Iveco Daily. Manual

74948

41104

Figure 112

Figure 113

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, Figure 112), check the clearance (X)
between the ring (2) and the slot (1); this clearance must
have the prescribed value.

75398

Figure 114

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).

75400

75399

Figure 115

Figure 116

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

- 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 62.842 — 62.848 mm marked with the
letter O and the weight class marked with the number 33.
It is not permissible to remove material.

Each connecting rod has its cap marked:

- with a letter: O or X indicating the diameter

class of the big end mounted in production;

NOTE

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Figure 117

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

Bushes

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).

Figure 118

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 119

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.

75401

Assembling connecting rod-piston assembly

Figure 120

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75402

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).

Figure 121

Figure 122

75394

Figure 123

Checking for connecting rod — piston distortion

75403

After fitting the connecting rod — piston assembly together,
check for distortion with the tool 99395363 (8) as follows:

- Fit the connecting rod (7) together with the piston (3)

on the spindle (4) of tool 99395363 (8) and lock it with
the screw (5).

- Rest the connecting rod (7) on the bar (6).

- Position the mount (1) of the dial gauge (2) so that this

is positioned at point A of the piston with a pre-load of
0.5 mm and zero the dial gauge (2).

- Shift the spindle (4) so as to position the dial gauge (2)

at point B of the piston (3) and check for any deviation.

Figure 124

Assembling piston rings

Fit the piston rings (1) on the piston (2) using the pliers
99360183 (3).

41097

Figure 125

Assembling connecting rod — piston assemblies
in cylinder barrels

75404

Lubricate the pistons well, including the piston rings and the
inside of the cylinder liners.
With the aid of the clamp 99360605 (2), fit the connecting
rod — piston assembly (1) in the cylinder liners, checking that:

- The number of each connecting rod corresponds to the

cap mating number.

The 1

and 2

slot rings need to be mounted with

the word ”TOP” facing upwards.

NOTE

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- Fit the connecting rod caps (2) with the associated

bearing shells.

- Tighten the screws (3) in two steps:

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

Step 2: closing to an angle of 60

°.

Figure 126

- The openings of the piston rings are staggered 120

° apart.

- The pistons are all of the same weight.

- The symbol punched on the top of the pistons faces the

engine flywheel, or the recess in the skirt of the pistons
tallies with the oil spray nozzles.

540831

Measuring crankpin assembly
clearance

75405

To measure the clearance, carry out the following steps:
- Thoroughly clean parts (1) and (4) and eliminate all

traces of oil.

- Place a length of calibrated wire (3) on the crankshaft

pins (4).

75408

Figure 127

- Remove the cap (2) and determine the existing clearance

by comparing the width of the calibrated wire (3,
Figure 126) with the graduated scale on the case (2,
Figure 126) that contained the calibrated wire. On finding
a clearance other than as prescribed, replace the bearing
shells and repeat the check.
On obtaining the prescribed clearance, lubricate the
connecting rod bearing shells and fit them permanently by
tightening the connecting rod cap fixing screws as
described.

Manually check that the connecting rods slide axially on the
pins of the crankshaft.

75409

Figure 128

Checking piston protrusion

After mounting the connecting rod — piston assemblies, check
the protrusion of the pistons (2) at the T.D.C. in relation to the
top surface of the crankcase with a dial gauge (1).

75283

Figure 129

Mount the suction strainer (1) together with the pipe (6).
Screw down the fixing screws (2-3-4-6) and tighten them to
the prescribed torque.

Not finding it necessary to replace the connecting
rod bearings, you need to fit them back in exactly
the same sequence and position found on
disassembly.

NOTE

Use tool 99395216 (1) for the angle closing.

NOTE

The connecting rod cap fixing screws must always
be replaced for permanent assembly.

NOTE

The difference between the minimum and
maximum protrusions of the four pistons must be
= 0.15 mm.

The cylinder head gasket in the set of spare gaskets
needed for complete engine overhaul is supplied
with a single thickness. Clearly, it is supplied
separately too.

NOTE

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Content .. 93 94 95 96 ..

Iveco Daily. Manual - part 95