Iveco Daily. Manual — part 92
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Figure 64
Figure 65
Figure 66
Figure 67
Take out the screws (2), (3), (4) and (5) and remove the
suction strainer (1) together with the pipe (6).
Take out the screws (2) and remove the connecting rod caps
(3).
Extract the pistons (1) from the top of the crankcase.
Block rotation of the flywheel (1) with tool 99360306 (3).
Take out the screws (2) and remove the engine flywheel (1).
Take out the screw (5) and remove the guard (4).
Apply tool 99340058 (2) to the rear O-ring (1) and extract
it from the crankcase.
On the same side of the connecting rod and its
associated cap, indicate the number of the cylinder
from which the connecting rod has been removed.
Keep the bearing shells in their respective housings
since, if they are used, they will need to be fitted in
the position found during removal.
NOTE
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Figure 68
Figure 69
Figure 70
Figure 71
Using an appropriate wrench and a hex-fluted wrench,
unscrew the screws (1) and (2) and remove the crankcase
base (3).
With the aid of a hoist and a rope, remove the crankshaft (1).
Take out the couplings (1) and remove the oil jets (2).
The central half ring (3) is fitted with thrust half-washers.
Note the assembly position of the bottom main
bearing shells (2) since, if they are reused, they will
need to be fitted in the position found during
removal.
NOTE
Note the assembly position of the top main bearing
shells (2) since, if they are reused, they will need to
be fitted in the position found during removal.
NOTE
On completing engine removal, it is necessary to
clean the removed parts thoroughly and check
their integrity.
The following pages give the instructions for the
main checks and measurements to make in order
to determine whether the parts can be reused.
NOTE
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The measurements must be made for each single cylinder at
three different heights up the liner and on two planes at right
angles to each other: one parallel to the longitudinal axis of
the engine (B) and the perpendicular (A); the greatest wear
is generally found on this last plane with the first
measurement.
On finding ovalization, taper or wear, go ahead and
bore/grind and finish the face of the cylinder liners. The
refacing of the cylinder liners should be done in relation to
the diameter of the pistons supplied as spare parts oversized
by 0.4 mm of the nominal value and to the prescribed
assembly clearance.
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Figure 72
Figure 73
After
removing
the
engine,
thoroughly
clean
the
cylinder-crankcase assembly. Use the rings 99365508 to
carry the cylinder block.
Carefully check that the crankcase has no cracks in it.
Check the state of the plugs. If they are rusty or there is any
doubt about their seal, replace them. Examine the surfaces
of the cylinder liners; they must show no sign of meshing,
scoring, ovalization, taper or excessive wear. The inside
diameter of the cylinder liners is checked, to ascertain the
extent of ovalization, taper and wear, using the bore meter
99395687 (1) fitted with a dial gauge previously reset on the
ring gauge of the diameter of the cylinder liner or on a
micrometer.
REPAIRS
CYLINDER BLOCK
Checks and measurements
Figure 74
* Surface roughness parameters:
Rt
=
4
÷ 10 µm
Rz
=
3
÷ 8 µm
Ra
=
0.25
÷ 0.6 µm
Wt <
1.5
µm
Permissible surface porosity for machined cylinder
(see Figure 75)
ZONE B1 = Area of greatest mechanical stress,
segment/liner
contact:
No.2
non-continuous
porosities
are
permissible max. 0.5x0.5.
ZONE B2 = Surface involved in segment rubbing:
No.2 non-contiguous porosities are
permissible max. 1x0.8.
C
C
100%
100%
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Figure 75
1
st
measurement
2
nd
measurement
3
rd
measurement
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For undersized crankpins, letter M.
For undersized main journals, letter B.
For undersized crankpins and main journals, letter MB.
See that the head mating surface, on the cylinder block, has
no deformation.
This check can be made, after taking out the grub screws (3),
with a surface plate spread with carbon black or with a
calibrated rule (1) and a feeler gauge (2). After ascertaining
the areas of deformation, level the bearing surface with a
grinding machine.
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Figure 76
Figure 77
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Figure 78
The main journals and crankpins must always be
ground to the same undersize class.
The undersizing performed, on the main journals or
crankpins, must be marked by punching on the side
of crank arm no. 1.
The undersize classes are:
0.254 — 0.508 mm.
TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS
5408
CRANKSHAFT
540810
Measuring main journals and
crank pins
Checking head mating surface on cylinder
block
On finding signs of seizure, scoring or excessive ovalization
on main journals and crankpins, it is necessary to regrind the
pins. Before grinding the pins (2), measure the shaft pins with
a micrometer (1) to establish to what diameter it is necessary
to decrease the pins.
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NOMINAL
VALUE
NOMINAL
VALUE
NOMINAL
VALUE
MINIMUM
∅
MAXIMUM
∅
MINIMUM
∅
MAXIMUM
∅
The crankcase can only be surfaced after making
sure that, on completing the work, the piston
protrudes from the cylinder liner by no more than
the prescribed value.
NOTE
It is advisable to enter the measurements in a table.
See Figure 77.
NOTE
NOTE
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