Iveco Daily. Manual

If any traces of seizing, scoring or excessive ovalitys are de-
tected on main journals and crank pins it is necessary to re-
grind journals (2), measure crank pins with micrometer (1)
in order to determine to which diameter pins must be re-
duced.

Undersize classes are of:
0.254 - 0.508 mm.

50709

Figure 67

5408

CRANKSHAFT

540810

Measuring main journals and con-
necting rods

44035

Figure 68

RATED
VALUE

MINIMUM Ø
MAXIMUM Ø

RATED
VALUE

TABLE ON WHICH MEASURED VALUES OF MAIN JOURNALS AND CRANK PINS OF CRANKSHAFT

MUST BE RECORDED

It is advisable to record measured values on a table.
See Figure 68.

NOTE

Main journals and crank pins must be all ground to
the same undersize.
The performed undersize, on main journal and
crank pins, must be identified by a special printing
applied on the side of crank arm n.1.
For undersized crank pins: letter M
For undersized main journals: letter B
For undersized crank pins and main journals: letter
MB

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

Figure 69

44034

MAIN DATA ON MAIN JOURNALS AND ON CRANKS PINS

CRANKCASE, VALVE GEAR SIDE

INTERMEDIATE CRANKCASES

CRANK PINS

CRANKCASE, FLYWHEEL SIDE

Bef

rollin

After rolling

Bef

rollin

Bef

rollin

Since when reducing by 0.254 or 0.508 mm crank pin
or main journal diameters, the rolled section of their
side grooves can be damaged, grooves shall be
turned according to data shown in the figure and
rolling shall be performed according to the following
specifications.
Rolling force:
- 1st main journal 925

± 25 daN

- 2nd - 3rd - 4th - 5th main journal 1850

± 50 daN

- 1st - 4th crank pin 1850

± 50 daN

- 2nd- 3rd crank pin 2040

± 50 daN

- rolling turns: 3 approaching, 12 actual, 3 output turns

- rolling speed: 56 rev/min

- crank pin groove depth reduction after rolling: 0.15

0.30 * mm

- main journal groove depth reduction after rolling: 0.15

÷ 0.35 * mm

* measured with 2.5 mm diameter gauged pins

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

45065

45066

Figure 70

Figure 71

CRANKSHAFT MAIN TOLERANCES

SYMMETRY OF MAIN JOURNALS AND CRANK PINS
1. Crank pins
2. Main Journals
3. Normal position.

Checking crankshaft

Once grinding is completed, observe the following notices:

- Round the burr edges of main journals and crank pins

lubricating holes;

- remove oil duct sealing plugs, reface seats with a suitable

miller to remove any calking, clean ducts accurately, fit
plugs using a suitable tool (1, Figure 72) and calk them
on the relevant seats;

- make sure the plugs do not show any leakage under an

inner pressure of 1.5 bars.

100

0,125

The checks of tolerances indicated in the figures
must be carried out after grinding crankshaft pins,
if necessary.

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

CHARACTERISTIC SUBJECT TO TOLERANCE

GRAPHIC SYMBOL

OF SHAPE

Circularity

○

OF SHAPE

Taper

OF ORIENTATION

Parallelism

OF ORIENTATION

Perpendicularity

⊥

OF POSITION

Concentricity

OF OSCILLATION

Circular oscillation

↗

OF OSCILLATION

Total oscillation

↗↗

CLASS OF IMPORTANCE ATTRIBUTED TO PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL

CRITICAL

IMPORTANT

⊕

SECONDARY

⊝

61712

61886

Figure 72

Figure 73

Replacing gearbox input shaft centering ring

Use puller 99348004 to remove drive shaft (3) gearbox input
shaft centering ring (2).
Use a generic tool for refitting.

Should timing gear toothing be damaged or worn, proceed
with removal as follows:

- mill gear (1) in the two points indicated by the arrows,

heat the gear to a temperature not exceeding 350

°C,

then take out the gear by extractor 99348001 (2) and
block (3).

To fit the new gear on the drive shaft, the gear shall be heated
so that

≥ 200 ºC temperature difference is present between

the two parts and gear keyhole shall coincide with shaft
spline.
After fitting, under 900 N load, gear must not be withdrawn
from shaft.

Replacing timing control gear

18569

18919

18920

Figure 74

Figure 75

Figure 76

By means of ring 99360508 (1) lift engine block (2) and
secure it on rotating stand 99322205 with clamps 99361029
(3).

Rotate engine block, fit oil spray nozzles (2) with the
respective safety plates and tighten screws with a torque
wrench (1) to specified torque.
Bend safety plates on screws.

Small end bearings (1) are supplied as spare parts, with an
undersized inside diameter of 0.254 - 0.508 mm.

Assembling main bearings

Put the main bearing shells (1) with the lubrication hole into
their respective seats.

When fitting the engine, replace always: safety spring rings,
sealing rings and gaskets.

ENGINE ASSEMBLY

Max. gear heating temperature is 350

°C.

NOTE

Having not found the need to replace small end
bearings, refit them in the same order and position
they were before being dismantled.

NOTE

Do not perform any adaptation on bearings.

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

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Iveco Daily. Manual - part 21