Iveco Daily. Manual — part 161
87792
75306
88345
90064
Figure 82
Figure 83
Figure 84
Figure 85
Take out the screws (4) and replace the phonic wheel (3).
The screws (4) are coated with LOCTITE 218 and must be
replaced with fresh ones after each disassembly.
They must be tightened to a torque of 10
± 1 Nm.
Replacing timing control gear
On finding the timing control gear teeth (1) damaged or
worn, remove them from the crankshaft (2) using a suitable
extractor.
The new gear is fitted onto the crankshaft by heating it to a
temperature of 180
°C for no longer than 15 minutes.
On completing assembly and after the gear has cooled, it
must withstand a torque of 150 Nm without slipping.
ENGINE ASSEMBLY
The following parts must be replaced with new ones at the
time of assembly: retaining rings, seals and gaskets, screws
whose thread is coated with sealant.
Fit on the oil spray nozzles (2) and tighten the couplings (1)
to the prescribed torque.
The main bearings (1) are supplied as spare parts undersized
on the inside diameter by 0.254
÷ 0.508 mm.
540811
Measuring main journal assembly
clearance
Mount the crankshaft (1).
Check the clearance between the crankshaft main journals
and their respective bearings by proceeding as follows:
- Thoroughly clean the pins.
- Apply a calibrated wire onto the main journals.
Not having found it necessary to replace the main
bearings, they need to be fitted back on in the same
sequence and position found upon disassembly.
Do not do any accommodating on the bearings.
Assembling main bearings
Thoroughly clean the top main bearing shells (1) and position
them in the crankcase.
The middle half ring (2) is fitted with thrust washers.
NOTE
NOTE
NOTE
540
F1C ENGINE
D
AILY
Base - May 2004
88289
88292
75310
88293
Figure 86
Figure 87
Figure 88
Thoroughly clean the bottom main bearing shells (2) and
mount them in the crankcase base (1).
Mount the crankcase base (12).
Tighten the screws in the sequence shown in the figure in
three steps:
- Step 1: with a torque wrench, to a torque of 50 Nm.
- Step 2: closing to an angle of 60
°.
- Step 3: closing to an angle of 60
°.
The end float is checked by setting a dial gauge (2) with a
magnetic base on the crankshaft (1) as shown in the figure.
The normal assembly clearance is 0.060 — 0.310 mm.
If you find the clearance to be greater than as required,
replace the rear main bearing shells carrying the thrust
bearings and repeat the clearance check between the
crankshaft pins and the main bearing shells.
If the end float of the crankshaft does not come within the
prescribed values, it is necessary to grind the crankshaft and
accordingly change the main bearing shells.
NOTE: The middle main bearing has half thrust washers
integrated in it, so it performs the function of a thrust bearing.
It is supplied as a spare part only with the normal shoulder
thickness.
α
Figure 89
- Remove the bottom crankcase.
The clearance between the main bearings and their
associated pins is measured by comparing the length of the
calibrated wire (1), at the point of greatest crushing, with the
graduated scale on the casing containing the calibrated wire.
The numbers on the scale indicate the clearance of the
coupling in millimetres, which must be 0.032
÷ 0.102 mm.
If the clearance is not as prescribed, replace the bearings and
repeat the check.
Then tighten the outer screws to torque 26 Nm.
Use tool 99395216 (11) for the angle closing.
NOTE
Checking crankshaft end float
F1C ENGINE
541
D
AILY
Base - May 2004
88294
88292
88296
88297
Figure 90
Figure 91
Figure 92
Figure 93
Thoroughly clean the crankcase / crankcase base mating
surface.
Apply, on base, sealant LOCTITE 510 IVECO no. 93162432,
as indicated in the scheme. The sealant must result to be
even, not patchy.
Mount the crankcase base (12) and tighten the fixing screws
in three stages, following the sequence shown in the figure:
- Step 1: with a torque wrench, to a torque of 50 Nm.
- Step 2: closing to an angle of 60
°.
- Step 3: closing to an angle of 60
°.
Then tighten the outer screws (1) to a torque of 26 — 30 Nm.
Carefully clean the seal seat.
Lubricate the rear shank of the crankshaft with engine oil.
Fit part (2) of tool 99346259 onto the rear shank of the
crankshaft; secure it with the screws (3) and key the fresh seal
(1) onto it.
Position part (4) on part (2); screw down the nut (5) to fit
the seal (1) fully inside the crankcase.
Mount the crankcase base within 10 minutes of
applying the sealant.
α
Use tool 99395216 (11) for the angle closing.
540460
Assembling rear seal
NOTE
NOTE
542
F1C ENGINE
D
AILY
Base - May 2004
88054
88298
88299
75392
Figure 94
Figure 95
Figure 96
Figure 97
Double-mass engine flywheel, one integral with the drive
shaft and one with the input shaft of the gearbox and in
between a torsion elastic dampening system.
The advantages of this type of flywheel compared to the
normal one are:
- Dampening of engine irregularities transmitted to the
gearbox and resulting drive noise reduction;
- Noise reduction in the cabin as a result of the overall
noise reduction.
Check the clutch disc mating surface, if there are too many
scratches, change the engine flywheel (3).
Check conditions of the teeth of crown wheel (1); where
excessive cracking or wear is found, replace engine flywheel.
Position the metal sheet guard (3) on the cylinder block.
Mount the engine flywheel (1) and screw down the screws (2).
Fit tool 99360351 (4) onto the crankcase to block rotation
of the engine flywheel (1).
Tighten the screws (2) fixing the engine flywheel (3) in two
steps:
- Step 1: with a torque wrench, to a torque of 30 Nm.
- Step 2: closing to an angle of 90
°.
5408
CONNECTING ROD — PISTON
ASSEMBLY
PISTON — CONNECTING ROD ASSEMBLY
1. Piston — 2. Piston ring — 3. Pin — 4. Trapezoidal ring —
5. Oil scraper ring — 6. Slotted oil scraper ring with spiral
spring — 7. Connecting rod body — 8. Bearing shells —
9. Connecting rod cap — 10. Cap fixing screws.
Check the pistons. They must show no signs of seizure,
scoring, cracking or excessive wear; replace them if they do.
α
Take off tool 99360351 (4).
Use tool 99395216 (1) for the angle closing.
NOTE
540852
Replacing bearing supporting gear-
box input shaft
The bearing (2) supporting the gearbox input shaft is
removed and fitted using a general-purpose drift.
Revi - February 2005
F1C ENGINE
543
D
AILY
ENGINE FLYWHEEL
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