Iveco Daily. Manual

The check of mating surface of the head (1) to cylinder group
is performed by means of a rule (2) and a thickness gauge (3).
If a deformation is found, measure cylinder head thickness,
whose rated value is 150

± 0.1 mm.

When checking, if the amount of material to be removed for
flattening cylinder head is greater than 0.4 mm, replace
cylinder head.

If the amount of material to be removed is within 0.2 mm
there is no need to dismantle combustion prechamber plugs,
otherwise proceed as stated in the following figure.

Checking cylinder head mating surface

SECTION F-F

1. Glow plug - 2. Injector seat - 3. Combustion

prechamber plug

49074

18879

49076

49075

Figure 46

Figure 47

Figure 48

Figure 49

MAIN DATA - VALVE SEATS

Intake

Exhaust

(REFERENCE DIA.)

Ø 34.8

Ø 40.9

ENGINES 8140.63

270

AILY

Base - May 2004

Precombustion chamber (1) plugs driving is carried out with
tool 99360356 (2), making their centring balls (

←) coincide

with the milling (

→) of relevant seat on cylinder heads.

After cylinder heads regrinding, with material removal of
more than 0.2 mm thickness, measure with dial gauge (1) the
depth Y of pre-combustion chamber seats.
According to the class of the pre-combustion chambers,
shown in the previous figure, restore depth Y of respective
seats, to the corresponding classes listed here below:

depth Y

Class

4.480

÷ 4.505

4.505

÷ 4.530

4.530

÷ 4.555

Precombustion chambers (1) are subdivided into classes
according to base thickness X and selected as follows:

Should it be required to replace one or more precombustion
chambers (1) (being not necessary to regrind respective seats
on cylinder heads), measure thickness X of their base to fit
the new part of same class and in the same order found upon
dismantling.

Class

4.500

÷ 4.520

4.520

÷ 4.540

4.540

÷ 4.560

X mm

Assembly

41802

52219

41803

52189

Figure 50

Figure 51

Figure 52

Figure 53

Number the pre-combustion chambers (3) in order to refit
them in the same order of disassembly and remove them
from the cylinder head (1) taking special care with a suitable
punch (2).

PRECOMBUSTION CHAMBERS
Disassembly

ENGINES 8140.63

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AILY

Base - May 2004

Check the efficiency of each single glow plug (2) by
connecting the two tester terminals (1) to glow plug
terminals and verify its continuity, otherwise replace glow
plug.

Assembly

Fit incandescence plugs to the cylinder head and tighten them
to a torque of 15

÷ 1 Nm (1.5 ÷ 0,1 kgm).

Checking glow plugs continuity

Remove glow plugs (1) from cylinder heads.

52220

41807

Figure 54

Figure 55

Figure 56

Figure 57

GLOW PLUGS
Disassembly

50681

LUBRICATION

543110

Heat exchanger

On supplying heat exchanger (1) with air at 1 bar pressure,
verify that no leaks exist from oil flow side (2) and also from
water flow side.

Test conditions:

Oil type

SAE 30

Oil temperature at heat exchanger inlet

115

°C

Oil delivery

30 litres/minute

Water temperature at heat exchanger inlet

°C

Water delivery

20 litres/minute

PERFORMANCE
Exchanged heat quantity

5.0 kW

Oil pressure drop

0.85 bar

Built-in safety valve (2)
Opening pressure

0.82

÷ 1.03 bars

10-element heat exchanger

52222

Screw the injectors (1) into the cylinder head and, with the
right wrench, tighten them to the required torque.
Fit the glow plugs (2) and electric cable (4), and tighten the
fixing nuts (3) to the required torque.

Re-check continuity after fitting glow plugs, since
deforming effect, due to assembly pressure, may
cause the interruption of said continuity

NOTE

ENGINES 8140.63

272

AILY

Base - May 2004

52614

Figure 58

OIL VAPOUR FULL RÉCIRCULATION SYSTEM DIAGRAM (8140.63 engine)

1. Suction conveyer - 2. Flow relief valve - 3. Delivery pipe - 4. Oil vapour outlet pipe -

5. Oil vapour condenser - 6. Oil drainage pipe - 7. Crankcase

The vapours that develop in the sump during engine
operation, are collected in a condenser (5).
A portion of such vapours condense and, through pipe (6),
return in the sump, while the remaining portion, through pipe
(3) is sucked by engine and burnt.
The flow of vapours sucked by engine, is controlled by a relief
valve (2).

This valve, applied on pipe (3) in proximity to suction
conveyer (1), limits the flow of vapours, by choking flowing
section according to the vacuum existing in suction pipe.
In this way most of the vapours will return in the sump.

ENGINES 8140.63

273

AILY

Base - May 2004

Oil vapour full recirculation system (Blow-by)

Content .. 70 71 72 73 ..

Iveco Daily. Manual - part 72