Iveco Daily Euro 4. Manual

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Figure 86

Figure 87

Figure 88

Figure 89

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.

NOTE

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Figure 90

Figure 91

Figure 92

Figure 93

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.

NOTE

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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 94

Figure 95

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 conditions of processing caps. If the caps are
rusted or if you have even the slightest doubt about their
sealing efficiency, the caps shall be replaced. Apply LOCTITE
270 sealant (IVECO NO. 93162429) to the caps when fitting
the latter back into place.. 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 96

* Surface roughness parameters:

÷ 10 μm

÷ 8 μm

0,25

÷ 0,6 μm

Wt <

1,5

μm

Permissible surface porosity for machined cylinder
(see Figure 97)

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 97

measurement

F1A ENGINE

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Iveco Daily Euro 4. Manual - part 22