Iveco Daily. Manual — part 99
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Figure 181
Figure 182
Figure 183
Figure 184
Figure 185
Lubricate the seal of the oil filter (1) with engine oil.
Using tool 99360076 (2), tighten the oil filter to the
prescribed torque.
Thoroughly clean the mating surface (à) of the water pump
(1) and position fresh seals (2 and 3) on it.
Mount the water pump (1) and tighten the fixing screws (2)
to the prescribed torque.
Fit the high-pressure pump (2) onto the flange of the water
pump (1) and tighten the fixing screws (3) to the prescribed
torque.
Fit the driving gear (1) onto the shaft of the high-pressure
pump and block rotation of this shaft by applying tool
SP.2263 (2) as illustrated in the figure. Tighten the nut (3) to
the prescribed torque and remove the tool (2).
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Figure 186
Figure 187
Figure 188
Figure 189
Check that tool 99360619 (2) inserted in the hole (
→) of the
oil vacuum pump assembly (1) blocks crankshaft rotation.
This condition is necessary for setting up the timing system
and to prevent the valves interfering with the pistons.
Check that the mating surfaces of the cylinder head and
crankcase are clean.
Keep the cylinder head gasket clean.
Position the cylinder head gasket (1) of the thickness
determined under the heading “checking piston protrusion”
with the lettering ”TOP” facing the cylinder head.
Mount the cylinder head (1).
Screw down the fixing screws (3) and tighten them, in three
successive stages, following the order and methods shown in
the following figure.
Diagram of the tightening sequence for the cylinder head
fixing screws:
- 1
st
phase: pre-tightening with torque wrench
•
screws 1-2-3-4-5-6 to a torque of 100
±5 Nm;
•
screws 7-8-9-10 to a torque of 50
±2.5 Nm.
- 2
nd
phase: angle closing
•
screws 1-2-3-4-5-6 90
° ±5°;
•
screws 7-8-9-10 60
° ±3°.
- 3
rd
phase: angle closing
•
screws 1-2-3-4-5-6 90
° ±5°;
•
screws 7-8-9-10 60
° ±3°.
A = flywheel side.
α
A
It is essential to keep the gasket sealed in its package
until just before assembly.
NOTE
The angle closure is done with tool 99395216 (2).
NOTE
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Figure 190
Figure 191
Figure 192
Figure 193
Thoroughly clean the hydraulic tappets (2), lubricate them and
fit them in the cylinder head (3), positioning the rocker arms (1)
on the valves correctly.
Fit on the gasket (5).
Insert the two tools SP. 2264 (4) into the electro-injector seats
for subsequent centring of the overhead on the cylinder head.
Mount the overhead (1) together with the tools 99360614
(3) for the timing and tighten the fixing screws (2) to the
prescribed torque.
Take out the tools SP. 2264 (4).
Mount the fixed tightener (1) and tighten the fixing screw (2)
to the prescribed torque.
Mount the automatic tightener (4) without fully tightening
the fixing screw (3), max. closing torque 5 Nm.
Turn the automatic tightener (1) clockwise, positioning it as
shown in frame A.
Turn the timing belt (10) as shown in the figure observing the
precautions below.
Do not bend the timing belt. Arrows indicating the direction
of assembly of the timing belt on the engine are shown on
the back of the belt. The arrows must correspond to the
direction of rotation of the belt and the notches must
coincide with those on the pulley (7) and the gear (12).
If required to fit the timing belt (10) on the pulley (7), remove
tool 99360608 (8) and turn the pulley (7) clockwise by no
more than half a pulley tooth.
On completing assembly, adjust the toothed pulley (7) to put
the section X of the belt under tension and tighten the screw
(9) to a torque of 90 Nm
Keeping the screw (2) stationary and using a suitable wrench
on the hexagon of the plate (3) of the tightener, turn it
anticlockwise to cover the reference hole (5) located on the
fixed portion of the tightener (see frame B).
In the above conditions, tighten the fixing screw (2) to a
torque of 36
± 4 Nm
Remove the tools 99360614 (6) and 99360615 (11) for the
timing.
Turn the engine in its direction of rotation by 8 turns to be
able to put the tools (6) and (11) back in to do the timing.
In these conditions, the notches of the timing belt (10) must
coincide with those of the pulley (7) and the gear (12).
X = Direction of movement of the tightener —
Y = Direction of rotation of the key.
85844a
If the engine has run for a period equivalent to
≥
25,000 km, the toothed belt must be replaced with
a fresh one, no matter what its state of wear.
NOTE
Do not turn the engine in the opposite direction;
if, on turning the engine, you pass the point for
inserting the tools (6) and (11), turn the engine
clockwise by another two turns.
NOTE
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See frame C: Figure 193, holding the tightener plate (3)
stationary with the wrench inserted in its hexagon, loosen
the fixing screw (2). Keeping the fixing screw (2) stationary,
turn the plate (3) clockwise until its reference mark (4)
coincides with the reference hole (5) of the fixed portion of
the tightener. In the above conditions, tighten the screw (2)
to a torque of 36
±4 Nm.
After assembly, the belt (10) tension measured using tool
99395849 must be as follows in the following points: X = 212
± 12 Hz -X
1
= 178
± 10 Hz.
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Figure 194
Figure 195
Remove the tools (6 and 11, Figure 193).
Screw the plug (1) into the oil-vacuum pump mounting (2)
and the plugs on the holes of the overhead.
Mount the timing cover (1) and tighten the screws (2) to the
prescribed torque.
Mount the damper pulley (3) and tighten the screws (4) to
the prescribed torque.
76252
Figure 196
Fit on the mounting (1) together with the electromagnetic
coupling (4) and tighten the fixing screws (2 and 3) to the
prescribed torque.
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Figure 197
Figure 198
Mount the oil level sensor (1).
Fit on the power steering (2) pump mounting (4) and tighten
the fixing screws (3) to the prescribed torque.
Position the alternator (2) on the mounting (5) and secure
it with the bottom screws (3 and 4) and the bolt.
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