Iveco Daily. Manual

23022

Remove lower crankcase (1) with its gasket.

18833

Unscrew lower/upper crankcase fastening screws (1) using
wrench (2).

23023

Remove crankshaft (1) using a hoist and a suitable rope.

19183

Recover main half bearings (2).

Straighten safety plate bends and remove oil spray nozzles
(1).

50668

Figure 53

Remove the crankshaft rear cover (1) from the crankcase,
complete with oil seal.

Figure 54

Figure 55

Figure 56

Figure 57

At removal, take note of the assembling position of
lower and upper crankshaft half bearings since if re-
used they shall be refitted in the same position.

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

Measurements shall be taken for each cylinder, at three
different heights on the barrel and on two perpendicular
surfaces: the first one parallel to engine longitudinal axis (A)
and the other one perpendicular (B); max. wear is generally
found on this latter surface and in correspondence with the
first measurement.
Bore/recondition and plateau finish by honing cylinder barrels
if ovalization, excessive taper or any sign of wear are found.
Cylinder barrel reboring shall be performed according to the
diameter of spare pistons oversized by 0.4 mm of rated value
and prescribed assembling clearance. Should cylinder barrel
be bored to higher diameter, oversize shall be performed by
fitting a spare cylinder barrel and proceeding as described in
the relevant chapter.

18836

18837

61689

Figure 58

Figure 59

Once engine is dismantled, clean cylinder-crankcase group
accurately.
For handling cylinder group use rings 99365508.
Make sure crankcase has no cracks.
Check working plug conditions. If rusted or not perfectly
tightening, replace them.
Check cylinder liner surfaces: they should not show any
traces of binding, scoring, ovality or excessive taper.
The inside diameter of the cylinder liners, in order to
ascertain the extent of their ovalization, taper and wear, is
checked with the bore gauge 99395687 (1) fitted with the
dial gauge and reset on the ring gauge (2) of the diameter of
the cylinder liner.

With reaming gauge 99395687 (1), equipped with centesimal
comparator set to zero as previously described, check cylin-
der liner inside diameter, to verify the degree of ovality, taper
and wear.

REPAIR OPERATIONS

CYLINDER BLOCK

Checks and measurements

measurement

62067

Figure 60

A - B =

Main bearing longitudinal axis

Surface roughness parameters

R1 =

÷ 10 µm

Rz =

÷ 8 µm

Ra =

0.3

÷ 0.6 µm

W1 <

µm

Admitted surface pores with machined cylinder

ZONE B1 = max. stress area between piston

ring/barrel: two non-continuos pores,
max. 0.5 x 0.5 admitted

ZONE B2 = area interested by piston ring sliding:

two non-contiguous pores, max
1x0.8 admitted

100%

If ring gauge is not available use a micrometer to set
to zero.

NOTE

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

When levelling is over, reset cylinder barrel spot-facing and
bevelling as shown in the figure.
Check main bearing housings as follows:
- Fit lower crankcase on upper crankcase, without

bearings and gaskets;

- tighten fastening screws to specified torque;
- with a suitable inside diameter comparator, make sure

the seat diameter is equal to specified value.

If a greater value is found, replace crankcase.

Make sure mating surface, on cylinder block, does not show
any deformations.
This check can be done, after removing setscrews (1), with
a soot-coated surface plate or with a gauged rule (2) and
thickness gauge (3).
Once deformation areas are detected, flatten supporting sur-
face with a grinder.

18839

Figure 61

Figure 62

Spare cylinder barrel assembling

61688

B = Main bearing longitudinal axis

Figure 63

62068

SECTION A-A

Engine block surface

** Spot-faced surface Ø 111

Implement cylinder barrel seats into engine block by boring the latter
at the values shown in the above figure, so as to obtain the average
diameter measured according the methods described in the following

Crankcase flattening can be performed only after
being sure that, once the work is completed, piston
protrusion from cylinder liner will not be greater
than specified value.

NOTE

WT = 10 - PITCH 5

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

61690

Measurements shall be performed for every four barrel seats
at three different heights and on two perpendicular surfaces:
the first one parallel to engine longitudinal axis (A) and the
other one perpendicular (B) as shown in the diagram.

Average diameter D

med shall be calculated according to

the following formula:

med

(10)

+ A

(50)

+ A

(142)

+ B

(10)

+ B

(50)

+ B

(142)

It shall be

, the difference between max diam-

eter D

max

and min. diameter Dmin shall be: D

max

- D

min

≤ 0.03 mm

After implementing the proper seats, barrel fitting into
cylinder unit shall be performed by hydraulic press and plate
as follows:

- Check whether cylinder barrel outside diameter is equal

to the prescribed value.
Avoid using oil or grease when driving barrels;

- set barrel into block and check whether at 80 mm driving

the load is

≥ 1300 daN;

- proceed with driving and check whether load is

≥ 5000

daN when driving is over;

Figure 64

measurement

- to prevent breakage, check whether barrel edge is

perfectly resting on block:
cylinder barrel shall not protrude by 0.005 above block
bottom.

Otherwise, replace the cylinder barrol.

After driving in the cylinder liners, machine them to the
tolerance and roughness indicated in the “Checks and
measurements” section.

Figure 65

62069

Figure 66

20767

* engine block surface - ** spot-faced surface Ø 111 mm

SECTION A-A

97.500

− 0.05
+ 0.11

Value between brackets corresponds to the
measurement point from upper block edge.

NOTE

WT = 10 - PITCH 5

ENGINES 8140.43R/B/S/N

AILY

Base - May 2004

97.390

÷ 97.450

Y = barrel outside

∅

97.470

÷ 97.500

Z = barrel inside

∅

92.700

÷ 92.900

94.402

÷ 94.432

Dimension to be obtained after driving the liner into the
crankcase at the end of the work.

Content .. 18 19 20 21 ..

Iveco Daily. Manual - part 20