Iveco Daily. Manual — part 24
Figure 112
Figure 113
Figure 114
Figure 115
Checking for connecting rod - piston distortion
Assembling piston rings
41097
Fit piston rings (1) on piston (2), using pliers 99360183 (3).
Assembling connecting rod - piston assemblies
in cylinder barrels
18863
Lubricated pistons correctly, including piston rings and
cylinder liner interiors.
By means of ring clamp 99360605 (2) fit connecting
rod-piston assemblies (1) into cylinder liners, checking that:
- the number of each connecting rod corresponds to cap
fitting number.
1
2
45071
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO CYLINDER
1. Piston - 2. Accessory components group - 3. Number
printing area - A. Indirect injection engine piston
(prechamber) - *Piston crown cavity - B. Direct injection
engine piston
- piston ring openings are 120
° offset one another;
- all pistons are of same weight;
- the symbol printed on the piston crown is directed
towards flywheel, or the recess on the piston skirt
corresponds to the position of oil spray nozzles.
After assembling connecting rod-piston assembly, use tool
99395363 (8) to check squaring as follows:
- fit connecting rod (7) and piston (3) on tool 99395363
(8) chuck (4) and lock it by screw (5);
- set connecting rod (7) on bar (6);
- position dial gauge (2) support (1) so that dial gauge is
set on piston point A, with 0.5 mm preload and set dial
gauge (2) to zero;
- move chuck (4) so that dial gauge (2) is set on piston (3)
point B and check for any deviation.
61697
The piston rings for the 1
st
and 2
nd
slot must be
fitted with the word “TOP” facing upwards.
NOTE
Having not found any need to replace main
bearings, it is required to refit them in the same
order and position they were when dismantled.
NOTE
ENGINES 8140.43R/B/S/N
78
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AILY
Base - May 2004
Once
connecting
rods-pistons
assemblies
fitting
is
completed, check for piston (1) protrusion at T.D.C. with
respect to upper crankcase surface, with thickness gauge (3)
and calibrated rule (2).
In connection with measured protrusion, choose cylinder
head replacement gasket, according to the following table.
Cylinder head gasket thickness*
Check manually that connecting rods slide axially on
crankshaft pins.
~ 1.20
1.23
÷ 1.35
Piston average
protrusion
Fitted
Free
18534
18927
23598
Figure 116
Figure 117
Figure 118
To measure clearance carry out the following operations:
- clean carefully the parts and remove any oil traces;
- place a cut down size of calibrated wire (3) on crankshaft
pins (4).
- Fit connecting rod caps (2) with relevant half bearings.
- Remove cap (2) and determine existing clearance, by
comparing calibrated wire width (3, Figure 116) with
graduation of scale indicated on envelope (2, Figure 116)
containing such a wire. If a clearance other than the one
specified is found, replace half bearings and repeat check.
Once prescribed clearance is obtained, lubricate
connecting rod half bearings and fit them definitively by
tightening connecting rod caps fastening screws as
described.
- Tighten screws, previously lubricated with UTDM oil,
with torque wrench (1) to torque of 50 Nm + angle of
63
° ± 3°;
540831
Measuring connecting rod assembly
clearance
α
Checking piston protrusion
0.61
÷ 0.80
1.48
÷ 1.62
~ 1.40
0.40
÷ 0.60
1
2
4
3
1
2
The fitting of connecting rod cap of cylinder n. 4 is
practicable only when piston is at T.D.C.
NOTE
For angular closing use tool 99395216.
NOTE
Connecting rod caps fastening screws must be
replaced with new ones, when fitted definitively.
NOTE
* Thickness of cylinder head gasket is calculated on
the basis of maximum piston protrusion from the
crankcase measured on all four pistons.
The difference between minimum and maximum
protrusion of the four pistons should be equal to
or less than 0.200 mm.
The cylinder head gasket included in the engine
overhauling spare parts kit is
supplied in its
maximum size. Obviously, it can also be obtained
in other sizes, as required.
NOTE
ENGINES 8140.43R/B/S/N
79
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AILY
Base - May 2004
Apply tool 99360306 (3).
Tighten flywheel (1) fastening screws (2) in two stages:
- 1st stage: tightening with torque wrench to torque
30
± 3 Nm;
- 2nd stage: closing with 90
° ± 2° angle.
41134
41135
Figure 119
Figure 120
Figure 121
Make sure flywheel fastening screws (4) are slack.
Apply gauge 99395214 (3) to engine crankcase.
Rotate crankshaft so as to set piston (1) to T.D.C.
Rotate crankshaft in direction opposite to that of rotation of
~ 90° (89° 25’).
With the special dial gauge (2), determine exact balance
point of pistons of cylinders 1 and 2, operating as follows:
set to zero dial gauge (2) on piston of cylinder n.1;
move dial gauge so set to zero, on piston of cylinder n. 2 and
record deviation.
If no deviation is found, it means that pistons of cylinders 1
and 2 are perfectly balanced. In the opposite case, share out
halved value of measured deviation, by rotating crankshaft
conveniently.
Example:
- If deviation is in default, i.e.: 0.2 mm before zero setting point,
it is required to rotate crankshaft in opposite direction to that
of rotation, so that deviation is halved, that is, 0.1 mm.
- If deviation is in excess, i.e. 0.2 mm after zero setting point,
it is required to rotate crankshaft in its direction of rotation
of
~ 1/4 of turn, to recover crank mechanism clearances,
then invert rotation direction until deviation is halved, that is,
0.1 mm.
Once balance of pistons is so determined, without moving
crankshaft, direct flywheel in such a way that pin of tool
99395214 (3) is inserted into flywheel milling (
→).
Slightly tighten screws (4).
Remove tool 99395214.
Then tighten flywheel fastening screws (4) according to
procedures described in the following figure.
α
540850
Flywheel adjustment
41825
Rotate the engine, fit oil suction strainer (1), place sealing ring
(2) and fit oil sump.
The angle closing is performed with tool 99395216
(4).
NOTE
ENGINES 8140.43R/B/S/N
80
D
AILY
Base - May 2004
Measure camshaft pins (2) diameter with a micrometer (1),
and with an inside micrometer gauge the diameter of the hole
defined by the union of caps to the relevant supports on
cylinder head, that should be 0.035
÷ 0.081 mm. If not so,
replace concerned parts.
If it is necessary to replace the basin plugs on the ends of the
camshaft, use a suitable punch for removal - refitting.
Figure 122
Figure 123
Figure 124
Set tool 99361004 on adjustable support 99365014 and
secure cylinder head on said support.
Remove cover (3), unscrew camshaft (2) caps (1) fastening
nuts, remove caps and shaft.
18876
1
Checks
The surfaces of the shaft support pins and of the cams must
be ultra-smooth. If they show signs of seizure and scoring,
replace the shaft.
41112
MAIN DATA ON CAMSHAFT, RELEVANT SUPPORTS AND CAPS ON CYLINDER HEAD
* Normal diameter - ** 0.2 mm oversize diameter
18868
2
3
541210
Disassembling camshaft
To avoid bending the camshaft too much, loosen
the nuts fixing the caps (1) gradually and evenly.
NOTE
Before mounting the plugs, apply sealant on their
sealing surfaces.
NOTE
ENGINES 8140.43R/B/S/N
81
D
AILY
Base - May 2004
CYLINDER HEADS
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