Iveco Daily Euro 4. Manual

108558

Remove the air-conditioner compressor drive belt (11) (if
there is one) and the water pump / alternator drive belt as
described under the relevant headings.
Remove the fan (10) from the electromagnetic coupling (8).
Disconnect

the

electrical

connection

(9)

from

the

electromagnetic coupling (8).
Take out the fixing screws (2) and (3) and remove the
mounting together with the electromagnetic coupling (8).
Take out the screws and remove the fixed tightener (4) and
the automatic tightener (5).
Remove screws (7), then disassemble pulley (6).
Remove the wiring from the timing cover (12) and dismantle
this.
Take off the cap (2) and remove the soundproofing cover
(20).
Disassemble valve gear cover (12).
Disconnect the pipes (19) from the pipe (18).
Disconnect the electric connection (28) from sensor (27).
Take out the fixing screws (26) and remove the expansion
tank (29); disconnect the electrical connection for the level
indicator from the expansion tank and put the tank (29) aside
appropriately.
Take out the screws (23) and remove the bracket (22) fixing
the soundproofing cover (20).
Remove the plugs (24) from the overhead and the plug (14)
from the oil pump — vacuum pump assembly mounting.
Turn the crankshaft clockwise so as to be able to insert the pins
99360614 (25) through the holes in the plugs (24) into the
relevant holes of the camshafts and pin 99360615 (15)
through the hole in the plug (14) into the crankshaft.
Loosen the screw (17) securing the automatic tightener (16)
and remove the timing belt (13).

541257

Replacing timing drive belt

Remove, by following the power unit detachment procedures,
the radiator assembly together with the heat exchanger and
the drying filter condenser (if any), then place it aside properly.

Disassembly

Figure 7

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85844

Assembling

Only for the engines featuring intake valve distributing shafts with
tapered shank (full section).
Insert tool 99360608 (8) into the hole of the toothed pulley (7)
and into the corresponding hole of the overhead to prevent
changing the assembly position of the toothed pulley (7) in the
following operations.
Loosen the screw (9) fixing the toothed pulley (7) and, using tool
99340028, drive the pulley (7) out of the camshaft.

See frame C: 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.

Rotate the engine by two turns in its direction of rotation until the point of
tool 99360615 (1) engagement into the drive shaft is reached. When this
point is exceeded, the drive shaft shall be rotated by two more turns. Verify,
under the above conditions, that reference hole (5) is found within index (4)
as represented in box C; otherwise, the aforesaid operations shall be
repeated.
After assembly, the belt (10) tension measured using tool 99395849 must
be as follows in the following points: X, 212

± 12 Hz - X

, 178

± 10 Hz.

Then complete assembly by carrying out the steps described for disassembly
in reverse order.

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.

Tighten screw (9) to the torque values below:
- screw (9) securing pulley (7) to the distributing shaft with tapered shank

(full section): 90 Nm;

- screw (9) securing pulley (7) to the distributing shaft with cylindrical

shank (hollow section): 130 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).

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).

x = direction of movement of the tightener
y = direction of rotation of the wrench

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

Only for the engines featuring intake valve distributing shafts with
tapered shank (full section).
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.

NOTE

Figure 8

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Figure 9

When electrical injectors mounted on the vehicle must be
replaced, meet following warnings:
- where electrical injectors are dismounted and do not

need to be replaced, their mounting position has to be
noted down in order to remount them later in the same
position; this is done to avoid to reprogram the central
unit;

- after replacing one or more injectors, the central unit has

to be reprogrammed;

- before mounting a new electrical injector, note down

IMA code printed on the injector, because the code is
difficult to read after the injector has been mounted;

- where the central unit is replaced, reprogram the new

central unit with the IMA codes of the electrical injectors
mounted on the engine and copy down the rectification
coefficients (ZFC) of replaced central unit; where it is not
possible, they must be reset and self-learning process
must be started up again.

During engine running, EDC 16 central unit performs some
checks on electrical injectors minimum flow rate.
In certain conditions (overrun: vehicle deceleration with
pedal released) an increasing (very small) fuel quantity
starting from zero is injected and its effect on engine rotation
smoothness is observed.
Injection start threshold is detected and stored by the central
unit.
This self-learning process is carried out on each single
cylinder.
Therefore, replacing an electrical injector involves the need
of reprogramming the central unit by entering the IMA codes
of new electrical injectors and resetting the rectification
factors (ZFC) of the cylinder considered.
Replacing all electrical injectors extends the need of resetting
to all the rectification coefficients (ZFC) of each single
electrical injector.

105067

At assistance, code written in clear has to be used (3, Figure 9)
for central unit replacement and reprogramming procedures.
In the table there is shown the conversion of OCR characters
into Arial characters.

105066

Figure 10

1. IMA Matrix code- 2. Bosch spare part no.-

3. IMA code in clear - 4. Iveco spare part no. - 5. Code -

6. Series no. - 7. Production date

Electrical injectors are not assigned any more to classes Min (01)
- Med (02) - Max (03); therefore, flow rate deviations from
design values are detected, during final check step, by the
manufacturer on each single injector and printed with I.M.A.
(Injector Menge Abgleichung) [Injector Quantity Offset] code
on injector magnet.
At engine production plant, I.M.A. code is read on line from an
automatic reading station, converted into bar code, printed on
engine identification label and applied on the engine itself.
At vehicles production plant, at line end, E.D.C. 16 central unit
is programmed automatically reading the engine identification
label.

Conversion table of OCR

characters into ARIAL characters

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755010

REPLACING THE ELECTRIC INJECTORS

108559

Figure 11

Thoroughly clean the seat of the electro-injectors, taking care
no foreign bodies get into the cylinder barrels.
Fit a fresh gasket (12) onto the electro-injector (10) and fit
this in the overhead.

Complete assembly by carrying out the operations described
for disassembly in reverse order, taking the following
precautions:

With each disassembly, the fuel pipes must be replaced
with fresh ones.

Tighten the nuts, screws and fittings to the prescribed
torque.

To tighten the fittings of the fuel pipes, use the wrench
in the 99317915 series and the torque wrench
99389829.

After assembly, replenish the coolant as described under
the relevant heading.

Check assembly of the timing sensor as described under the
relevant heading.

Partly drain the coolant off from the radiator.
Remove

the

plug

(21,

Figure 9)

and

detach

the

soundproofing cover (20, Figure 9).
Disconnect the pipes (19, Figure 9) from the pipe (18,
Figure 9).
Remove fastening screws (26, Figure 9), then take off
expansion tank (29, Figure 9) and disconnect level gauge
electric connections (6, figure 7) and sensor (27) electric
connections (28, figure 7) from the expansion tank.
Disconnect the pipe (20, Figure 12) from the coalescence
filter (1, Figure 12).
Disconnect the electrical connections (1) from the
electro-injectors (10) and (2) from the fuel pressure sensor
(8).
Press the springs (3) in the direction shown by the arrow and
disconnect the fittings of the pipe (4) to recover fuel from the
electro-injectors (10).
Disconnect the fuel pipes (7) from the electro-injectors (10)
and from the hydraulic accumulator (9).
Take out the screws (6) and the brackets (5) fixing the
electro-injectors (10) to the cylinder head.
Using tool 99342153 (11) extract the electro-injectors (10)
from the overhead.

Removal

Refitting

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Content .. 5 6 7 8 ..

Iveco Daily Euro 4. Manual - part 7