Iveco Daily. Manual

75299

45066

Figure 79

Figure 80

MAIN CRANKSHAFT TOLERANCES

SYMMETRY

BETWEEN

MAIN

JOURNALS

AND

CRANKPINS
1.

Crankpins

Main journals

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

F1A ENGINE

AILY

350

Base - May 2004

TOLERANCE CHARACTERISTIC

SYMBOL

SHAPE

Circularity

○

SHAPE

Cylindricality

DIRECTION

Parallelism

DIRECTION

Perpendicularity

⊥

POSITION

Concentricity or coaxiality

OSCILLATION

Circular oscillation

↗

OSCILLATION

Total oscillation

↗↗

CLASS OF IMPORTANCE ASCRIBED TO THE PRODUCT CHARACTERISTICS

SYMBOL

CRITICAL

IMPORTANT

⊕

SECONDARY

⊝

75300

75302

75301

75303

75304

Figure 81

Figure 82

Figure 83

Figure 84

Figure 85

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

.0.

360

llin

honed

.0.

360

llin

honed

.0.

360

llin

honed

waviness

in circumferential direction

waviness

in axial direction

RACE AREA FOR ALL MAIN JOURNALS
(MACHINED BY TURNING)

.0.

360

llin

honed

waviness

in circumferential direction

waviness

in axial direction

RACE AREA FOR ALL MAIN JOURNALS
(MACHINED BY TURNING)

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

F1A ENGINE

351

AILY

Base - May 2004

75305

75306

75307

75289

Figure 86

Figure 87

Figure 88

Figure 89

Take out the screws (4) and replace the phonic wheel (3).
The screws (4) are coated with LOCTITE 218 and must be
replaced with fresh ones after each disassembly.
They 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

F1A ENGINE

AILY

352

Base - May 2004

75288

75309

75310

75311

Figure 90

Figure 91

Figure 92

Thoroughly clean the bottom main bearing shells (2) and
mount them in the crankcase base (1).

Mount the crankcase base (12).

Tighten the screws in the sequence shown in the figure in
three steps:

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

- Step 2: closing to an angle of 60

°.

- Step 3: closing to an angle of 60

°.

The end float is checked by setting a dial gauge (1) with a
magnetic base on the crankshaft (2) as shown in the figure.
The normal assembly clearance is 0.060 — 0.310 mm.

If you find the clearance to be greater than as required,
replace the rear main bearing shells carrying the thrust
bearings and repeat the clearance check between the
crankshaft pins and the main bearing shells.

If the end float of the crankshaft does not come within the
prescribed values, it is necessary to grind the crankshaft and
accordingly change the main bearing shells.

NOTE: The middle main bearing has half thrust washers
integrated in it, so it performs the function of a thrust bearing.
It is supplied as a spare part only with the normal shoulder
thickness.

Figure 93

- Remove the bottom crankcase.

The clearance between the main bearings and their
associated pins is measured by comparing the length of the
calibrated wire (1), at the point of greatest crushing, with the
graduated scale on the casing containing the calibrated wire.
The numbers on the scale indicate the clearance of the
coupling in millimetres, which must be 0.032

÷ 0.102 mm.

If the clearance is not as prescribed, replace the bearings and
repeat the check.

Checking crankshaft end float

Use tool 99395216 (11) for the angle closing.

NOTE

F1A ENGINE

353

AILY

Base - May 2004

Content .. 91 92 93 94 ..

Iveco Daily. Manual - part 93