Iveco Daily Euro 4. Manual

Figure 12

Removal

108560

Take off the camshaft drive belt, as described in the
respective chapter (operation 541257).
Disconnect coolant pipes (15) and (14) from pipe (13).
Disconnect the electric connection from pressure sensor
(18).
Remove the fastening screws, then take off expansion tank
(17) by disconnecting from the latter the electric connection
from the level sensor.
Remove oil dipstick pipe (12) from the inlet manifold.
Disconnect oil vapour pipes (20) and (19) from coalescence
filter (1), then remove the latter from the overhead.
Disconnect pipe (2) from the heat exchanger engine coolant
outlet pipe.

Take off electric injectors (4), as described in the ”Replacing
the electric injectors” chapter (operation 775010).
Disconnect the electric connections from phase sensor (3),
water temperature sensor (8), air pressure/temperature
sensor (9), preheating plugs (6), throttle valve assembly
actuator (10), fuel pressure sensor (16).
Take

fuel

pipe

(7)

off

hydraulic

accumulator (5),

high-pressure pump and inlet manifold.

F1A ENGINE

AILY

URO

540610

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.

Figure 13

Loosen clamp (9), then take the air conveyor off.
Take air suction sleeve (10) off turboblower (8).
Disconnect the oil pipe (11) from the cylinder head and from
the turbocharger (8).
Loosen the clamp (7) and disconnect the oil pipe (5) from
the crankcase union.
Take out the screws and disconnect the exhaust pipe (4)
from the turbocharger (8).
Take off the nuts (3) and remove the turbocharger (8) with
its gasket from the exhaust manifold.

Take out the screws and remove the overhead together with
the pins 99360614.

the

turbocharger

air

outlet/inlet

appropriately

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

108561

Disconnect the vacuum pipes from E.G.R. valve (2) and
turboblower (if any) actuator (6).

F1A ENGINE

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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 13) and 99360608 (8, Figure 13)
are inserted in the overhead;

99360615 (11, Figure 13) 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

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

phase: angle closing

• screws 1-2-3-4-5-6 90° ±5°;
• screws 7-8-9-10 60° ±3°.

- 3

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.

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

F1A ENGINE

AILY

URO

75271

75272

75273

75569

Figure 16

Figure 15

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

Removal

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 high-pressure pump as described
under the relevant heading.

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.

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.

F1A ENGINE

AILY

URO

REPLACING HIGH-PRESSURE
PUMP CPH1

Content .. 6 7 8 9 ..

Iveco Daily Euro 4. Manual - part 8