Iveco Daily. Manual

62857

Figure 34

Figure 35

Figure 36

Disconnect the fuel pipes (2) from the electro-injectors (1)
and from the hydraulic accumulator (rail) (7) as follows.
Keeping the hexagon (4) of the electro-injector (1) stationary
with a wrench, undo the coupling (3) using the wrench
99365160.
Keeping the hexagon (6) of the flow limiting valve stationary,
if applicable, unscrew the coupling (5) and disconnect the fuel
pipe (2).
Take out the screws (8) fixing the brackets (9) retaining the
electro-injectors (1).
Disconnect the electro-injectors (1) from the cylinder head.

62858

Disconnect the pipe (6) from the high-pressure pump (3) and
from the hydraulic accumulator (rail) (7).

Remove nuts (2) and then remove protection (1).

52168

Disconnect: rail (3), high pressure pump (4), oil dipstick pipe
(2) and oil filler (1).

52163

Remove the screw (2) fastening the pipe (4 and 1) bracket
(3) to the intake manifold (5).
Remove the pipe (4) from the cylinder head.
Remove the nuts (7) fastening the pipe (1) to the water
pump (6).
Remove the screw (9) fastening the pipe (8) to the bedplate.

Figure 37

For engine 8140.43S only.
Since engine No. 3089322, a rail with the same
configuration but without flow limiters and
pressure relief valve has been mounted. The same
prescriptions specified for the previous one shall be
complied with.

NOTE

Stop high pressure pump hexagon (4) by means of
the proper wrench when loosening connection
(5).

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

52169

Figure 38

Figure 39

Figure 40

Figure 41

Figure 42

Figure 43

Remove the intake manifold (1), tappet cover (4) complete
with speed sensor (2). Recover the brackets (5) and the
timing cover (3).

50658

Using the right wrench on the automatic tightener (2),
slacken the tension of the belt (1) and remove it.

50660

50659

Using tool 99360306 (3), applied as shown in the figure, stop
crankshaft rotation and loosen the screws (1) securing the
flywheel (2). Take out the screws (5), remove the mounting
(6) complete with speed sensor (4).

Take out the screw securing the pulley (1) to the crankshaft.
disconnect the pulley (1) from the crankshaft and the spacer,
if any.

Loosen gear fixing screws (1 and 7). Fit proper wrench (5)
between push rod (3) and belt tightener cylinder (4).
Remove nut (2). Remove lower cover (6) and timing belt (8).

50661

Disconnect the pipe (4) from the heat exchanger (3). Take
out the screw (1 and 5) and disconnect the pipe (2) complete
with pipes (1 and 8, Figure 33) from the crankcase base.

62859

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

Unscrew the screws (1) securing the cylinder head (2) and
remove it with its gasket.

50663

50664

50665

With a suitable plate (1) applied as shown in the figure, block
rotation of the electromagnetic pulley (2), unscrew the nut
(3) securing the hub (4) clockwise and remove the hub.

Remove the key (1) and washer (3) from the water pump
shaft (2).

Extract the pulley (9) from the water pump shaft (2).

Take out the nuts (7) and extract the electromagnetic
coupling (8).

Remove the mounting (5) complete with alternator (4) from
the crankcase and from the water pump (2).

Remove the water pump (2).

Remove the adjustable tightener (6).

Remove the crankshaft front cover (10).

Remove the fixed tightener mounting (5) and the guard
beneath (6).
Remove the thermostat box (1) complete with switches (2
and 3) and pipe (4).

50662

Figure 44

Figure 45

Figure 46

Figure 47

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

NOTE

The hub nut (3) has a left-hand thread.

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

50667

41090

41091

Turn the engine 180º and take out the oil sump (1).

Take out the engine oil suction rose (2).

Take out the tool 99360306 for blocking flywheel rotation.

Turn the engine 90º and loosen the screws (3) of the
connecting rod caps (1) with the appropriate wrench (2).

Using the wrench (3), take out the screws (2) securing the
engine flywheel (1) and remove it from the crankshaft.

18830

Take out the screws fixing the connect rod caps, remove
them and extract the pistons (1) from the top of the crank-
case.

Remove screws (2) and disconnect auxiliary component unit
(1) including hydraulic power steering pump (3), vacuum
device (4), oil filter (6) and heat exchanger (5).

Figure 48

50666

Figure 49

Figure 50

Figure 51

Figure 52

To be able to remove the connecting rod cap (1,
Figure 50) of the piston No. 4, take it to TDC.

NOTE

Keep the half bearings in their respective housings
because, if utilized, they must be fitted in the same
position they were in when dismantled.

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

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Iveco Daily. Manual - part 19