Iveco Daily. Manual — part 96
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).
α
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
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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
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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
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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
D
AILY
Base - May 2004
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