Engine Iveco Vector 8. Manual — part 34

Figure 1

- Remove the gear fitted on the camshaft: unscrew the

screw (1) and remove the spacer (2); extract the gear (3)
from the camshaft.

During disassembly, the components (5) and (6) are
fastened by the screws (7) on the gear (3). If
necessary, separate the various parts and replace the
worn ones.

Figure 2

Check the protrusion of the pistons (6) from the crankcase
and note it down.
Set the cylinder assembly upright. Extract the pistons as
follows:

- Loosen the nuts (1) of the bolts fixing the connecting rod

caps to the connecting rods.

- Turn the crankshaft until the piston is exactly at the TDC;

in any other position it would not be possible to extract
the piston because the connecting would interfere with
the cylinder liner.

- Remove the connecting rod cap (2) and extract the

piston from the cylinder liner.

Set the crankcase horizontally. Remove the top (4) and side
(3) bolts fixing the main bearing caps to the crankcase and ex-
tract them.

On the central main bearing housings (5) and on the
cap there are the thrust half—rings for adjusting the
crankshaft end float.

82230

ENGINE OVERHAUL

Dismantling the engine at the bench

The instructions below assume that the engine has been fitted on an overhaul stand and all the specific components for Iveco Motors
application components have been removed (see Section 3 of this manual).The section therefore includes all the most important
overhaul procedures for the engine block.

103196

NOTE

NOTE

10

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

VECTOR 8 ENGINES

Base - April 2006

Print P2D32V001E

Figure 3

Figure 4

- Once engine is disassembled, clean accurately the

cylinder—block assembly. Use the proper rings to handle
the cylinder unit. The engine block shall not show cracks.

- Check operating plug conditions and replace them in case

of uncertain seal or if rusted.

- Inspect cylinder barrel surfaces; they shall be free from

seizing, scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation,
taper and wear shall be performed using the bore dial
gauge 99395687 (1) fitted with the dial gauge previously
set to zero on the ring gauge (2) of the cylinder barrel
diameter.

Figure 5

REPAIR OPERATIONS
CYLINDER UNIT
Checks and measurements

Should the ring gauge be not available, use a
micrometer for zero—setting.

- Measurements shall be performed on each cylinder, at

three different heights in the barrel and on two planes
perpendicular with each other: one parallel to the
longitudinal axis of the engine (A), and the other
perpendicular (B). Maximum wear is usually found on plane
(B) in correspondence with the first measurement.

- Using a hoist (1) and tool 99360500 (2), appropriately

fitted on the crankpins, extract the crankshaft (3) from the
cylinder assembly.

- Extract the camshaft from the cylinder assembly, taking

care not to damage the supporting bushings. Extract the
roller tappets.

1

2

3

16788

16792

NOTE

2284

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

11

VECTOR 8 ENGINES

Print P2D32V001E

Base - April 2006

Figure 6

Figure 7

Figure 8

Figure 9

The diagram gives the diameters: the outside diameter of the
cylinder liner and the inside diameter of its seat.
If necessary, the cylinder liners can be extracted and fitted
several times in different seats.

Replacing Cylinder Liners

!

The crankcase can be levelled off only after making
sure that, after machining, the piston protrudes from
the cylinder liner from 0.19 to 0.59 mm.

If the measurements are higher than as shown in the figure, it
is necessary to change the cylinder liners. Their internal surface
is treated with liquid nitriding, so grinding, lapping or facing are
not permissible.

- Check the flatness of the cylinder head mating surface with

a calibrated rule and feeler gauge.
After finding the areas of deformation, level off the
supporting surface, after taking out the centring pins (2),
with tool (1), and the cylinder liners (3) according to the
procedures given under the heading REPLACING
CYLINDER LINERS.

- Remove the cylinder liners (2) from the cylinder assembly

with tool 99360799 (1) fitted as illustrated in the figure.
Carefully check the seats of the cylinder liners and the side
surfaces of the crankcase.
Check the state of the plugs fitted in the cylinder assembly
machining holes and replace them if they are rusty or there
is any doubt about their seal

1

2

3

164.003
164.028

164.000
164.025

162.000

162040

161.961
161.986

82231

16796

16797

2290

12

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

VECTOR 8 ENGINES

Base - April 2006

Print P2D32V001E

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

- Always change the coolant seals (3, 4 and 5).

Fit the top brass ring (2) onto the cylinder liner (1).
Lubricate its bottom portion and fit it in the cylinder
assembly with the plate (5) of tool 99360799 (6).

- Using a dial gauge (1), check that the protrusion of the

cylinder liner (2) from the mating surface of the cylinder
head is from 0.025 to 0.095 mm.

- Change the seals (5) of the bushing (3) for the left—hand

main oilway. The bushing (3) is removed from the cylinder
assembly with a percussion extractor (1) and a suitable
part (2). Use an appropriate drift to fit the bushing.

- Change the seals (5) of the bushing (3) for the right—hand

main oilway. The bushing (3) is removed from the cylinder
assembly with a percussion extractor 99340205 (1) and a
suitable part (2). Use an appropriate drift to fit the bushing.

- If changing the bushing (1) for the coolant duct, use general

tools for removal; use an appropriate drift (2) for assembly.

82720

16804

16805

16799

16803

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

13

VECTOR 8 ENGINES

Print P2D32V001E

Base - April 2006