Iveco Daily. Manual — part 72
The check of mating surface of the head (1) to cylinder group
is performed by means of a rule (2) and a thickness gauge (3).
If a deformation is found, measure cylinder head thickness,
whose rated value is 150
± 0.1 mm.
When checking, if the amount of material to be removed for
flattening cylinder head is greater than 0.4 mm, replace
cylinder head.
If the amount of material to be removed is within 0.2 mm
there is no need to dismantle combustion prechamber plugs,
otherwise proceed as stated in the following figure.
Checking cylinder head mating surface
SECTION F-F
1. Glow plug - 2. Injector seat - 3. Combustion
prechamber plug
49074
18879
49076
49075
Figure 46
Figure 47
Figure 48
Figure 49
F
F
MAIN DATA - VALVE SEATS
Intake
Exhaust
(REFERENCE DIA.)
(REFERENCE DIA.)
Ø 34.8
Ø 40.9
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Precombustion chamber (1) plugs driving is carried out with
tool 99360356 (2), making their centring balls (
←) coincide
with the milling (
→) of relevant seat on cylinder heads.
After cylinder heads regrinding, with material removal of
more than 0.2 mm thickness, measure with dial gauge (1) the
depth Y of pre-combustion chamber seats.
According to the class of the pre-combustion chambers,
shown in the previous figure, restore depth Y of respective
seats, to the corresponding classes listed here below:
depth Y
mm
Class
A
4.480
÷ 4.505
B
4.505
÷ 4.530
C
4.530
÷ 4.555
Precombustion chambers (1) are subdivided into classes
according to base thickness X and selected as follows:
Should it be required to replace one or more precombustion
chambers (1) (being not necessary to regrind respective seats
on cylinder heads), measure thickness X of their base to fit
the new part of same class and in the same order found upon
dismantling.
Class
A
4.500
÷ 4.520
B
4.520
÷ 4.540
C
4.540
÷ 4.560
X mm
Assembly
41802
52219
41803
52189
Figure 50
Figure 51
Figure 52
Figure 53
Number the pre-combustion chambers (3) in order to refit
them in the same order of disassembly and remove them
from the cylinder head (1) taking special care with a suitable
punch (2).
PRECOMBUSTION CHAMBERS
Disassembly
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Check the efficiency of each single glow plug (2) by
connecting the two tester terminals (1) to glow plug
terminals and verify its continuity, otherwise replace glow
plug.
Assembly
Fit incandescence plugs to the cylinder head and tighten them
to a torque of 15
÷ 1 Nm (1.5 ÷ 0,1 kgm).
Checking glow plugs continuity
Remove glow plugs (1) from cylinder heads.
52220
41807
Figure 54
Figure 55
Figure 56
Figure 57
GLOW PLUGS
Disassembly
50681
LUBRICATION
543110
Heat exchanger
On supplying heat exchanger (1) with air at 1 bar pressure,
verify that no leaks exist from oil flow side (2) and also from
water flow side.
Test conditions:
Oil type
SAE 30
Oil temperature at heat exchanger inlet
115
°C
Oil delivery
30 litres/minute
Water temperature at heat exchanger inlet
85
°C
Water delivery
20 litres/minute
PERFORMANCE
Exchanged heat quantity
5.0 kW
Oil pressure drop
0.85 bar
Built-in safety valve (2)
Opening pressure
0.82
÷ 1.03 bars
10-element heat exchanger
52222
Screw the injectors (1) into the cylinder head and, with the
right wrench, tighten them to the required torque.
Fit the glow plugs (2) and electric cable (4), and tighten the
fixing nuts (3) to the required torque.
Re-check continuity after fitting glow plugs, since
deforming effect, due to assembly pressure, may
cause the interruption of said continuity
NOTE
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52614
Figure 58
OIL VAPOUR FULL RÉCIRCULATION SYSTEM DIAGRAM (8140.63 engine)
1. Suction conveyer - 2. Flow relief valve - 3. Delivery pipe - 4. Oil vapour outlet pipe -
5. Oil vapour condenser - 6. Oil drainage pipe - 7. Crankcase
The vapours that develop in the sump during engine
operation, are collected in a condenser (5).
A portion of such vapours condense and, through pipe (6),
return in the sump, while the remaining portion, through pipe
(3) is sucked by engine and burnt.
The flow of vapours sucked by engine, is controlled by a relief
valve (2).
2
7
1
3
4
5
6
This valve, applied on pipe (3) in proximity to suction
conveyer (1), limits the flow of vapours, by choking flowing
section according to the vacuum existing in suction pipe.
In this way most of the vapours will return in the sump.
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Oil vapour full recirculation system (Blow-by)
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