Iveco Daily. Manual

75410

75411

75412

75413

Figure 130

Figure 131

Figure 132

Figure 133

Fit the gasket (4) and the frame (3) onto the oil sump (1).
Screw down the fixing screws (2) and tighten them to the
prescribed torque.
Screw down the oil drain plug (5) and tighten it to the
prescribed torque.

Place the cylinder head (1) on the mounting SP.2271 (7).
Remove the brackets (6) for lifting the engine.

Use the wrench SP 2262 to remove the timing sensors (2 and
3).

Take out the screws (5) and remove the thermostat casing
(4).

Fit part (4) of tool 99360260 onto the cylinder head (5) and
secure it with the screws (3).

Fit part (2) of tool 99360260 onto part (4), screw down the
nut (1) so that on compressing the springs (8) it is possible
to remove the cotters (6). Then take out the plates (7) and
the springs (8).

Using suitable pliers, remove the oil seal (9).

Repeat these operations on the remaining valves.

Turn the cylinder head over.

The intake (1) and exhaust (2) valves have the same diameter
mushroom.

The central cavity (

→) of the mushroom of the intake valve

(1) is distinguished from that of the exhaust valve (2).

560610

CYLINDER HEAD

Disassembly

541210

Removing valves

Remove the intake (1) and exhaust (2) valves.

Before dismounting the valves from cylinder head,
number them, to the purpose of being able to
remount them in the position that was found on
dismounting operation where they should not be
replaced.

A = intake side — S = exhaust side

NOTE

F1A ENGINE

AILY

362

Base - May 2004

75451

75452

18625

18882

Figure 134

Figure 135

Figure 136

Figure 137

The mating surface of the head (1) with the cylinder block
is checked using a rule (2) and a feeler gauge (3).
The deformation found on the entire length of the cylinder
head must be no greater than 0.20 mm.
For greater values, regrind the cylinder head according to the
values and instructions given in the following figure.

The nominal thickness A of the cylinder head is 112

±0.1 mm;

the maximum permissible removal of metal must not exceed
a thickness of 0.2 mm.

Checking cylinder head seal

Check the hydraulic seal using a suitable tool.
Pump in water heated to approx. 90

°C at a pressure of 2 ÷

3 bars.

Replace the cup plugs if they are found to leak at oil, using
a suitable drift for their removal — assembly.

Checking cylinder head mating surface

If there is any leakage from the cylinder head, it must be
replaced.

MAIN DATA OF INTAKE AND EXHAUST VALVES

Remove the carbon deposits on the valves with a wire brush.
Check that the valves show no signs of seizure, cracking or
burning.

540662

VALVES

Removing deposits, refacing and checking
valves

Using a micrometer (2), measure the stem of the valves (1):
it must be 5.975 — 5.990 mm. If necessary, regrind the seats
on the valves with a grinding machine 99305018, removing
as little material as possible.

EXHAUST

VALVE

INTAKE

VALVE

Before mounting the plugs, apply LOCTITE 270
water-reacting sealant on their sealing surfaces.

NOTE

After regrinding, check the valve recessing and if
necessary regrind the valve seats to make the
prescribed valve recessing.

NOTE

F1A ENGINE

363

AILY

Base - May 2004

75453

75455

75456

75457

Figure 138

Figure 139

Figure 140

Figure 141

Figure 142

The checks are made using a dial gauge (2) with a magnetic
base, positioned as illustrated. The assembly clearance is
0.033 — 0.063 mm.
Making the valve (1) turn, check that the centring error is no
greater than 0.03 mm.

MAIN DATA OF VALVE GUIDES — SEATS

Valve guide seat inside

∅

9.980

÷ 10.000 mm

Valve guide outside

∅

10.028

÷ 10.039 mm

* Measurement to be made after driving in the valve guides.

Remove the valve guides (2) with the drift SP.2312 (1).

Heat the cylinder head to 80 — 100

°C and, using the drift

SP.2312 (1) provided with part SP.2311 (2), mount the new
valve guides (3) previously chilled in liquid nitrogen.
Where above indicated tools are not available, mount valve
guides positioning them in cylinder head according to
dimension indicated in Figure 139.

After driving in the valve guides (2), regrind them with the
smoother SP.2310 (1).

Checking clearance between valve stem and
valve guide and centring valves

540667

VALVE GUIDES

Replacing valve guides

Boring valve guides

88774

F1A ENGINE

AILY

364

Base - May 2004

75459

75458

54760

Figure 143

Figure 144

Figure 145

Check the valve seats. On finding any slight scoring or burns,
regrind them with an appropriate tool according to the
angles given in Figure 143.
Having to replace them, with the same tool and taking care
not to affect the cylinder head, remove as much material
from the valve seats as possible until, with a punch, it is
possible to extract them from the cylinder head.

Heat the cylinder head to 80

÷ 100°C and, using a suitable

drift, fit in it the new valve seats, previously chilled in liquid
nitrogen.
Using a specific tool, regrind the valve seats according to the
angles given in Figure 143.

Using the milling cutter 99394038 (1), clean the injector seat
of any deposits.

Mount the valves, block the seat of the electro-injectors and
glow plugs; using a suitable tool, check the seal of the
valves/seats.

Using a dial gauge (1), check that, from the plane of the
cylinder head, the valve recessing (2) and the protrusion of
the injector (3) and of the glow plug have the prescribed
value:

Valve recessing: 0.5

÷ 0.8 mm.

Injector protrusion: 2.77

÷ 3.23 mm.

Glow plug protrusion: 3.78 mm.

540661

VALVE SEATS

Regrinding - replacing valve seats

F1A ENGINE

365

AILY

Base - May 2004

Content .. 94 95 96 97 ..

Iveco Daily. Manual - part 96