Iveco Daily Euro 4. Manual

75393

75394

107732

88300

Figure 148

Figure 149

Figure 150

Figure 151

Remove the piston rings (1) from the piston (2) using pliers
99360183 (3).

Remove the piston (1) from the connecting rod, taking out
the piston ring (2) and extracting the pin (3).

MAIN DATA FOR MONDIAL PISTON, PINS AND PISTON RINGS

The value is measured at 1.5 mm from the outer diameter

The value of the diameter measured is 91.4 mm

X = 0.5

Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance. The diameter has
to be measured at the value shown.

The clearance between the piston and cylinder liner can also
be checked using a feeler gauge (1) as illustrated in the figure.

107733

540840

Piston

Measuring piston diameter

The pistons are supplied as spare parts with the
standard, normal and 0.4mm oversize diameters
together with rings, pin and retaining rings.

Figure 152

NOTE

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18857

74947

75397

16552

88301

41104

Figure 153

Figure 154

Figure 155

Figure 156

Figure 157

Figure 158

Measuring the diameter of the piston pin (1) with a
micrometer (2).

Conditions for correct pin-piston coupling

Lubricate the pin (1) and its seat on the hubs of the piston
(2) with engine oil. The pin must go into the piston by lightly
pressing with the fingers and must not drop out by gravity.

The trapezoidal split rings (1

slot) and the oil scraper rings

slot) have the word TOP etched in them; when fitting

them on the piston, the word TOP must be facing upwards.

Check the thickness of the piston rings (2) with a micrometer
(1).

Check the clearance between the trapezoidal ring (2) (1

slot) and the associated slot on the piston with a feeler gauge
(1), proceeding as follows: insert the piston into the cylinder
liner so that the ring (2) comes approximately half way out
of it.

DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE

TRAPEZOIDAL RING

1. Piston slot — 2. Trapezoidal piston ring —

3. Cylinder liner

Using a feeler gauge (1, SENZA CODICE), check the
clearance (X) between the ring (2) and the slot (1); this
clearance must have the prescribed value.

540842

Piston rings

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540841

Piston pin

- with a letter: O or X indicating the diameter class of the

big end mounted in production;

- with a number indicating the weight class of the

connecting rod mounted in production.

In addition, it could be stamped with the number of the
cylinder in which it is fitted.

In the event of replacement it is therefore necessary to
number the new connecting rod with the same number as
the one replaced.

The numbering must be done on the opposite side to the
bearing shell retaining slots.

The connecting rods are supplied as spare parts with the
diameter of the big end 67.833 — 67.848 mm marked with the
letter O and the weight class marked with the number 33.

It is not permissible to remove material.

75398

87796

75399

Figure 159

Figure 160

Figure 161

Figure 162

Check the clearance between the piston rings (2) of the 2

and 3

slot and the associated seats on the piston (3) with

a feeler gauge (1).

Check the opening between the ends of the piston rings (2)
inserted in the cylinder liner using a feeler gauge (1).

MAIN DATA OF THE CONNECTING ROD, BUSHING,

PISTON PIN AND BEARING SHELLS

Internal diameter to obtain after driving into the small
end and grinding with a reamer.

Dimension cannot be measured in the free state.

*** Thickness of the bearing shell supplied as a spare part.

540830

Connecting rods

Each connecting rod has its cap marked:

Check that the bush in the small end has not come loose and
shows no sign of seizure or scoring. If it does, replace the
complete connecting rod.

540834

Bushing

Checking connecting rods

61696

Check the alignment of the axes of the connecting rods (1)
with device 99395363 (5), proceeding as follows:

- Fit the connecting rod (1) on the spindle of the tool

99395363 (5) and lock it with the screw (4).

- Set the spindle (3) on the V-prisms, resting the

connecting rod (1) on the stop bar (2).

NOTE

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Figure 163

Etched on the top of the piston are: the type of engine (1),
class selection (2) and supplier (3) as well as the direction of
fitting the piston in the cylinder liner (4). The mark (5) is for
passing the 1

slot insert adhesion test.

87797

87798

Connect the piston (1) to the connecting rod (2) together
with its cap so that the piston assembly reference, position
of the connecting rod and of the cap are observed as shown
in the figure.

Position the piston (1) on the connecting rod, insert the pin
(3) and secure it with the split rings (2).

Assembling connecting rod-piston assembly

Check the torsion of the connecting rod (5) by comparing
two points (A and B) of the pin (3) on the horizontal plane
of the axis of the connecting rod.
Position the mount (1) of the dial gauge (2) so that this
pre-loads by approx. 0.5 mm on the pin (3) at point A and
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side B of the pin (3): the difference between A and
B must be no greater than 0.08 mm.

Checking torsion

61694

Checking bending

Check the bending of the connecting rod (5) by comparing
two points C and D of the pin (3) on the vertical plane of the
axis of the connecting rod.
Position the vertical mount (1) of the dial gauge (2) so that
this rests on the pin (3) at point C.
Swing the connecting rod backwards and forwards seeking
the highest position of the pin and in this condition zero the
dial gauge (2).
Shift the spindle with the connecting rod (5) and repeat the
check on the highest point on the opposite side D of the pin
(3). The difference between point C and point D must be no
greater than 0.08 mm.

61695

Figure 164

Figure 165

Figure 166

Figure 167

75394

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Content .. 60 61 62 63 ..

Iveco Daily Euro 4. Manual - part 62