Iveco Daily. Manual — part 163
Figure 118
Figure 119
Figure 120
Figure 121
Checking for connecting rod — piston distortion
Assembling piston rings
Fit the piston rings (1) on the piston (2) using the pliers
99360183 (3).
Assembling connecting rod — piston assemblies
in cylinder barrels
88302
Lubricate the pistons well, including the piston rings and the
inside of the cylinder liners.
With the aid of the clamp 99360605 (2), fit the connecting
rod — piston assembly (1) in the cylinder liners, checking that:
- The number of each connecting rod corresponds to the
cap mating number.
- 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.
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.
After fitting the connecting rod — piston assembly together,
check for distortion with the tool 99395363 (8) as follows:
- Fit the connecting rod (7) together with the piston (3)
on the spindle (4) of tool 99395363 (8) and lock it with
the screw (5).
- Rest the connecting rod (7) on the bar (6).
- Position the mount (1) of the dial gauge (2) so that this
is positioned at point A of the piston with a pre-load of
0.5 mm and zero the dial gauge (2).
- Shift the spindle (4) so as to position the dial gauge (2)
at point B of the piston (3) and check for any deviation.
75403
41097
540831
Measuring crankpin assembly
clearance
88303
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).
The 1
st
and 2
nd
slot rings need to be mounted with
the word ”TOP” facing upwards.
NOTE
NOTE
548
F1C ENGINE
D
AILY
Base - May 2004
88326
88327
88285
Figure 122
Figure 123
Figure 124
Mount the suction strainer (1) together with the pipe.
Screw down the fixing screws (2) and tighten them to the
prescribed torque.
α
- Fit the connecting rod caps (3) with the associated
bearing shells.
- Tighten the screws (2) in two steps:
-
Step 1: with a torque wrench, to a torque of 50 Nm.
-
Step 2: closing to an angle of 70
°.
- Remove the cap (3) and determine the existing
clearance by comparing the width of the calibrated wire
(3, Figure 121) with the graduated scale on the case (2,
Figure 121) 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.
Checking piston protrusion
At the end of the connecting rod-piston assembly refitting,
check the piston protrusion (2) at the T.D.C. compared to
the top level of the cylinder block by means of a dial gauge
(1) and relevant base 99370415.
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
F1C ENGINE
549
D
AILY
Base - May 2004
88329
88328
75412
88426
Figure 125
Figure 126
Figure 127
Figure 128
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.
Apply the support SP. 2271 (5) on the cylinder head and
tighten the support in a vice.
Remove the brackets (6) for lifting the engine.
Remove the sensors (1 and 2), if needed.
Take out the screws (3) 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
Disassembling valves
Remove the intake (1) and exhaust (2) valves.
Before removing the valves from the cylinder
heads, number the valves in order to refit them
correctly if they are not changed.
A = intake side — S = exhaust side
NOTE
550
F1C ENGINE
D
AILY
Base - May 2004
2,25+07.5’
5,985
6,000
5,975
5,990
O30,8
32,3
32,5
60 +7.5’
88331
87799
18625
18882
Figure 129
Figure 130
Figure 131
Figure 132
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
Use a micrometer (2) to measure the valve stem (1): it must
have the value shown in Figure 132. If necessary, grind the
valve seats by means of the grinding machine 99305018, and
remove as little 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
EXHAUST
VALVE
INTAKE
VALVE
F1C ENGINE
551
D
AILY
Base - May 2004
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