Iveco Daily. Manual — part 20
23022
Remove lower crankcase (1) with its gasket.
18833
Unscrew lower/upper crankcase fastening screws (1) using
wrench (2).
1
23023
Remove crankshaft (1) using a hoist and a suitable rope.
19183
Recover main half bearings (2).
Straighten safety plate bends and remove oil spray nozzles
(1).
50668
Figure 53
Remove the crankshaft rear cover (1) from the crankcase,
complete with oil seal.
Figure 54
Figure 55
Figure 56
Figure 57
At removal, take note of the assembling position of
lower and upper crankshaft half bearings since if re-
used they shall be refitted in the same position.
NOTE
ENGINES 8140.43R/B/S/N
62
D
AILY
Base - May 2004
Measurements shall be taken for each cylinder, at three
different heights on the barrel and on two perpendicular
surfaces: the first one parallel to engine longitudinal axis (A)
and the other one perpendicular (B); max. wear is generally
found on this latter surface and in correspondence with the
first measurement.
Bore/recondition and plateau finish by honing cylinder barrels
if ovalization, excessive taper or any sign of wear are found.
Cylinder barrel reboring shall be performed according to the
diameter of spare pistons oversized by 0.4 mm of rated value
and prescribed assembling clearance. Should cylinder barrel
be bored to higher diameter, oversize shall be performed by
fitting a spare cylinder barrel and proceeding as described in
the relevant chapter.
18836
18837
61689
Figure 58
Figure 59
Once engine is dismantled, clean cylinder-crankcase group
accurately.
For handling cylinder group use rings 99365508.
Make sure crankcase has no cracks.
Check working plug conditions. If rusted or not perfectly
tightening, replace them.
Check cylinder liner surfaces: they should not show any
traces of binding, scoring, ovality or excessive taper.
The inside diameter of the cylinder liners, in order to
ascertain the extent of their ovalization, taper and wear, is
checked with the bore gauge 99395687 (1) fitted with the
dial gauge and reset on the ring gauge (2) of the diameter of
the cylinder liner.
With reaming gauge 99395687 (1), equipped with centesimal
comparator set to zero as previously described, check cylin-
der liner inside diameter, to verify the degree of ovality, taper
and wear.
REPAIR OPERATIONS
CYLINDER BLOCK
Checks and measurements
1
st
measurement
2
nd
measurement
3
rd
measurement
62067
Figure 60
A - B =
Main bearing longitudinal axis
*
Surface roughness parameters
R1 =
4
÷ 10 µm
Rz =
3
÷ 8 µm
Ra =
0.3
÷ 0.6 µm
W1 <
2
µm
Admitted surface pores with machined cylinder
ZONE B1 = max. stress area between piston
ring/barrel: two non-continuos pores,
max. 0.5 x 0.5 admitted
ZONE B2 = area interested by piston ring sliding:
two non-contiguous pores, max
1x0.8 admitted
C
C
100%
100%
D
If ring gauge is not available use a micrometer to set
to zero.
NOTE
ENGINES 8140.43R/B/S/N
63
D
AILY
Base - May 2004
When levelling is over, reset cylinder barrel spot-facing and
bevelling as shown in the figure.
Check main bearing housings as follows:
- Fit lower crankcase on upper crankcase, without
bearings and gaskets;
- tighten fastening screws to specified torque;
- with a suitable inside diameter comparator, make sure
the seat diameter is equal to specified value.
If a greater value is found, replace crankcase.
Make sure mating surface, on cylinder block, does not show
any deformations.
This check can be done, after removing setscrews (1), with
a soot-coated surface plate or with a gauged rule (2) and
thickness gauge (3).
Once deformation areas are detected, flatten supporting sur-
face with a grinder.
18839
Figure 61
1
2
3
Figure 62
Spare cylinder barrel assembling
61688
B = Main bearing longitudinal axis
Figure 63
62068
SECTION A-A
*
Engine block surface
** Spot-faced surface Ø 111
Implement cylinder barrel seats into engine block by boring the latter
at the values shown in the above figure, so as to obtain the average
diameter measured according the methods described in the following
B
Crankcase flattening can be performed only after
being sure that, once the work is completed, piston
protrusion from cylinder liner will not be greater
than specified value.
NOTE
WT = 10 - PITCH 5
0,
4
÷
1
ENGINES 8140.43R/B/S/N
64
D
AILY
Base - May 2004
61690
Measurements shall be performed for every four barrel seats
at three different heights and on two perpendicular surfaces:
the first one parallel to engine longitudinal axis (A) and the
other one perpendicular (B) as shown in the diagram.
Average diameter D
1
med shall be calculated according to
the following formula:
D
1
med
=
A
1
(10)
+ A
1
(50)
+ A
1
(142)
+ B
1
(10)
+ B
1
(50)
+ B
1
(142)
6
It shall be
, the difference between max diam-
eter D
max
and min. diameter Dmin shall be: D
max
- D
min
=
≤ 0.03 mm
After implementing the proper seats, barrel fitting into
cylinder unit shall be performed by hydraulic press and plate
as follows:
- Check whether cylinder barrel outside diameter is equal
to the prescribed value.
Avoid using oil or grease when driving barrels;
- set barrel into block and check whether at 80 mm driving
the load is
≥ 1300 daN;
- proceed with driving and check whether load is
≥ 5000
daN when driving is over;
Figure 64
1
st
measurement
2
nd
measurement
3
rd
measurement
- to prevent breakage, check whether barrel edge is
perfectly resting on block:
cylinder barrel shall not protrude by 0.005 above block
bottom.
Otherwise, replace the cylinder barrol.
After driving in the cylinder liners, machine them to the
tolerance and roughness indicated in the “Checks and
measurements” section.
Figure 65
62069
Figure 66
20767
* engine block surface - ** spot-faced surface Ø 111 mm
SECTION A-A
97.500
− 0.05
+ 0.11
Value between brackets corresponds to the
measurement point from upper block edge.
NOTE
WT = 10 - PITCH 5
ENGINES 8140.43R/B/S/N
65
D
AILY
Base - May 2004
97.390
÷ 97.450
Y = barrel outside
∅
97.470
÷ 97.500
Z = barrel inside
∅
92.700
÷ 92.900
£
94.402
÷ 94.432
*
Dimension to be obtained after driving the liner into the
crankcase at the end of the work.
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