Iveco Daily. Manual

41122

Lubricate stem of valves and insert them in the relevant valve
guides.
With tool 99360292 (1) fit sealing ring (2) on intake and
exhaust valve guides (3).

Prior to reassembly, test valve spring flexibility by means of
tool 99305047. Compare load and elastic deformation data
with those applying to new springs shown in the following
figure.

50676

Figure 146

Figure 147

Figure 148

Figure 149

Figure 150

MAIN DATA FOR ADJUSTING CONTROL

VALVES SPRING EXHAUST

62386

62071

Should rear cover (1) be removed from cylinder head (3), fit
a new gasket (2) at refitting and tighten fixing nuts to the
specified torque.

Place on cylinder heads: lower cap (6), springs (4 and 5) and
upper cap (3); with tool 99360268 (1) press springs (4 and
5) and secure parts to the valve by means of lock cones (2).

41113

540665

VALVE SPRINGS

ASSEMBLING CYLINDER HEADS

Assembling valves

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

INTERNAL SPRING

Height

Under a load of

Height

H 52

Free

H 45.5

38.5

P 43.8

 2.5 P

16.4

 1

33.5

28.5

77.4

 4 P

 1.5

23.5

Figure 151

Figure 152

Figure 153

Figure 154

Figure 155

Lubricate tappet seats and fit tappets (1) complete with
adjusting cap, in the same sequence they were before
dismantling.

18877

41123

Lubricate supports on camshaft (1) cylinder heads and fit
camshaft.
Fit caps (2) on relevant supports, making sure that the
numbers indicated on caps are turned to the same side as
those indicated on cylinder heads.

41124

Screw nuts (1), that fasten caps (2) to cylinder heads,
gradually and uniformly until bringing caps in contact with
cylinder heads.
Then tighten nuts (1) to prescribed torque.

Fit the seal ring (3) together with the chock into the front
cover (4) using the keying device 99374336 (2) and the grip
99370006 (1).
Lubricate the shank of the camshaft.
Spread IVECO 1905685 sealant on the mating surface of the
front cover (4) and fit it onto the cylinder head. Tighten the
fixing nuts to the prescribed torque.
Remove the chock.

VALVE GEAR DIAGRAM

Adjustment of valve tappet clearance must be carried out
accurately so as not to alter the required valve gear diagram,
as would occur if the clearance were greater or lesser than
prescribed.
In fact, an excessive clearance causes noise or delays opening
and advances valve closing, while an insufficient clearance
causes the opposite effect; while if the clearance is quite null
the valves always remain a little open with very harmful
consequences as far as the life of the valves and seats is
concerned.

Assembling tappets

Assembling camshaft

Adjusting tappet clearance

6423

45081

The seal ring (3) is supplied as a spare together with
the choke; this must not be removed from the seal
ring until the front cover (4) has been fitted on the
cylinder head.

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

The thickness value of adjusting caps (1) is printed on one of
their two surfaces. Should this value be illegible, measure it
with a micrometer (2).

If it is necessary to replace the adjusting caps, to obtain the
required operating clearance, proceed as follows:

- rotate valve tappets so as milling on edge are directed

towards intake and exhaust ducts;

- insert tool 99360309 (1), between intake and exhaust

valve tappets, and use it as a lever until valve tappets are
fully compressed;

For adjusting valve tappet clearance proceed as follows:

- insert key 99350114 (2) on valve gear control fastening

screws and rotate camshaft until setting valves to closing
position;

- check, with a thickness gauge (1), that clearance

between valve tappets and intake/exhaust cams is
0.5

± 0.05 mm.

Figure 156

Figure 157

Figure 158

Figure 159

23030

23031

18894

- with gun (3), address a compressed air jet in milling (2)

so as to lift adjusting cap (1) to be replaced;

- remove adjusting cap with pliers 99380701.

18895

On fitting adjusting cap, printed value must be oriented to-
wards valve tappets.

Valve tappet clearance adjusting caps are supplied
as spare parts with the following thickness: 3,25 -
3,30 - 3,35 - 3,40 -3,45 - 3,50 - 3,55 - 3,60 - 3,65 -
3,70 - 3,72 - 3,75 - 3,77 - 3,80 - 3,82 - 3,85 - 3,87
- 3,90 - 3,92 - 3,95 - 3,97 - 4,00 - 4,05 - 4,10 - 4,15
- 4,20 - 4,25 - 4,30 - 4,35 - 4,40 - 4,45 mm.

NOTE

Having to adjust valve tappet clearance with cylin-
der heads installed on engine, before compressing
valve tappet with tool 99360309 (1, Figure 157),
rotate engine with special tool, so as to set intake
valve cam of the cylinder involved in valve tappet
adjusting, turned approximately upward; in these
conditions piston will be 10-13 mm from T.D.C.,
thus avoiding piston crawling with valves.

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

Tightening order diagram for cylinder heads fastening screws:

- 1st step: pre-tightening with torque wrench to torque of

± 5 Nm;

- 2nd step: return to torque of 60

± 5 Nm;

- 3rd step: closing with 180

° ± 10° angle.

6448

Turn camshaft (2) to close cylinder 1 valves.
Refit cylinder head (3).

41144

61889

Figure 160

Figure 161

Figure 162

Figure 163

Refitting cylinder head

62072

Fill spaces A between rear cover (6) and cylinder head (5)
with Silastic 732 RTV sealant.
Fit seal (2) on tappet cover (1). Smear tappet cover corners
(

⇒) with SILASTIC 732 RTV (approx. 10g). Refit tappet

cover (1) on cylinder head and tighten fixing nuts (7) to the
specified torque.
Fit pipe and electric cable locking clamps (8) and tighten fixing
nuts (5) to the specified torque.
Fit sensor (4) and support on tappet cover and check air gap
as described in the relevant chapter.
Fit intake manifold (3).

Set cylinder piston 1 to TDC and keep it in this position by
locking engine flywheel (4) rotation and applying tool
99392214 (3) to block.
This condition is required to set timing.
Check that joining surface of cylinder heads and that on
crankcase are clean.
Do not soil cylinder head gasket.
Place cylinder head gasket (2), according to thickness speci-
fied in paragraph ”Checking piston protrusion”, with inscrip-
tion ”ALTO” [top] (1) oriented towards head.
Arrow indicates the point where fitted gasket thickness is
specified.

Screw and tighten screws in three consecutive stages
according to the sequence and procedure shown in the
following figure.

It is absolutely necessary to keep gasket sealed in
its packing and to remove it from envelope only a
short time before fitting it.

NOTE

Before reusing cylinder head fixing screws, check by
micrometer whether screw thread diameter,
measured at any point, is higher than 11.5 mm,
otherwise replace screws.

NOTE

Angle closing is carried out by means of tool
99395216 (1).

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

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Iveco Daily. Manual - part 26