Iveco Daily Euro 4. Manual - part 9

Figure 19

108562

Remove oil filling plug (1) and take off sound deadening cover
(2).
Loosen clamp and disconnect air tube (8) from radiator and
throttle valve assembly (7).
Disconnect electrical connection (6) from pressure switch
(5).
Remove expansion tank (4), disconnect electrical connection
(3) from the level sensor placed under the tank and put the
tank on one side.

Release engine cable (1) from the fastening clamps
Disconnect electric connections (2) from the electric
injectors, then move channel (3) aside.
Disconnect electric connection (4) from throttle valve
assembly actuator (6).
Remove screws (5) securing throttle valve assembly (6) to
the inlet manifold.

Figure 20

Figure 21

108563

108564

Remove nuts (2) securing pipe (3) to throttle valve assembly
(1).
Loosen screws (4) securing pipe (3) to heat exchanger (5),
then take throttle valve assembly (1) off the inlet manifold.

Refitting

For refitting, reverse the operations described for
disconnection observing following warnings:

- replace gasket by new parts;

- tighten nuts and screws at prescribed torque.

Removal

PREHEATING PLUG REMOVAL/REFITTING

Figure 22

108565

Refitting

For refitting, reverse the operations described for
disconnection observing following warnings:

- replace gasket by new parts;

- tighten nuts and screws at prescribed torque.

Take off the throttle valve assembly, as described in the
respective chapter.
Disconnect electric connections (3) from preheating plugs
(2).
Use wrench SP 2275 (1) to take off preheating plugs (2).

Removal

F1A ENGINE

AILY

URO

THROTTLE VALVE ASSEMBLY REMOVAL-
REFITTING

Figure 23

108566

Partially drain the engine coolant.
Take the full exhaust pipe off the engine and the chassis, as
described in the respective chapter.
Loosen the clamps, then disconnect coolant pipes (1 and 3)
from E.G.R. valve (7).
Disconnect vacuum pipe (6) from E.G.R. valve (7).
Remove fastening screws (5-9-10), then remove E.G.R. valve
(7), together with elbow (11), from heat exchanger (2), pipe
(8) from bracket (4).

Act from inside the engine compartment to take off the
cylinder head sound-proofing cover.
Disconnect cab heater coolant pipe (2) from the similar
E.G.R. valve outlet pipe (1).
Remove the nut, then take the pipe off coalescence paper
filter (3).

Figure 24

Figure 25

108623

108624

Take off the E.G.R. valve, as described in the respective
chapter.

Loosen connecting pipe (6) fastening nuts (5) in order to
make screws (7) able to be accessed.

Remove screws (7), then take off engine lifting bracket (8).
Remove screws (9), take pipe union (2) off the cylinder head,
then take off heat exchanger (1) together with pipes (3 and
4) and pipe union (2).

Refitting

For refitting, reverse the operations described for
disconnection observing following warnings:

- replace gasket by new parts;

- tighten nuts and screws at prescribed torque.
- fill expansion tank with coolant.

Removal

Refitting

For refitting, reverse the operations described for
disconnection observing following warnings:

- replace gasket by new parts;

- tighten nuts and screws at prescribed torque.
- fill expansion tank with coolant.

Removal

HEAT EXCHANGER REMOVAL/REFITTING

Remove nut (4) used for upper securing of throttle valve
assembly (5) connecting pipe (9) to heat exchanger (7).
Lower fastening nut (6) shall be removed from under the
vehicle.
Act from under the vehicle to remove the heat exchanger
supporting and engine lifting bracket (8) fastening screws.

F1A ENGINE

AILY

URO

E.G.R. VALVE REMOVAL/REFITTING

Figure 26

BURNT GAS EXHAUST SYSTEM

The following exhaust systems are available on light-duty
(LD) vehicles with a total weight on ground (P.T.T.) of up to
2,840 kg:

Description

- two standard exhaust systems:

- F1A engines: single-monolith catalyst;
- F1C engines: double-monolith catalyst;

- the catalyst may be equipped with an optional

continuous-regeneration particulate filter (DPF).

The standard exhaust system is made up of three
components:

A. system length with hose;
B. Oxicat catalyst;
C. silencer.

The exhaust system is made by two different manufacturers:
CorTubi and ArvinMeritor (ArM). The components of both
systems cannot be interchanged with each other.

507130

OXICAT - OXYDIZER CATALYST

Description

The oxidizing catalyst (1) is a post-treatment device for ex-
haust gases. It is used to oxidize CO, HC transforming them
into carbon dioxide (CO

) and steam (H

O).

This catalyst also treats saturated and aromatic hydrocarbons
forming part of the particulate, such as the carbon in the form
of soot, metals, water and sulphur compounds that are ex-
hausted.

The cylindrical-shaped catalyst consists of a ceramic honey-
comb monolith whose cells are platinum-impregnated, a ca-
talyzing substance of oxidation reactions. Its total volumetric
capacity is equal to 600 cm

with a density of 400 cells per

square inch.

The exhaust gases passing through the cells heat the catalyst,
converting the pollutants into inert compounds.

The chemical oxidation reaction of CO, HC and of the parti-
culate is efficient with temperatures ranging between
200

°C ÷350°C.

With temperatures higher than 350

°C it starts oxidizing the sul-

phur contained in the diesel oil, generating sulphur dioxide
(SO

) and sulphur trioxide (SO

), which are the cause of acid

rain.

Correct catalyst sizing enables limiting the temperature, ob-
taining the greatest percentage of conversion of polluting
emissions, while reducing the freezing of sulphur compounds.

108625

F1A ENGINE

AILY

URO

108626

Figure 27

The optional exhaust system is made up of three
components:

A. system length with hose;
B. catalyst with particulate filter (DPF);
C. silencer

This system is manufactured by ArvinMeritor (ArM).

F1A ENGINE

AILY

URO

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