Iveco daily euro 4, Repair Manual

Page: 195 / 1132

Refitting
To refit the engine assembly, carry out the operations
described for removal in reverse order, following these
instructions:
-
Before refitting the gearbox to the engine, it is necessary
to remove the pressure plate bearing from the
diaphragm spring by opening out the retaining circlip.
Fit the pressure plate bearing on the sleeve of the drive
input shaft cover, connecting it to the clutch release
lever. Spread the gearbox input shaft with Molikote
molybdenum disulphide grease.
As regards the 6 S 400 O.D. gearbox units, proceed as
follows.
Engage a gear to let the main shaft turn, rotating the
propeller shaft connecting flange. Push the gearbox fully
in so that the pressure plate bearing couples with the
diaphragm spring correctly.
As regards the 6 S 400 O.D. gearbox units, follow the
procedures described in the specific chapter.
-
Pay special attention to the operations needed to install
the engine assembly in the engine bay.
-
Check the conditions of the coolant pipes or sleeves and
of the air ducts. Replace them if they show any sign of
deterioration.
-
Check the flexible mountings of the assemblies: engine
and gearbox. Replace them if they show any sign of
deterioration.
-
Check that the exhaust pipe members have not
deteriorated and are not about to deteriorate. If this is
so, replace them along with the flexible parts for securing
them.
-
Tighten the screws or nuts to the required torque.
-
Meticulously check the state of the vacuum pipe. It must
show no sign of cracking, cutting, scoring or of being
crushed. Replace it if there is any doubt at all about its
soundness. When mounting it, make sure the pipe does
not come into contact with sharp metal parts or corners
or with any particularly hot parts. In addition, after
assembly, the pipe must have no bends or constrictions,
its radius of curvature should be broad and it must be
secured to the vacuum pump fitting with a suitable
clamp.
- Make sure that fuel pipes rapid engagement fittings are
accurately clean, and result to have been fully inserted
and not going to be disconnected after their being
connected to relating engagement unions.
-
Fill the cooling system with coolant.
-
Fill the hydraulic power steering circuit and bleed the air
as described under the relevant heading.
-
Check the level of oil in the engine and gearbox.
-
Recharge the air-conditioning system (if any), as
described in the relevant chapter in the “Bodywork and
chassis” section.
-
Check, if necessary, the headlamp orientation.
-
No water leaks from the connecting sleeves of the
engine cooling and cab heating circuit pipes; tighten the
collars if necessary.
- No oil leaks from between the cover and cylinder head,
oil sump and crankcase, oil filter and its seat, heat
exchanger and crankcase or from between the various
pipes of the lubricating circuit.
-
No fuel leaks from injection pump and injector lines.
Tighten fittings if necessary.
-
Check the indicator and warning lights on the instrument
panel and the devices disconnected on removing the
engine all work properly.
Check the level of oil in the tank and top it up if necessary.
Lift the vehicle at the front, start up the engine and let it idle
for some time.
Check there is no oil leakage from the hydraulic circuit and
check the level in the tank.
Slowly turn the steering wheel in both directions of steering
so that the air in the hydraulic system comes out.
Check the level of oil in the tank again and top up if necessary.
Checks and tests
Start up the engine, leave it running just a little faster
than idling speed and wait for the coolant
temperature to reach the value for opening the
thermostat, then check that:
When positioning the engine in the engine bay,
take special care not to damage the top pipe of the
power steering and the soundproof-heatproof
cladding of the engine bay.
Once positioned, meticulously check that the top
pipe of the power steering is sound.
Before using it again, check that the power steering
oil and coolant contain no impurities. If they do,
filter with suitable mesh filters. For any topping up,
refer to the REPLENISHING FLUIDS table in the
“GENERAL” section. NOTE
501430 Power steering system air
bleed
F1C ENGINE
167
D
AILY
E
URO
4
Print 603.93.651 Base - March 2006