Iveco Daily Euro 4. Manual — part 24
75288
75309
75310
75311
Figure 112
Figure 113
Figure 114
Thoroughly clean the bottom main bearing shells (2) and
mount them in the crankcase base (1)
Mount the crankcase base (12).
Tighten the screws in the sequence shown in the figure in
three steps:
- Step 1: with a torque wrench, to a torque of 50 Nm.
- Step 2: closing to an angle of 60
°.
- Step 3: closing to an angle of 60
°.
The end float is checked by setting a dial gauge (1) with a
magnetic base on the crankshaft (2) as shown in the figure.
The normal assembly clearance is 0.060 — 0.310 mm.
If you find the clearance to be greater than as required,
replace the rear main bearing shells carrying the thrust
bearings and repeat the clearance check between the
crankshaft pins and the main bearing shells.
If the end float of the crankshaft does not come within the
prescribed values, it is necessary to grind the crankshaft and
accordingly change the main bearing shells.
NOTE: The middle main bearing has half thrust washers
integrated in it, so it performs the function of a thrust bearing.
It is supplied as a spare part only with the normal shoulder
thickness.
α
Figure 115
- Remove the bottom crankcase.
The clearance between the main bearings and their
associated pins is measured by comparing the length of the
calibrated wire (1), at the point of greatest crushing, with the
graduated scale on the casing containing the calibrated wire.
The numbers on the scale indicate the clearance of the
coupling in millimetres, which must be 0.032
÷ 0.102 mm.
If the clearance is not as prescribed, replace the bearings and
repeat the check.
Checking crankshaft end float
Use tool 99395216 (11) for the angle closing.
NOTE
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75309
75406
85843
Figure 116
Figure 117
Figure 118
Figure 119
Thoroughly clean the crankcase / crankcase base mating
surface.
Apply, on base, sealant LOCTITE 510 IVECO no. 93162432,
as indicated in the scheme. The sealant must result to be
even, not patchy.
Mount the crankcase base (12) and tighten the fixing screws
in three stages, following the sequence shown in the figure:
- Step 1: with a torque wrench, to a torque of 50 Nm.
- Step 2: closing to an angle of 60
°.
- Step 3: closing to an angle of 60
°.
Then tighten the outer screws (1) to a torque of 36 — 30 Nm.
Carefully clean the seal seat. Apply LOCTITE 510 IVECO nr.
2992504 on the seal (1) for 30
° in the points shown in the
figure.
Lubricate the rear shank of the crankshaft with engine oil.
Fit part (2) of tool 99346255 onto the rear shank of the
crankshaft; secure it with the screws (3) and key the fresh seal
(1) onto it.
Position part (4) on part (2); screw down the nut (5) to fit
the seal (1) fully inside the crankcase.
α
540460
Assembling rear seal
Mount the crankcase base within 10 minutes of
applying the sealant.
NOTE
Use tool 99395216 (11) for the angle closing.
NOTE
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75389
Figure 120
Figure 121
Figure 122
540852
Replacing bearing supporting gear-
box input shaft
Use a suitable beater to take off engine flywheel bearing (1),
taking care that the bearing does not set itself sideways or get
stuck, with resulting flywheel housing damage.
To fit back into place, put engine flywheel hub (2) onto a
suitable support (4) by using a suitable beater (3) placed on
bearing (1) outer race, then fit the bearing into the engine
flywheel. This operation shall be carried out by using a
hydraulic press.
Check clutch disk rest surface: if it shows deep scoring, a
replacement must be performed.
Check conditions of the teeth of crown wheel (1); where
excessive cracking or wear is found, replace engine flywheel.
The nominal thickness of the engine flywheel is 50
±0.6 mm.
NOTE
”LUK” ENGINE FLYWHEEL FOR ENGINES FITTED TO
THE VEHICLES EQUIPPED WITH MECHANIC
TRANSMISSION
”SACHS” ENGINE FLYWHEEL FOR ENGINES FITTED
TO THE VEHICLES EQUIPPED WITH AUTOMATIC
TRANSMISSION
75390
Mount the sheet metal guard (1) and secure it to the crankcase
tightening the screw (2) to the prescribed torque.
Mount the engine flywheel (3) and screw down the screws (4).
108193
108194
Figure 123
F1A ENGINE
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540850
ENGINE FLYWHEEL
75393
75394
Figure 124
Figure 125
Remove the piston rings (1) from the piston (2) using pliers
99360183 (3).
Take plunger (1) off the connecting rod by removing snap
ring (2) and taking pin (3) out.
Figure 126
540840
Pistons
Disassembly
Figure 127
MAIN DATA ON PISTON MAHLE MONDIAL, PINS AND SPRING RINGS
ENGINE F1AE 0481B (116 HP)
* Measured on the diameter of 85 mm.
Fit tool 99360351 (4) onto the crankcase to block rotation
of the engine flywheel (1).
Tighten the screws (3) fixing the engine flywheel (1) in two
steps:
- Step 1: with a torque wrench, to a torque of 30 Nm.
- Step 2: closing to an angle of 90
°.
5408
CONNECTING ROD — PISTON
ASSEMBLY
α
Use tool 99395216 (2) for the angle closing.
NOTE
75391
Check the pistons. They must show no signs of seizure,
scoring, cracking or excessive wear; replace them if they do.
107947
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