Iveco Daily. Manual

75283

75284

75285

75286

Figure 64

Figure 65

Figure 66

Figure 67

Take out the screws (2), (3), (4) and (5) and remove the
suction strainer (1) together with the pipe (6).

Take out the screws (2) and remove the connecting rod caps
(3).
Extract the pistons (1) from the top of the crankcase.

Block rotation of the flywheel (1) with tool 99360306 (3).
Take out the screws (2) and remove the engine flywheel (1).
Take out the screw (5) and remove the guard (4).

Apply tool 99340058 (2) to the rear O-ring (1) and extract
it from the crankcase.

On the same side of the connecting rod and its
associated cap, indicate the number of the cylinder
from which the connecting rod has been removed.
Keep the bearing shells in their respective housings
since, if they are used, they will need to be fitted in
the position found during removal.

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75287

75289

75288

75290

Figure 68

Figure 69

Figure 70

Figure 71

Using an appropriate wrench and a hex-fluted wrench,
unscrew the screws (1) and (2) and remove the crankcase
base (3).

With the aid of a hoist and a rope, remove the crankshaft (1).

Take out the couplings (1) and remove the oil jets (2).

The central half ring (3) is fitted with thrust half-washers.

Note the assembly position of the bottom main
bearing shells (2) since, if they are reused, they will
need to be fitted in the position found during
removal.

NOTE

Note the assembly position of the top main bearing
shells (2) since, if they are reused, they will need to
be fitted in the position found during removal.

NOTE

On completing engine removal, it is necessary to
clean the removed parts thoroughly and check
their integrity.
The following pages give the instructions for the
main checks and measurements to make in order
to determine whether the parts can be reused.

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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

75292

Figure 72

Figure 73

After

removing

the

engine,

thoroughly

clean

the

cylinder-crankcase assembly. Use the rings 99365508 to
carry the cylinder block.
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. 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.

REPAIRS
CYLINDER BLOCK
Checks and measurements

Figure 74

* Surface roughness parameters:

÷ 10 µm

÷ 8 µm

0.25

÷ 0.6 µm

Wt <

1.5

µm

Permissible surface porosity for machined cylinder
(see Figure 75)

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%

75293

Figure 75

measurement

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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.

75296

Figure 76

Figure 77

75297

Figure 78

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.

The undersize classes are:
0.254 — 0.508 mm.

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

NOMINAL

VALUE

NOMINAL

VALUE

NOMINAL

VALUE

MINIMUM

∅

MAXIMUM

∅

MINIMUM

∅

MAXIMUM

∅

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.

NOTE

It is advisable to enter the measurements in a table.
See Figure 77.

NOTE

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Content .. 90 91 92 93 ..

Iveco Daily. Manual - part 92