Iveco Daily Euro 4. Manual - part 23

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 98

Figure 99

75297

Figure 100

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.

Undersize classes are of:
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

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 99.

NOTE

NOMINAL

VALUE

NOMINAL

VALUE

MINIMUM

∅

MAXIMUM

∅

NOMINAL

VALUE

MINIMUM

∅

MAXIMUM

∅

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75299

45066

Figure 101

Figure 102

MAIN CRANKSHAFT TOLERANCES

SYMMETRY BETWEEN MAIN JOURNALS AND CRANK-
PINS
1. Crank pins
2. Main Journals
3. 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.

0,125

180

°±

15’

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

NOTE

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TOLERANCE CHARACTERISTIC

SYMBOL

SHAPE

Circularity

○

SHAPE

Cylindricality

DIRECTION

Parallelism

DIRECTION

Perpendicularity

⊥

OF POSITION

Concentricity or coaxiality

OSCILLATION

Circular oscillation

↗

OSCILLATION

Total oscillation

↗↗

CLASS OF IMPORTANCE ASCRIBED TO THE PRODUCT CHARACTERISTICS

SYMBOL

CRITICAL

IMPORTANT

⊕

SECONDARY

⊝

75303

Figure 103

Figure 104

Figure 105

Figure 106

Figure 107

INTERMEDIATE JOURNALS No. 2-4

INTERMEDIATE JOURNAL No. 3

CRANKPINS

* On both races, on all 360

°.

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

- Rolling speed: 56 rpm.

- Decrease in crankpin race depth after rolling: 0.15 — 0.30

mm*.

- Decrease in main journal race depth 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

108189

108190

108192

108191

honed

waviness

RACE AREA FOR ALL MAIN JOURNALS
(MACHINED BY TURNING)

honed

CRANKPIN GROOVE AREA
(EXTERNAL MILLING PROCESSED)

honed

in circumferential direction

in axial direction

honed

in circumferential direction

waviness

in axial direction

waviness

honed

llin

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75305

75306

75307

90063

Figure 108

Figure 109

Figure 110

Figure 111

Take out the screws (4) and replace the phonic wheel (3).
The screws (4) hey must be tightened to a torque of 15 Nm.

Replacing timing control gear

On finding the timing control gear teeth (1) damaged or
worn, remove them from the crankshaft (2) using a suitable
extractor.

The new gear is fitted onto the crankshaft by heating it to a
temperature of 200

°C for no longer than 15 minutes.

On completing assembly and after the gear has cooled, it
must withstand a torque of 150 Nm without slipping.

ENGINE ASSEMBLY

The following parts must be replaced with new ones at the
time of assembly: retaining rings, seals and gaskets, screws
whose thread is coated with sealant.

Fit on the oil spray nozzles (2) and tighten the couplings (1)
to the prescribed torque.

The main bearings (1) are supplied as spare parts undersized
on the inside diameter by 0.254

÷ 0.508 mm.

540811

Measuring main journal assembly
clearance

Mount the crankshaft (1).
Check the clearance between the crankshaft main journals
and their respective bearings by proceeding as follows:

- Thoroughly clean the pins.

- Apply a calibrated wire onto the main journals.

Assembling main bearings

Thoroughly clean the top main bearing shells (1) and position
them in the crankcase.

Not having found it necessary to replace the main
bearings, they need to be fitted back on in the same
sequence and position found upon disassembly.

NOTE

Do not do any accommodating on the bearings.

NOTE

The middle half ring (2) is fitted with thrust washers.

NOTE

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