Iveco Daily. Manual — part 23
Figure 95
41101
Measure piston diameter (1), with a micrometer (2), to
determine assembly clearance; measured diameter value
must be equal to that indicated in the table of page 43.
540840
Pistons
Measuring the pistons diameter
The clearance between piston and cylinder liner can be also
checked by means of a thickness gauge (1), as shown in this
figure.
Figure 96
41102
540841
Piston gudgeon pins
Lubricate pin (1) and the relevant seat on piston (2) hubs
with engine oil; piston must allow to be inserted with a slight
finger pressure and it should not come out by gravity.
41103
Figure 97
Figure 98
Conditions for correct pin-piston coupling
1
2
18857
Measurements of piston gudgeon pin diameter (1) with a
micrometer (2).
Spare pistons have standard diameter with 0.4 mm
oversize and include rings, pin and safety rings.
NOTE
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41105
16552
Figure 99
Figure 100
Check piston ring (2) thickness with a micrometer (1).
Check the clearance between the seal rings (2) of the 2
nd
and
3
rd
slot and the associated seats on the piston (3) with the
feeler gauge (1).
540842
Piston rings
41104
Figure 101
DIAGRAM FOR MEASURING THE CLEARANCE
BETWEEN THE FIRST PISTON SLOT AND THE
PISTON RING
1. 1
st
piston slot - 2. Piston ring - 3. Cylinder barrel
Using a feeler gauge (1, Figure 101) check the clearance (X)
between the ring (2) and the slot (1); this clearance must be
of the prescribed value.
1
2
74947
The piston rings (1
st
slot) and oil scraper rings (2
nd
slot) have
TOP etched on them: this should be facing upwards when
they are fitted on the piston.
Figure 102
74948
Checking the clearance between the V-ring (2) 1
st
slot and
the associated slot on the piston with a feeler gauge (1) as
follows. Insert the piston into the cylinder barrel so that the
ring (2) comes approximately half way out of it.
Figure 103
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18858
Figure 104
Checking, with a thickness gauge (1), the opening between
piston ring ends (2), introduced in cylinder liner.
1
2
Figure 105
540830
Connecting rods
49073
MAIN DATA FOR CONNECTING ROD, BUSHING,
PISTON PIN AND HALF BEARINGS
* Internal diameter to be obtained after driving into the
connecting rod small end and regrinding with reamer.
** Cannot be measured in free state.
• ∅ of the connected rod supplied as a spare
Connecting rods are marked as follows:
- body and cap with a number identifying the
coupling;
- Connecting rod cap with a letter: O or X identifying the
diameter class for connecting rod head mounted in
production;
- connecting rod cap with a number identifying the load
class for the connecting rod mounted in production;
- it could also be marked with the corresponding cylinder
number.
In case of replacement, the new connecting rod shall be
marked with the same numbers and letters as the old one.
Numbering shall be performed on the opposite side to half
bearing retaining slots.
Spare connecting rods are supplied with 60.341
÷ 60.348
head diameter marked with letter O and load class identified
with number 33.
Material removal is not admitted.
Make sure that bushing, in connecting rod small end, is not
loose and free from any scoring and traces of seizure,
otherwise replace it.
Dismantling and refitting are performed with a suitable
punch.
When driving, check accurately that oil flow holes, on bushing
and connecting rod small end, coincide.
With reamer reface bushing so as to obtain 32.010
÷ 32.020
mm diameter.
540834
Bushes
61696
Use tool 99395363 (5) to check connecting rod (1) axes
parallelism and proceed as follows:
- fit connecting rod (1) on tool 99395363 (5) chuck and
lock it by screw (4);
- set chuck (3) on V-prisms and rest connecting rod (1)
on stop bar (2).
Figure 106
Checking connecting rod for distortion
NOTE
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Etched on the top of the piston are, at reference (1): the type
of engine, selection of the class and supplier*; at reference
(2): the direction for fitting the piston in the cylinder barrel;
(3), mark on testing adhesion of 1
st
slot insert; at reference
(4): adhesive label with the numerical code for optical reading
of the type of engine and class selection.
45070
Fit piston (1) to connecting rod (2) so as piston assembly
reference and connecting rod numbers (3) can be seen as
shown in the figure.
Set piston (1) on connecting rod, fit pin (3) and secure it with
piston rings (2).
41840
Assembling connecting rod - piston assembly
Coupling connecting rod - pistons
Check connecting rod (5) torsion by comparing the two
piston pin (3) points (A and B) on connecting rod axis
horizontal surface.
Position dial gauge (2) support (1) so that dial gauge is
precharged by approx. 0.5 mm on piston pin (3) on point A
and set dial gauge (2) to zero. Move chuck (4) with
connecting rod (5) and compare the difference, if any, on the
opposite side (B) of piston pin (3): the difference between A
and B shall not exceed 0.08 mm.
61694
Checking bending
Check connecting rod (5) bending by comparing two piston
pin (3) points C and D on vertical connecting rod axis. Set dial
gauge (2) vertical support (1) on piston pin (3) point C.
Move connecting rod forward and backward searching the
highest piston pin position and set dial gauge (2) to zero when
finding this condition.
Move chuck and connecting rod (5) and repeat the above
operation on piston pin (3) point D. The difference between
points C and D shall not exceed 0.08 mm.
61695
Figure 107
Figure 108
Figure 109
Figure 110
Figure 111
41107
ENGINES 8140.43R/B/S/N
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Base - May 2004
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