Iveco Daily Euro 4. Manual - part 60

The measurements must be made for each single cylinder at
three different heights up the liner and on two planes at right
angles to each other: one parallel to the longitudinal axis of
the engine (B) and the perpendicular (A); the greatest wear
is generally found on this last plane with the first
measurement.
On finding ovalization, taper or wear, go ahead and
bore/grind and finish the face of the cylinder liners. The
refacing of the cylinder liners should be done in relation to
the diameter of the pistons supplied as spare parts oversized
by 0.4 mm of the nominal value and to the prescribed
assembly clearance.

18837

87781

Figure 118

Figure 119

Once the engine removal is complete, carefully clean the
cylinder block. For the cylinder block transportation use the
suitable rings.
Carefully check that the crankcase has no cracks in it.
Check the state of the plugs. If they are rusty or there is any
doubt about their seal, replace them. When fitting the caps
into place, apply Loctite 270 sealant (IVECO NO. 93162429)
to the same. Examine the surfaces of the cylinder liners; they
must show no sign of meshing, scoring, ovalization, taper or
excessive wear. The inside diameter of the cylinder liners is
checked, to ascertain the extent of ovalization, taper and
wear, using the bore meter 99395687 (1) fitted with a dial
gauge previously reset on the ring gauge of the diameter of
the cylinder liner or on a micrometer.

CYLINDER BLOCK
Checks and measurements

Figure 120

* Surface roughness parameters:

R1 =

÷ 10 μm

÷ 8 μm

0,3

÷ 0,6 μm

W1 <

μm

Permissible surface porosity for machined cylinder
(see Figure 121)
ZONE B1 = Area of greatest mechanical stress,

segment/liner

contact:

No.2

non-continuous

porosities

are

permissible max. 0.5x0.5.

ZONE B2 = Surface involved in segment rubbing:

No.2 non-contiguous porosities are
permissible max. 1x0.8.

100%

87782

Figure 121

87783

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For undersized crankpins, letter M.
For undersized main journals, letter B.
For undersized crankpins and main journals, letter MB.

See that the head mating surface, on the cylinder block, has
no deformation.
This check can be made, after taking out the grub screws (3),
with a surface plate spread with carbon black or with a
calibrated rule (1) and a feeler gauge (2). After ascertaining
the areas of deformation, level the bearing surface with a
grinding machine.

88290

Figure 122

Figure 123

87784

Figure 124

The main journals and crankpins must always be
ground to the same undersize class.
The undersizing performed, on the main journals or
crankpins, must be marked by punching on the side
of crank arm no. 1.

TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS

5408

CRANKSHAFT

540810

Measuring main journals and crank
pins

Checking head mating surface on cylinder
block

On finding signs of seizure, scoring or excessive ovalization
on main journals and crankpins, it is necessary to regrind the
pins. Before grinding the pins (2), measure the shaft pins with
a micrometer (1) to establish to what diameter it is necessary
to decrease the pins.

75298

The crankcase can only be surfaced after making
sure that, on completing the work, the piston
protrudes from the cylinder liner by no more than
the prescribed value.

It is advisable to enter the measurements in a table.
See Figure 123.

NOTE

NOMINAL

VALUE

NOMINAL

VALUE

NOMINAL

VALUE

∅ MIN

∅ MAX

∅ MIN

∅ MAX

The undersize classes are:
0.254 — 0.508 mm.

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87785

87786

Figure 125

Figure 126

MAIN CRANKSHAFT TOLERANCES

SYMMETRY

BETWEEN

MAIN

JOURNALS

AND

CRANKPINS
1.

Crankpins

Main journals

Normal position

Checking crankshaft

After grinding, keep to the following:

- Round off the edges of deburring the holes for

lubrication of the main journals and crankpins.

The checks on the tolerances indicated in the
figures must be made after grinding the crankshaft
pins.

NOTE

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TOLERANCE CHARACTERISTIC

GRAPHIC SYMBOL

SHAPE

Circularity

○

SHAPE

Cylindricality

ORIENTATION

Parallelism

ORIENTATION

Perpendicularity

⊥

POSITION

Concentricity or coaxiality

OSCILLATION

Circular oscillation

↗

OSCILLATION

Total oscillation

↗↗

CLASS OF IMPORTANCE ATTRIBUTED TO PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL

CRITICAL

IMPORTANT

⊕

SECONDARY

⊝

87787

87789

87788

87790

87791

Figure 127

Figure 128

Figure 129

Figure 130

Figure 131

INTERMEDIATE JOURNALS NO. 2-4

INTERMEDIATE JOURNAL NO. 3

CRANKPINS

As far as both values are concerned, for the whole 360

°.

- Rolling turns: 3 approach, 12 effective, 3 out.

- Rolling speed: 56 rpm.

- Reduction of the connecting rod pin slot diameter after

rolling: 0.15

÷ 0.30 mm*.

- Reduction of the journal slots after rolling: 0.15

÷ 0.30

mm.

* Measured with calibrated rollers

∅ 2.5 mm.

JOURNAL ON TIMING SYSTEM SIDE

JOURNAL ON FLYWHEEL SIDE

MAIN DATA OF MAIN JOURNALS AND CRANKPINS

Since, during the 0.254 and 0.508 mm undersizing
on the diameter of the crankpins and main journals,
the rolled portion of the side races of the pins may
get involved, it is necessary to turn the races
keeping to the data given in the figure and to do the
rolling keeping to the following instructions.

Rolling force:

- 1

main journal 925

±25 daN.

- 2

— 3

— 4

— 5

main journal 1850

±50 daN.

- crankpin 1850

±50 daN.

NOTE

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