remove the injectors (17 or 13), the
fuel recovery pipe (16) and the fuel pipes (15). For engine
8140.43C, take out the screws (18) securing the injector
brackets and remove the injectors from the cylinder head.
For engine 8140.63, unscrew the injectors (13).
For assembly, carry out the operations described for disas-
sembly in reverse order, taking the following precautions:
- tighten the injectors of engine 8140.63 at a torque of 60
Nm (6 kgm);
- bleed the fuel air as described under the relevant heading.
50963
Figure 17
Remove
the
transverse
air
manifold
(10)
without
disconnecting the fuel pipe and electric cables from the
thermostart components. Put the transverse air manifold
(10) appropriately to one side in the engine bay.
Remove the top (11) and side (if any) soundproofing covers.
Remove the timing cover (6). Turn the crankshaft so as to
align the camshaft pulley mark A with the tappet cover mark
B, making it possible to insert tool 99360608 into the hole
(5) in the pulley and into the hole in the auxiliary member
assembly. If this is not possible, turn the crankshaft by one
turn.
Remove the pipe bracket for the oil dipstick (7) from the
auxiliary member assembly.
Disconnect the following from the injection pump:
- Electric cables:
D (9), KSB device.
D (14), electrostop.
D (12), EGR potentiometer (if present);
Disassembly
Assembly
771010
REPLACING INJECTION PUMP
Disassembly
ENGINES 8140
21
D
AILY
Base - May 2004
REPLACING INJECTORS (ENGINE 8140.63 - 8140.43C)
Remove the tool 99360608 from the injection pump control
pulley.
Turn the engine in the opposite direction to that of rotation
until the injection pump timing piston reaches TDC, indicated
by the dial gauge (3). Zero the dial gauge (3). Insert tool
99360608 (5) into the hole (
⇒) of the gearbox cover (6).
Slowly turn the crankshaft in its direction of rotation to insert
tool 99360608 (5) into the slot in the engine flywheel (4).
In the above condition, marks A and B (Figure 17) must
coincide and the injection pump piston must have made the
required travel. If this is not so, turn the pump body in its slot
to obtain the required value shown by the dial gauge. Fully
lock the nuts securing the pump to the auxiliary member
assembly.
Connect the electric cable to the bulb (1, Figure 18) of the
KSB device and power it with the voltage of the vehicle. This
deactivates the KSB device.
From underneath the vehicle:
- remove the soundproofing guards of the engine/gear-
box;
- disconnect the oil dipstick pipe (7, Figure 17);
- take out a nut securing the injection pump.
From the engine bay, take out the nuts securing the injection
pump and remove the pump.
- fuel pipes (3 - 7, Figure 17);
- pipes delivering fuel to the injectors (15, Figure 17);
- vacuum pipe (8, Figure 17)
- bowden throttle control cable (1, Figure 17);
Disconnect the injection pump.
50694
Figure 18
Assembly and injection pump adjustment
18941
Figure 19
Take out the plug located on the pump closure screw and
screw down tool 99395100 (2), with the rod in contact with
the top of the timing piston.
Preload the dial gauge 99395603 (3) by approx. 3 mm.
Check the timing is correct.
Key the injection pump onto the auxiliary member assembly,
making the groove (2), obtained in the pump drive shaft, with
the protrusion (1) of the coupling. Screw down the nuts
securing the pump without fully locking them.
Remove tool 99360608 (5).
Cut off supply to the KSB device.
Remove tool 99395100 (2, Figure 18) and screw the plug
back onto the closing screw.
Finish mounting the parts removed, following the reverse
order to disassembly.
Having to refit the same injection pump that has
been removed. Mark its assembly position on its
mounting.
NOTE
Having to replace the coupling (1), take the new
part with the spare part number corresponding to
the angle stamped on it.
NOTE
The KSB device is deactivated when the timing
advance control lever is no longer pulled.
NOTE
The injection pump fixing nut, crankcase side, is
tightened with wrench 99352114.
NOTE
ENGINES 8140
22
D
AILY
Base - May 2004
540850 ENGINE FLYWHEEL REMOVAL-RE-
FITTING
Figure 20
This operation includes:
- propeller shafts removal-refitting (see relevant section
505620)
- gearbox removal-refitting (see
relevant
section
530210)
- clutch removal-refitting (operation 505210).
For engines 8140.43C-8140.43 B/R/S proceed as
follows:
Remove cylinder 1 injector (6) as specified in engine over-
haul.
Fit tool 99395098 (2) with dial gauge 99395603 (1) into in-
jector seat and secure it to cylinder head by clip (5) and
screw (4).
Rotate the output shaft until reading piston (3) TDC posi-
tion on dial gauge (1).
Apply gauge 99395214 (10) to engine block.
Operate on engine flywheel (13) to fit tool 99395214 (10)
pin (11) into engine flywheel (13) milling.
Lock pin (11) by screw (12).
Removal
Check on dial gauge (1) whether piston (3) is at TDC,
otherwise operate on the output shaft to position it in said
condition.
Position engine flywheel (13) on output shaft to fit tool pin
(11) into flywheel milling and secure the fastening screws.
Tighten flywheel fastening screws to the required torque.
Refit injector as specified in engine overhaul.
For engines 8140.63:
Refitting
Remove the flywheel fastening screws, lift pin (11) from en-
gine flywheel (13) milling and remove it.
62851
Removal
Set cylinder 1 piston to TDC at compression stage (valves
closed).
Fit tool 99395100 (8) including the dial gauge 99395603 (9)
on injection pump (7) (after removing the plug); preload and
set the dial gauge to zero.
Apply gauge 99395214 (10) to engine block and proceed as
described for engines 8140.43C-8140.43 B/R/S.
Refitting
Check for no rotation of the output shaft on dial gauge (9).
Otherwise reset it to dial gauge zero position.
Refit
engine
flywheel
as
described
for
engines
8140.43C-8140.43 B/R/S.
Should rear cover leaks be found, replace the cover
as described in the relevant chapter (operation
540460).
NOTE
ENGINES 8140
23
D
AILY
Base - May 2004
ENGINES 8140.43R/B/S/N
25
D
AILY
Base - May 2004
Engines with electronic
high-pressure injection system
-
8140.43R.43XX/44XX
-
8140.43B.43XX/44XX
-
8140.43S.41XX
-
8140.43S.43XX/44XX
-
8140.43N.43XX/44XX
Page
EMISSIONS VALUES
29
. . . . . . . . . . . . . . . . . . . . . .
- Engine 8140.43R.43XX/44XX
29
. . . . . . . . . . . . .
- Engine 8140.43B.43XX/44XX
30
. . . . . . . . . . . . .
- Engine 8140.43S.41
31
. . . . . . . . . . . . . . . . . . . . .
- Engine 8140.43S.43XX/44XX
32
. . . . . . . . . . . . .
- Engine 8140.43N.43XX/44XX
33
. . . . . . . . . . . . .
GENERAL SPECIFICATIONS
38
. . . . . . . . . . . . . . .
ASSEMBLY DATA - CLEARANCES
41
. . . . . . . . . .
TIGHTENING TORQUES
46
. . . . . . . . . . . . . . . . . .
TOOLS
49
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING ENGINE
57
. . . . . . . . . . . . . . . . . .
DISASSEMBLING THE ENGINE AT THE BENCH
57
REPAIR OPERATIONS
63
. . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK
63
. . . . . . . . . . . . . . . . . . . . . . .
- Checks and measurements
63
. . . . . . . . . . . . . . . .
- Checking head mating surface
on cylinder block
64
. . . . . . . . . . . . . . . . . . . . . . .
- Spare cylinder barrel assembling
64
. . . . . . . . . . . .
CRANKSHAFT
66
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring main journals and connecting rods
66
.
- Checking crankshaft
68
. . . . . . . . . . . . . . . . . . . . .
- Replacing gearbox input shaft
centering ring
69
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing timing control gear
69
. . . . . . . . . . . . . .
ENGINE ASSEMBLY
69
. . . . . . . . . . . . . . . . . . . . . .
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