Iveco EuroCargo (12 to 26 t). Manual — part 18
DIAGRAM FOR TIGHTENING THE REAR TIMING
GEAR CASE FASTENING SCREWS
Refit the case (1) to the engine block.
Screw the fastening screws in the same position found at
removal and tighten them to the following torque values in
the sequence shown in the figure:
Screws M12
65 - 89 Nm
Screws M8
20 - 28 Nm
Screws M10
42 - 52 Nm
IVECO N. 2992545 SEALANT APPLICATION AREAS
Clean accurately the timing gear case (1) and the engine
block.
Perfect seal is only obtained by cleaning accurately the
surface to seal.
Smear the case with IVECO N. 2992545 to obtain a bead of
few mm diameter.
It shall be uniform (no clots), without air bubbles, thin areas
or discontinuities.
Any imperfection shall be corrected as soon as possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides and cause
lubricant passage clogging.
After applying the sealant, the joint shall be assembled
immediately (10 — 20 minutes).
70207
70208
70209
70210
Figure 99
Figure 100
Figure 101
Figure 102
If a different clearance value is found, replace the half bearings
and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
Once connecting rod-piston assemblies refitting is over, use
dial gauge 99395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Protrusion shall be 0.28 — 0.52 mm.
!
Before the final fitting of the connecting rod cap
fastening
screws,
check
that
their
diameter
measured at the centre of the thread length is not
< 0.1 mm than the diameter measured at approx. 10
mm from screw end.
Check manually that the connecting rods (1) are sliding
axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.10 — 0.33 mm..
Checking piston protrusion
Timing gear case
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ENGINE F4 AE 0481
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70211
70213
70212
70214
70215
Figure 103
Figure 104
Figure 105
Figure 106
Figure 107
Use a felt pen to mark the driving gear (1) tooth fitted on the
output shaft (2) having the mark (
→) for timing on the side
surface.
Direct the output shaft (4) and the camshaft (2) so that when
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding.
Tighten the screws (1) fastening gear (2) to camshaft (3) to the
specified torque.
IVECO N. 2992545 SEALANT APPLICATION AREAS
Clean accurately the flywheel housing (1) and timing gear case
coupling surfaces.
Perfect seal is only obtained by cleaning accurately the surface
to seal.
Smear housing (1) with IVECO N. 2992545 to obtain a bead
of few mm diameter.
It shall be uniform (no clots), without air bubbles, thin areas
or discontinuities.
Any imperfection shall be corrected as soon as possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides and cause
lubricant passage clogging.
After applying the sealant, the joint shall be assembled
immediately (10 — 20 minutes).
SEQUENCE FOR TIGHTENING THE FLYWHEEL
HOUSING FASTENING SCREWS
Refit the housing (1) to the engine block and screw the
fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
shown in the figure:
Screws M12
75 - 95 Nm
Screws M10
44 - 53 Nm
Timing
540460
Flywheel housing
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ENGINE F4 AE 0481
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Base - February 2003
Apply tool 99346253 part (5) to the rear output shaft tang (6),
secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).
70216
70217
70152
70218
70219
Figure 108
Figure 109
Figure 110
Figure 111
Figure 112
Check clutch plate supporting surface and turn it if scored.
540853
Replacing engine flywheel ring gear
Check ring gear teeth (2), if breakage or excessive wear is
found remove the ring gear from the engine flywheel (1, Figure
109) using a generic beater and fit the new one, previously
heated to 150
°C for 15 — 20 minutes. Chamfering on ring gear
inside diameter shall be facing the engine flywheel.
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
hoister.
Tighten the screws (4) fastening the engine flywheel (3) to the
output shaft. Apply tool 99360351 (2) to the flywheel housing
(1) to stop engine flywheel (3) rotation.
Tighten engine flywheel (2) fastening screws (1) in two stages:
- 1
st
stage, tightening to 30
± 4 Nm torque with
dynamometric wrench;
- 2
nd
stage, tightening to 60
° ± 5° angle.
540850
ENGINE FLYWHEEL
!
Engine flywheel rated thickness is 49.6
± 0.13 mm.
α
!
Tightening to angle is performed using tool
99395216.
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ENGINE F4 AE 0481
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Apply tool 99346252 part (5) to the front output shaft tang
(6), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into front cover (7).
70220
70222
70221
70223
70224
70225
Figure 113
Figure 114
Figure 115
Figure 116
Figure 117
Figure 118
Fit the oil pump (1).
Tighten the fastening screws (2) to the specified torque.
Apply a new sealing ring (2) to the water pump (1).
Fit the water pump (1).
Tighten the screws (2) to the specified torque.
Remove the sealing ring (2) from the front cover (1), clean
accurately the coupling surfaces and smear them with IVECO
N. 2992545.
Clean accurately the front cover (2) surface and refit it.
Tighten the screws (1) to the specified torque.
r
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ENGINE F4 AE 0481
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Base - February 2003
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