Iveco Daily Euro 4. Manual — part 26
- Fit the connecting rod caps (2) with the associated
bearing shells.
- Tighten the screws (3) in two steps:
-
Step 1: with a torque wrench, to a torque of 50 Nm.
-
Step 2: closing to an angle of 60
°.
Figure 148
- The openings of the piston rings are staggered 120
° apart.
- The pistons are all of the same weight.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil spray nozzles.
540831
Measuring crankpin assembly
clearance
75405
To measure the clearance, carry out the following steps:
- Thoroughly clean parts (1) and (4) and eliminate all
traces of oil.
- Place a length of calibrated wire (3) on the crankshaft
pins (4).
75408
Figure 149
α
- Remove the cap (2) and determine the existing clearance
by comparing the width of the calibrated wire (3,
Figure 148) with the graduated scale on the case (2,
Figure 148) that contained the calibrated wire. On finding
a clearance other than as prescribed, replace the bearing
shells and repeat the check. On obtaining the prescribed
clearance, lubricate the connecting rod bearing shells and
fit them permanently by tightening the connecting rod cap
fixing screws as described.
Manually check that the connecting rods slide axially on the
pins of the crankshaft.
75409
Figure 150
Checking piston protrusion
After mounting the connecting rod — piston assemblies, check
the protrusion of the pistons (2) at the T.D.C. in relation to the
top surface of the crankcase with a dial gauge (1).
75283
Figure 151
Mount the suction strainer (1) together with the pipe (6).
Screw down the fixing screws (2-3-4-6) and tighten them to
the prescribed torque.
Not finding it necessary to replace the connecting
rod bearings, you need to fit them back in exactly
the same sequence and position found on
disassembly.
NOTE
Use tool 99395216 (1) for the angle closing.
NOTE
The connecting rod cap fixing screws must always
be replaced for permanent assembly.
NOTE
The difference between the minimum and
maximum protrusions of the four pistons must be
= 0.15 mm.
The cylinder head gasket in the set of spare gaskets
needed for complete engine overhaul is supplied
with a single thickness. Clearly, it is supplied
separately too.
NOTE
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75413
Figure 152
Figure 153
Figure 154
Figure 155
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 (6).
Remove the brackets (5) for lifting the engine.
In the event that temperature sensor (2) need disassembling,
wrench SP 2262 shall be used.
Take out the screws (4) and remove the thermostat casing
(3).
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 HEADS
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
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75412
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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.
75451
18625
18882
Figure 156
Figure 157
Figure 158
Figure 159
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 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
Use micrometer (2) to measure valve (1) stem: it shall
correspond to the value shown in figure 135. Use grinding
machine 99305018 to grind, if necessary, the valve seats
(remove as less material as possible).
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
108196
EXHAUST
VALVE
INTAKE
VALVE
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75453
75455
75456
75457
Figure 160
Figure 161
Figure 162
Figure 163
Figure 164
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 GUIDE
Replacing valve guide
Boring valve guides
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