Iveco Daily. Manual

75248

75502

75503

Figure 199

Figure 200

Figure 201

Figure 202

Using a wrench on the automatic tightener (2), mount the
drive belt (1), taking care to position its ribs correctly in the
respective races of the pulleys.

Fit the tightener (1) without tightening the screw (4).
Fit the drive belt (5) taking care to position its ribs correctly
in the respective races of the pulleys.

Fit a new seal (3) on the electro-injector (1) and mount this
in the overhead (2).

544035

Adjusting air-conditioner —
compressor drive belt tension

With tool SP. 2341 (2) inserted in the holes of the tightener
(1) and torque wrench (3), turn the tightener (1) with a
torque of 8.2 — 10 Nm; in this condition, tighten the screw
(4) to a torque of 25 Nm.

Turn the engine in its direction of rotation to have the belt
(5) make two full turns.

With appliance 99395849, measure the tension of the belt
(5) in section A, which must be 204

±10 Hz corresponding

to a load on the tightener of 1010

± Nm.

In the case of engines with a compressor drive belt of elastic
type, no tensioning is needed. For mounting, operate as
follows.

75501

Mount the fixed tightener (2) and tighten the fixing screw (1).

Mount the automatic tightener (3) and tighten the screw (4)
to the prescribed torque.

90155

Fit the flexible belt (3) equipped with tool 99360191 (2) on
the pulley (4) and apply the tool on the pulley (1).
Fit the drive ring (5) on the flexible belt (3) and fasten the ring
on the compressor support.
Turn the drive shaft clockwise until the belt fits perfectly on
the pulley (1).

Figure 203

The elastic belt must be replaced by a new elastic
belt at each dismounting operation.

NOTE

F1A ENGINE

AILY

378

Base - May 2004

75506

75508

75509

Figure 204

Figure 205

Connect the fuel pipes (2) to the electro-injectors (1) and to
the hydraulic accumulator (3).
Tighten the screws (4) fixing the electro-injector brackets to
the prescribed torque.

Mount the glow plugs (1) and, using the box-type wrench SP.
2275 (2) and torque wrench 99389819 (3), tighten them to
a torque of 8

÷ 10 Nm.

Mount the intake manifold (1) with a new gasket and, using
a torque wrench (3), tighten the fixing screws (2) to the
prescribed torque.

75507

Figure 206

Using the wrench (4) of the 99317915 series and the torque
wrench 99389829 (3), tighten the fuel pipe fittings (1) and (2)
to the prescribed torque.

88615

Forged version: on hydraulic accumulator (2), mount:
pressure sensor (1) tightening it at 35

± 5 Nm torque, and

pressure relief valve (3) tightening it at 27

± 2 Nm torque.

Welded version: mount pressure sensor and tighten it at 70
± 5 Nm torque.

Figure 207

75504

Mount the brackets (3) fastening the electro-injectors (1)
and screw down the screws (2) without locking them.
Mount the hydraulic accumulator (4) and tighten the fixing
screws to the prescribed torque.

Figure 208

Whenever they get removed, the fuel pipes must
be replaced with new ones.

NOTE

Figure 209

F1A ENGINE

379

AILY

Base - May 2004

75510

75511

75256

75512

Figure 210

Figure 211

Figure 212

Figure 213

Connect the fuel pipe (4) to the hydraulic accumulator (7)
and to the high-pressure pump (5).
With wrench (2) of series 99317915 and dynamometric
wrench 99389829 (1), tighten pipe fittings (3 and 6) at
prescribed torque.

Connect the fuel recovery pipe (1) with new seals to the
pressure relief valve (6) tightening the coupling (7) to the
prescribed torque (only for forged version hydraulic
accumulator).
Connect the fuel recovery pipes (1) and (5) with new seals
to the high-pressure pump (2) with the couplings (3) and (4).
Insert the oil dipstick tube (9) with a new seal into the
crankcase and secure it together with the pipe (10), using the
screw (8) tightened to the prescribed torque, to the intake
manifold.

Press the clips (3) in the direction shown by the arrow and
connect the fuel recovery pipe fittings (1) to the
electro-injectors (2).

Fit the exhaust manifold (5) with a new gasket and the
spacers (6) and tighten the nuts (7) to the prescribed torque.
On the exhaust manifold (6), mount: the turbocharger (4)
with a new gasket and tighten the nuts (3) with washers to
the prescribed torque, the compensator pipe (1) (if
applicable) with a new seal and tighten the nuts (2) with
washers to the prescribed torque.

Whenever they get removed, the fuel pipes (4)
must be replaced with new ones.

NOTE

Before fitting the turbocharger on the engine, it is
necessary to fill the central body with engine
lubricating oil.

NOTE

F1A ENGINE

AILY

380

Base - May 2004

75513

75263

75255

Figure 214

Figure 215

Figure 216

Figure 217

Connect the pipe (4) to the cylinder head (6) and to the
turbocharger (7).
Using the wrench (2) in the 99317915 series and the torque
wrench 99389829 (1), tighten the couplings (3 and 5) to the
prescribed torque.

Connect the air duct (5) to the turbocharger (2) and to the
overhead (3).
Tighten the clamp (1) and the screw (4) to the prescribed
torque.

For engines with E.G.R. only
Mount the flange (7) with a new gasket and tighten the
screws (8) to the prescribed torque.
Mount the heat exchanger (1) together with the E.G.R. valve
(5) and new gaskets and tighten the screws (2 and 6) to the
prescribed torque.
Connect the pipe (4) to the exchanger (1) and to the flange
(7) securing it with the clamps (3).

Mount the oil fillpipe (5) with a new seal and tighten the nuts
(6) to the prescribed torque.
Mount the coalescence filter (3) and tighten its fixing nuts (4)
to the prescribed torque.
Mount the bracket (1) and tighten the screws (2) to the
prescribed torque.

75264

F1A ENGINE

381

AILY

Base - May 2004

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Iveco Daily. Manual - part 100