Iveco Daily. Manual

Figure 118

Figure 119

Figure 120

Figure 121

Checking for connecting rod — piston distortion

Assembling piston rings

Fit the piston rings (1) on the piston (2) using the pliers
99360183 (3).

Assembling connecting rod — piston assemblies
in cylinder barrels

88302

Lubricate the pistons well, including the piston rings and the
inside of the cylinder liners.
With the aid of the clamp 99360605 (2), fit the connecting
rod — piston assembly (1) in the cylinder liners, checking that:

- The number of each connecting rod corresponds to the

cap mating number.

- The openings of the piston rings are staggered 120

° apart.

- The pistons are all of the same weight.

- The symbol punched on the top of the pistons faces the

engine flywheel, or the recess in the skirt of the pistons
tallies with the oil spray nozzles.

Not finding it necessary to replace the connecting
rod bearings, you need to fit them back in exactly the
same sequence and position found on disassembly.

After fitting the connecting rod — piston assembly together,
check for distortion with the tool 99395363 (8) as follows:

- Fit the connecting rod (7) together with the piston (3)

on the spindle (4) of tool 99395363 (8) and lock it with
the screw (5).

- Rest the connecting rod (7) on the bar (6).

- Position the mount (1) of the dial gauge (2) so that this

is positioned at point A of the piston with a pre-load of
0.5 mm and zero the dial gauge (2).

- Shift the spindle (4) so as to position the dial gauge (2)

at point B of the piston (3) and check for any deviation.

75403

41097

540831

Measuring crankpin assembly
clearance

88303

To measure the clearance, carry out the following steps:
- Thoroughly clean parts (1) and (4) and eliminate all

traces of oil.

- Place a length of calibrated wire (3) on the crankshaft

pins (4).

The 1

and 2

slot rings need to be mounted with

the word ”TOP” facing upwards.

NOTE

548

F1C ENGINE

AILY

Base - May 2004

88326

88327

88285

Figure 122

Figure 123

Figure 124

Mount the suction strainer (1) together with the pipe.
Screw down the fixing screws (2) and tighten them to the
prescribed torque.

- Fit the connecting rod caps (3) with the associated

bearing shells.

- Tighten the screws (2) in two steps:

Step 1: with a torque wrench, to a torque of 50 Nm.

Step 2: closing to an angle of 70

°.

- Remove the cap (3) and determine the existing

clearance by comparing the width of the calibrated wire
(3, Figure 121) with the graduated scale on the case (2,
Figure 121) that contained the calibrated wire. On
finding a clearance other than as prescribed, replace the
bearing shells and repeat the check.
On obtaining the prescribed clearance, lubricate the
connecting rod bearing shells and fit them permanently
by tightening the connecting rod cap fixing screws as
described.

Manually check that the connecting rods slide axially on the
pins of the crankshaft.

Checking piston protrusion

At the end of the connecting rod-piston assembly refitting,
check the piston protrusion (2) at the T.D.C. compared to
the top level of the cylinder block by means of a dial gauge
(1) and relevant base 99370415.

Use tool 99395216 (1) for the angle closing.

NOTE

The connecting rod cap fixing screws must always
be replaced for permanent assembly.

NOTE

The difference between the minimum and
maximum protrusions of the four pistons must be
= 0.15 mm.

The cylinder head gasket in the set of spare gaskets
needed for complete engine overhaul is supplied
with a single thickness. Clearly, it is supplied
separately too.

NOTE

F1C ENGINE

549

AILY

Base - May 2004

88329

88328

75412

88426

Figure 125

Figure 126

Figure 127

Figure 128

Fit the gasket (4) and the frame (3) onto the oil sump (1).
Screw down the fixing screws (2) and tighten them to the
prescribed torque.
Screw down the oil drain plug (5) and tighten it to the
prescribed torque.

Apply the support SP. 2271 (5) on the cylinder head and
tighten the support in a vice.

Remove the brackets (6) for lifting the engine.

Remove the sensors (1 and 2), if needed.

Take out the screws (3) and remove the thermostat casing
(4).

Fit part (4) of tool 99360260 onto the cylinder head (5) and
secure it with the screws (3).

Fit part (2) of tool 99360260 onto part (4), screw down the
nut (1) so that on compressing the springs (8) it is possible
to remove the cotters (6). Then take out the plates (7) and
the springs (8).

Using suitable pliers, remove the oil seal (9).

Repeat these operations on the remaining valves.

Turn the cylinder head over.

The intake (1) and exhaust (2) valves have the same diameter
mushroom.

The central cavity (

→) of the mushroom of the intake valve

(1) is distinguished from that of the exhaust valve (2).

560610

CYLINDER HEAD

Disassembly

541210

Disassembling valves

Remove the intake (1) and exhaust (2) valves.

Before removing the valves from the cylinder
heads, number the valves in order to refit them
correctly if they are not changed.

A = intake side — S = exhaust side

NOTE

550

F1C ENGINE

AILY

Base - May 2004

2,25+07.5’

5,985

6,000

5,975

5,990

O30,8

32,3

32,5

60 +7.5’

88331

87799

18625

18882

Figure 129

Figure 130

Figure 131

Figure 132

The mating surface of the head (1) with the cylinder block
is checked using a rule (2) and a feeler gauge (3).
The deformation found on the entire length of the cylinder
head must be no greater than 0.20 mm.
For greater values, regrind the cylinder head according to the
values and instructions given in the following figure.

The nominal thickness A of the cylinder head is 112

±0.1 mm;

the maximum permissible removal of metal must not exceed
a thickness of 0.2 mm.

Checking cylinder head seal

Check the hydraulic seal using a suitable tool.
Pump in water heated to approx. 90

°C at a pressure of 2 ÷

3 bars.

Replace the cup plugs if they are found to leak at oil, using
a suitable drift for their removal — assembly.

Checking cylinder head mating surface

If there is any leakage from the cylinder head, it must be
replaced.

MAIN DATA OF INTAKE AND EXHAUST VALVES

Remove the carbon deposits on the valves with a wire brush.
Check that the valves show no signs of seizure, cracking or
burning.

540662

VALVES

Removing deposits, refacing and checking
valves

Use a micrometer (2) to measure the valve stem (1): it must
have the value shown in Figure 132. If necessary, grind the
valve seats by means of the grinding machine 99305018, and
remove as little material as possible.

Before mounting the plugs, apply LOCTITE 270
water-reacting sealant on their sealing surfaces.

NOTE

After regrinding, check the valve recessing and if
necessary regrind the valve seats to make the
prescribed valve recessing.

NOTE

EXHAUST

VALVE

INTAKE

VALVE

F1C ENGINE

551

AILY

Base - May 2004

Content .. 161 162 163 164 ..

Iveco Daily. Manual - part 163