Iveco Daily. Manual — part 80
Figure 12
Remove the timing belt as described under the relevant
heading (operation 541257).
Disconnect the coolant pipes (12) and (13) from the pipe
(11).
Take out the fixing screws and remove the expansion tank
(16), disconnecting the level sensor electrical connection
from this.
Remove the pipe (18) for the oil dipstick from the intake
manifold.
Disconnect the pipes (1) and (17) from the coalescence filter
(2) and detach this from the overhead.
Disconnect the pipe (3) from the fitting.
Remove the electro-injectors (4) as described in “Replacing
electro-injectors” (operation 775010).
Disconnect the electrical connections from: timing sensor (5)
and remove this from the overhead, water temperature
sensors (6) and (7), air pressure and temperature sensor (10),
and glow plugs (15).
Detach the fuel pipe (9) from the hydraulic accumulator (8),
from the high-pressure pump and from the intake manifold.
Disconnect the fuel return pipe (14) from the pressure relief
valve of the hydraulic accumulator (8).
75567
Removal
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AILY
302
Base - May 2004
CYLINDER HEAD REMOVAL AND REFITTING
Take off the overhead gasket.
Take out the tappets and carefully put them aside.
Using the bushing 99355041, take out the glow plugs.
Take out the screws fixing the cylinder head and detach this
from the crankcase.
Remove the cylinder head gasket.
75568
Figure 13
Loosen the clamp and disconnect the sleeve (11) from the
air duct (10).
Loosen the collar (2), take out the screw (13) fixing the
bracket (12) and detach the air duct (10).
Disconnect the oil vapour recirculation pipe (8) from the air
intake sleeve (9) and disconnect this from the turbocharger
(5).
Disconnect the oil pipe (1) from the cylinder head and from
the turbocharger (5).
Loosen the clamp (7) and disconnect the oil pipe (6) from
the crankcase union.
Take out the screws and disconnect the exhaust pipe (4)
from the turbocharger (5).
Take off the nuts (3) and remove the turbocharger (5) with
its gasket from the exhaust manifold.
Take out the screws and remove the overhead together with
the pins 99360614.
Close
the
turbocharger
air
outlet/inlet
appropriately
to
prevent
foreign
bodies
accidentally getting inside and damaging it.
NOTE
The pins 99360614 applied so as not to alter the
timing after removing the timing belt must be
removed from the overhead only if this is to be
removed.
NOTE
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Base - May 2004
Refitting
Refitting requires carrying out the operations for removal in
reverse order, while taking the following precautions:
Check that the timing tools:
-
99360614 (6, Figure 10) and 99360608 (8, Figure 10)
are inserted in the overhead;
-
99360615 (11, Figure 10) is inserted in the crankcase as
described in “Replacing timing belt.”
Check that the mating surfaces of the cylinder head and
crankcase are clean.
Keep the cylinder head gasket clean.
Position the cylinder head gasket with the lettering ”TOP”
facing the cylinder head.
Figure 14
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.
-
Tighten the screws and nuts to the prescribed torque.
-
The seals and gaskets must not be reused, but replaced
with new ones.
75494
Mount the cylinder head. Insert the screws and tighten them,
in three successive stages, following the order and method
shown in the following figure.
To tighten the glow plugs, use the bushing 99355041 and
torque wrench 99389819.
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.
NOTE
If the engine has run for a period equivalent to =
25,000 km, the toothed timing drive belt must be
replaced with a fresh one, no matter what its state
of wear.
NOTE
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Base - May 2004
75271
75272
75273
75569
Figure 15
Figure 16
Figure 17
Figure 18
Lock rotation of the high-pressure pump gear (1) by applying
tool SP. 2263 (2) as illustrated in the figure. Remove the nut
(3) and take out the tool (2).
Using tool 99340035 (2) applied as shown in the figure,
extract the gear (1) from the shaft of the high-pressure pump
(3).
Take out the screws (1) and remove the high-pressure pump
(2) from the water pump mounting (3).
Take out the screw (2) and remove the fixed tightener (1).
Take out the screws (3) and remove the water pump
mounting (4).
Removal
Refitting
Re-attachment is carried out by reversing the order
of detachment operations. In particular, take care of
the following: replace the seal rings, gaskets and
high-pressure pipe with new parts; tighten the nuts,
screws and fittings to the specified torque values.
543210
REPLACING WATER PUMP
Refitting
If the engine has run for a period equivalent to =
25,000 km, the toothed timing drive belt must be
replaced with a fresh one, no matter what its state
of wear.
NOTE
Remove the timing drive belt, as described in the relevant
chapter (operation 541257).
Disconnect the following items:
-
electric connection from the pressure sensor;
-
fuel pipes from the high-pressure pump.
Fit two new seals on the water pump and fit it back
on the crankcase, carrying out the operations
described for removal in reverse order and
tightening the screws or nuts to the prescribed
torque.
Removal
Remove the high-pressure pump as described
under the relevant heading.
Revi - February 2005
F1A ENGINE
305
D
AILY
REPLACING HIGH-PRESSURE
PUMP CP3
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