Iveco Daily Euro 4. Manual

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Figure 194

Figure 195

Figure 196

Figure 197

Figure 198

Fit a new seal (3) on the cover (2) and fit this in the overhead.

Fit on the seal (1).

Lubricate the shank of the camshaft.

Using the keying device 99374458 (3), fit the seal (2) in the
overhead (1).

Fit the toothed pulley (1) Only for the intake shaft with
full-section front tapered shank, so as to align the pulley hole
with the overhead hole and fit tool 99360608 (4) into the
holes themselves. Screw down the screw (3) together with
the washer (2) without tightening fully.

Fit the oil pressure control valve (1) in the crankcase.

Fit on the plug (2) with the seal (3) and tighten it to the
prescribed torque.

Fit the centring tool 99396037 (2) onto the shank of the
crankshaft.
Mount the oil vacuum pump assembly (1) with a new gasket
and tighten the screws (1-15) according to the following
procedures:
- Tighten the screws from no. 1 to no. 6 to a torque of 5

±1 Nm while checking that the tool 99360037 (2) turns
freely.

- Tighten the screws from no. 7 to no. 15 to a torque of

±1 Nm.

- Tighten the screws from no. 1 to no. 6 to a torque of 10

±1 Nm.

- After checking that tool 99360037 (2) turns freely,

remove it.

540442

Assembling front seal ring

The toothed pulley (1, Figure 196) for the intake
shaft with full-section tapered shank is not locked
on the shaft since it must be able to turn when
fitting and tensioning the timing belt. For the same
reason, keep the tools 99360608 (4, Figure 196)
and 99360614 (3, Figure 190) fitted.

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Lubricate the shank of the crankshaft.

Screw down part (3) of tool 99346254 in the crankshaft and
place the seal (2) on the part (3).

Key part (5) of tool 99346254 onto part (3), screw down the
nut (4) until the seal (2) gets into position in the seat of the
oil vacuum pump assembly (1).

Take out the tool 99346254 (3, 4 and 5).

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Figure 199

Figure 200

Figure 201

Figure 202

Figure 203

Turn the crankshaft so as to be able to insert tool 99360615
(5) into the hole in the crank of the crankshaft, through the
hole in the oil vacuum pump assembly (1), to block crankshaft
rotation.

Mount the gear (2), screw down the screw (3) together with
the spacer (4) and tighten it to the prescribed torque.

Mount the speed sensor (1) with a fresh gasket and tighten
the fixing screw (2) to the prescribed torque (if applicable).

Fit on the compressor mounting (3) and tighten the fixing
screws (4) to the prescribed torque.

Mount the air-conditioner compressor (1) (if applicable) and
tighten its fixing (2) screws to the prescribed torque.

Mount the oil pressure transmitter (3) with a fresh gasket.

Mount the heat exchanger (1) with a fresh seal and tighten
the coupling (2) to the prescribed torque.

Do not remove the tool 99360615 (5) as it will be
needed for fitting the timing drive belt.

NOTE

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Figure 204

Figure 205

Figure 206

Figure 207

Figure 208

Lubricate the seal of the oil filter (1) with engine oil.
Using tool 99360076 (2), tighten the oil filter to the
prescribed torque.

Thoroughly clean the mating surface (à) of the water pump
(1) and position fresh seals (2 and 3) on it.

Mount the water pump (1) and tighten the fixing screws (2)
to the prescribed torque.

Fit the high-pressure pump (2) onto the flange of the water
pump (1) and tighten the fixing screws (3) to the prescribed
torque.

Fit the driving gear (1) onto the shaft of the high-pressure
pump and block rotation of this shaft by applying tool
SP.2263 (2) as illustrated in the figure. Tighten the nut (3) to
the prescribed torque and remove the tool (2).

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Figure 209

Figure 210

Figure 211

Figure 212

Check that tool 99360619 (2) inserted in the hole (

→) of the

oil vacuum pump assembly (1) blocks crankshaft rotation.

This condition is necessary for setting up the timing system
and to prevent the valves interfering with the pistons.

Check that the mating surfaces of the cylinder head and
crankcase are clean.
Keep the cylinder head gasket clean.
Position the cylinder head gasket (1) of the thickness
determined under the heading “checking piston protrusion”
with the lettering ”TOP” facing the cylinder head.

Mount the cylinder head (1).

Screw down the fixing screws (3) and tighten them, in three
successive stages, following the order and methods shown in
the following figure.

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.

It is essential to keep the gasket sealed in its package
until just before assembly.

NOTE

The angle closure is done with tool 99395216 (2).

NOTE

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Iveco Daily Euro 4. Manual - part 29