Iveco Daily. Manual — part 162
75393
75394
87794
88300
Figure 98
Figure 99
Figure 100
Figure 101
Remove the piston rings (1) from the piston (2) using pliers
99360183 (3).
Remove the piston (1) from the connecting rod, taking out
the piston ring (2) and extracting the pin (3).
MAIN DATA FOR MONDIAL PISTON, PINS AND PISTON RINGS
* The value is measured at 1.5 mm from the outer diameter
** The value of the diameter measured is 91.4 mm
Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance. The diameter has
to be measured at the value shown.
The clearance between the piston and cylinder liner can also
be checked using a feeler gauge (1) as illustrated in the figure.
87795
Figure 102
540840
Pistons
Measuring piston diameter
The pistons are supplied as spare parts with the
standard, normal and 0.4mm oversize diameters
together with rings, pin and retaining rings.
NOTE
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18857
74947
75397
16552
88301
41104
Figure 103
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Measuring the diameter of the piston pin (1) with a
micrometer (2).
Conditions for correct pin-piston coupling
Lubricate the pin (1) and its seat on the hubs of the piston
(2) with engine oil. The pin must go into the piston by lightly
pressing with the fingers and must not drop out by gravity.
The trapezoidal split rings (1
st
slot) and the oil scraper rings
(2
nd
slot) have the word TOP etched in them; when fitting
them on the piston, the word TOP must be facing upwards.
Check the thickness of the piston rings (2) with a micrometer
(1).
Check the clearance between the trapezoidal ring (2) (1
st
slot) and the associated slot on the piston with a feeler gauge
(1), proceeding as follows: insert the piston into the cylinder
liner so that the ring (2) comes approximately half way out
of it.
DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
1. Piston slot — 2. Trapezoidal piston ring —
3. Cylinder liner
Using a feeler gauge (1, Figure 107), check the clearance (X)
between the ring (2) and the slot (1); this clearance must
have the prescribed value.
540842
Piston rings
1
2
F1C ENGINE
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540841
Piston pins
- with a letter: O or X indicating the diameter class of the
big end mounted in production;
- with a number indicating the weight class of the
connecting rod mounted in production.
In addition, it could be stamped with the number of the
cylinder in which it is fitted.
In the event of replacement it is therefore necessary to
number the new connecting rod with the same number as
the one replaced.
The numbering must be done on the opposite side to the
bearing shell retaining slots.
The connecting rods are supplied as spare parts with the
diameter of the big end 67.833 — 67.848 mm marked with the
letter O and the weight class marked with the number 33.
It is not permissible to remove material.
75398
87796
75399
Figure 109
Figure 110
Figure 111
Figure 112
Check the clearance between the piston rings (2) of the 2
nd
and 3
rd
slot and the associated seats on the piston (3) with
a feeler gauge (1).
Check the opening between the ends of the piston rings (2)
inserted in the cylinder liner using a feeler gauge (1).
MAIN DATA OF THE CONNECTING ROD, BUSHING,
PISTON PIN AND BEARING SHELLS
*
Internal diameter to obtain after driving into the small
end and grinding with a reamer.
**
Dimension cannot be measured in the free state.
*** Thickness of the bearing shell supplied as a spare part.
540830
Connecting rods
Each connecting rod has its cap marked:
Check that the bush in the small end has not come loose and
shows no sign of seizure or scoring. If it does, replace the
complete connecting rod.
540834
Bushing
Checking connecting rods
61696
Check the alignment of the axes of the connecting rods (1)
with device 99395363 (5), proceeding as follows:
- Fit the connecting rod (1) on the spindle of the tool
99395363 (5) and lock it with the screw (4).
- Set the spindle (3) on the V-prisms, resting the
connecting rod (1) on the stop bar (2).
NOTE
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Figure 113
Etched on the top of the piston are: the type of engine (1),
class selection (2) and supplier (3) as well as the direction of
fitting the piston in the cylinder liner (4). The mark (5) is for
passing the 1
st
slot insert adhesion test.
87797
87798
Connect the piston (1) to the connecting rod (2) together
with its cap so that the piston assembly reference, position
of the connecting rod and of the cap are observed as shown
in the figure.
Position the piston (1) on the connecting rod, insert the pin
(3) and secure it with the split rings (2).
Assembling connecting rod-piston assembly
Check the torsion of the connecting rod (5) by comparing
two points (A and B) of the pin (3) on the horizontal plane
of the axis of the connecting rod.
Position the mount (1) of the dial gauge (2) so that this
pre-loads by approx. 0.5 mm on the pin (3) at point A and
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side B of the pin (3): the difference between A and
B must be no greater than 0.08 mm.
Checking torsion
61694
Checking bending
Check the bending of the connecting rod (5) by comparing
two points C and D of the pin (3) on the vertical plane of the
axis of the connecting rod.
Position the vertical mount (1) of the dial gauge (2) so that
this rests on the pin (3) at point C.
Swing the connecting rod backwards and forwards seeking
the highest position of the pin and in this condition zero the
dial gauge (2).
Shift the spindle with the connecting rod (5) and repeat the
check on the highest point on the opposite side D of the pin
(3). The difference between point C and point D must be no
greater than 0.08 mm.
61695
Figure 114
Figure 115
Figure 116
Figure 117
75394
F1C ENGINE
547
D
AILY
Base - May 2004
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