Iveco Daily Euro 4. Manual

Figure 57

Figure 58

Figure 59

Figure 60

Figure 61

Figure 62

Take out the screws (2) and the brackets (3) fixing the
electro-injectors (1) to the cylinder overhead.

Using tool 99342153 (1) extract the electro-injectors (2)
from the overhead.

Remove screw (1) and nut (3), then remove pipe (2).
Take oil dipstick pipe (4) out of the engine base.

Loosen clamp (6), then disconnect fuel pipe (5) from
high-pressure pump (7).
Remove screw (3) securing pipe (2) retaining bracket (4) to
the inlet manifold.
Disconnect pipe (2) from hydraulic accumulator (1) and
high-pressure pump (7).

Take out the screws (1) and remove the hydraulic
accumulator (2).

Remove screws (4), then disconnect low-pressure pipes (5)
from bracket (3).
Remove coupling (1), then disconnect pipes (5) from
high-pressure pump (2).

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Figure 63

Figure 64

Figure 65

Figure 66

Figure 67

Loosen clamp (7), then disconnect pipe (6) from EGR valve
(8).
Loosen clamp (4), then disconnect pipe (5) from heat
exchanger (3).
Remove screws (2 and 9), then disconnect heat exchanger
(3, with its respective gaskets), together with EGE valve (8),
from pipe (1) and elbow (10).

Remove nuts (4), then take pipe (5), together with its gasket,
off throttle valve assembly (1).
Remove screws (3), then take throttle valve assembly (1),
together with its gasket, off inlet manifold (2).

Remove screw (4), then disassemble air pressure/temperature
sensor (3).
Remove screws (1), then take off inlet manifold (2) together
with its gasket.

Use wrench SP. 2275 (1) to disassemble preheating plugs (2).

Remove nut (1), then take off phase sensor (2). Use a suitable
wrench to take off temperature sensor (3).
Remove screws (4), then take off thermostat case (5).

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Figure 68

Figure 69

Figure 70

Figure 71

Figure 72

Remove screw (2), then take off pipe union (1).
Remove screws (3) securing elbow (4) to bracket (5).

Remove coupling (5).
Disconnect oil pipe (4) from the cylinder head coupling and
turboblower (3) coupling.
Remove nuts (2), then take turboblower (3), together with
its gasket, off exhaust manifold (1).

Remove nuts (5) and spacers (4), then take off exhaust
manifold (1) together with its gasket, complete with pipe (2)
and elbow (3).

Take out the screws (1) and remove the overhead (2).

Figure 73

75269

Take off the gasket (1) and remove the hydraulic tappets
together with the rocker arms (2).

75270

Take out the screws (1) and remove the cylinder head (2).

Check the protrusion of the pistons as described
under the relevant heading to check the possibility
of facing the crankcase if it has deformed.

NOTE

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Figure 74

Figure 75

Figure 76

Figure 77

Figure 78

Figure 79

Block rotation of the high-pressure pump gear (1) by applying
tool SP 2263 (2) as shown in the figure. Take off the nut (3)
and remove the tool (2).

Take out the screws (1) and remove the oil pump — vacuum
pump assembly (2).

75271

Using tool 99340035 (2), applied as in the figure, extract the
gear (1) from the shaft of the high-pressure pump (3).

75272

75273

Take out the screws (1) and remove the high-pressure pump
(2) from the water pump mounting (3).

75274

Take out the screws (1) and remove the water pump
assembly (2).

75275

Remove the plug (6) from the oil pump — vacuum pump
assembly (1).
Position the crankshaft so as to be able to insert tool
99360615 (5) into its hole through the hole in the plug (6)
and block rotation of the crankshaft.
Take out the screw (3) with the spacer (4) beneath and
remove the gear (2).

Tool 99340059 (4) is used to take seal ring (3) off
cover (2) when the engine is fitted to the vehicle.

NOTE

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Iveco Daily Euro 4. Manual - part 21