IVECO 8361

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    industrial engines

    section 3.1

    new 8361 seriesworkshop manual

    Publication No L32023007Date 02 - 1995 IVECO ilifo

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    The data contained In this publication may not havebeen updated following modrlrcatrons earned out bythe manufacturer, at any time, for technical or commer-cial reasons and also to conform to the requirementsof the law In the various countries

    This publication supplies features and data together with the SUitable methods for repairoperations to be earned out on each single component of the engine.Followmp the supplied Instructions and using the Inherent specfic fixtures, a correct repairprocedure will be obtamed In due time, protecting the operators from all possible accidentsBefore starting any repair, be sure that all accident prevention devices are aveuab'e and effICIentTherefore check and wear what mdicated by the safety provrsion protective glasses,helmet, gloves, safety shoesBefore use, check all work, lifting and transport equipment

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    SECTION 3

    INDEX 8361SRI12Page

    GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1DATA ON ASSEMBLY CLEARANCES.................................... 2TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8TIGHTENING TORQUES ........... 9FAULT DIAGNOSIS ............. 10DISMANTLING THE ENGINE ON THE BENCH. 21REPAIR OPERATIONS........................................... . .. 26CYLINDER BLOCK.............................. . . . . . . . . . . . . . . . . . .. 26INJECTION PUMP DRIVE........................................... 31POWER STEERING PUMP DRIVE................. . . 32CRANKSHAFT. . . . . . . . . . . . .. 34CONNECTING ROD/PISTON ASSEMBLY .. 40ASSEMBLING THE CONNECTING ROD/PISTON ASSEMBLY .. 43TIMING GEARS........................... 45FITTING THE INJECTION PUMP AND SETTING THE TIMING 47

    '-~ CYLINDER HEAD - DISMANTLING OF VALVES - VALVES 48VALVE GUIDE ..... 49VALVE SPRINGS - FITTING THE CYLINDER HEAD 52PUSHRODS - ROCKER SHAFT - ROCKERS . 53LUBRICATION - HEAT EXCHANGER 55OIL FILTER - COOLING SYSTEM S6OVERHAULING THE TURBOCHARGER TYPE KGK,K27.2 61

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    8361 GENERAL ENGINE p, 1

    ENGINE SPECIFICATIONS

    E n g l n e t y p e . . 8 3 6 1 S R I 1 24 - s t r o k e D i e s e l w i t h d i r e c t i n J e c t l o nC y l l n d e r s , n u m b e r a n d a r r a n g e m e n t 6 , I n l 1 n eB o r e x s t r o k e 1 1 2 X 1 3 0 m mD l s p l a c e m e n t 7 , 7 lC o m p r e s s l 0 n rat r c 1 7 , 6 : 1M aX lm u m r at ln g( * > . . .. .. .. . .. .. .. .. . .. .. . . . 1 98 k W( 2 70 C V )A t . .. . .. .. .. .. .. . . .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. . 2 20 0 r pmtntermrttent r a t l n g 1 8 4 k W ( 2 5 0 C V )A t 2 2 0 0 r p mC o n t l n u o u s r a t l n g ( 1 0 % o v e r L o a d c a p a c l t y ) 1 6 5 k W ( 2 2 5 C V )A t 2 1 0 0 r p mE n g l n e r o t a t l o n :( s e e f r o m f l y w h e e L > . C C W

    (*) I S O F u e l S t o p P o w e r- A mb le n t r ef er en c e c o nd lt l on S:I S O 3 0 4 6 / 1 ; 2 5 C ; 1 0 0 k P a i 30% r e L a t l v e h u m l d l t y

    TIMINGV al v e T im l n g:

    - I n ta ke 'o p e n s : b e f o r e T. D . C 1 ~ 3 2 'c l o s e s : af t e r B . D . C 3 8 44'

    - E xh au sto p e n s . b e f o r e B . D . Cc lo se s: a f te r T . D. C

    . . .. . .. . .. . .. . .. . .. . .. 5 3 08'

    . . .. . .. . , . . . . . .. . .. . . 1 30 3 7 '

    C l e a r a n c e b e t w e e n v a l v e s a n dr o c k e r s f o r t l m l n g c h e c k s 0 , 4 0 m m

    O p e r a t l n g c l e a r a n c e b e t w e e n v a l v e s a n d r o c k e r s , c o l d e n g l n e ;- r n t a k e a n d e x h a u s t 0 , 4 0 : t 0 , 0 5 m m

    FUEL SYSTEM

    I n l 1 n e i n j e c t i o n p u m p t y p e P E S

    F 1 X e d l n j e c t l o n p u m p d e l i v e r y s t a r t a d v a n c e 1 5 : t 3 0 'F u e L mjectors s e t ' tinq 2 4 0 + 8 b a rF l r l n g o r d e r 1 - 5 - 3 - 6 - 2 - 4

    TURBOCHARGING

    T h e e n g l n e l S s u p e r c h a r g e d b y a t u r b o c h a r g e r d r l v e n b yt h e e x h a u s t g a s e s .

    C o o l l n g l n t a k e a l r w l t h a l r - w a t e r h e a t e x c h a n g e r

    T h e t u r b o c h a r g e r l S L u b r l c a t e d w l t h t h e e n g l n e o l L u n d e rp r e s s u r e .

    LUBRICATIONM ln lm um o l L p re ss ur e:- a t f u L L t h r o t t L e 3 , 5 k g / c m '- w h e n l d l l n g 1 k g / c m '

    COOLING SYSTEMF o r c e d w a t e r c l r c u L a t l o n c o n t r o L L e d b y c e n t r i f u g a L p u m p .W a te r t e mp e ra tu re c on tr o Ll ed b y t he rm os ta t .W a t e r f i L t e r l n g w l t h m u l t i p l e r e c y c L e f l l t e r .R a d l a t o r C O O L l n g f a n d r l v e n b y V - b e L t .

    STARTINGBy s ta rt er m ot or .

    ELECTRIC SYSTEM

    - V ol t a ge . .. .. .. . . . .. .. .. .. .. .. .. . . . .. .. .. .. .. .. .. . 2 4 V- S e l f - r e g u L a t e d a l t e r n a t o r 3 0 A- S t a r t i n g m o t o r p o w e r 4 k W- B at te ry (opt i c n a l . ) 2 , e a c h 11 0 A h

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    8361 ENGINE p. 2

    DATA ON ASSEMBLY CLEARANCESCYLINDER BLOCK AND CRANK MECHANISMCOMPONENTS

    x

    4,030 -s- 4,050

    mm01neasurementdimensionBores for cylinderliners 165 - 17001 1 20 ,4 70 - ,- 1 20 ,5 00

    02

    Cylinder linersoutside diameterlength

    02 120,470 - 120,490L

    Cylinder liners -crankcasehousmgOutside diameter

    - 0,02 - + 0,0302

    03x

    Cylinder linersInsidediameter ~ 0 3protrusion X(measured under a load of4000 kg)Pistonsmeasurement height Xoutside diameter 0 Ihousmg forgudgeon pin 0 2

    I I2,000 - I 12,0220,16 - 0,25

    22I I 1 ,8 53 - I I 1,867

    42,013-42,019

    X~02

    Piston- cylinder liner

    Piston diameter 0 I Tappets 0,5 - 1, 001=L- Rocker shaft 01 24,015 + 24,036~ - - E J B -L_T-

    ~ Rockers 02 24.060 - 24,08002ge Between rockers and shaft 0.024 - 0,065

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    8361 ENGINE p. 8

    TOOLS

    TOOL NUMBER DESCRIPTION993050499932223099340205993410039934100999341015993421459934800499350108993601839936029299360314993603219936035199360357993604199936044599360467993604819936049599360496993605009936050399360595993606059936072299360723993610349936506399370005993704549937419599390311993904259939401799394018993940199939521699395363993956829939568799395850

    Equipment for checking spr ing loadingSWivelling telescopic standImpact extractorSingle action bridgePair of bracketsClampExtractor for Injector holder caseUniversal extractor, Internal, 5 to 70 mmWrench for valve gear clearance adjustment screwTongs for fitting engine piston ringsInstalling tool for fitting seal to valve guideTool for removing cartridge filtersTool for rotating engine flywheelTool for locking engine f lywheelTool for removing and refitting engine valvesBox Wlt.h set of t.ools for recutting valve seatingsTool for compression and measurement of cylinder liner protrusionAdaptor for checking cylinder compression (to be used With 99395682)Dnft for removing valve gUideDrift for fitting Inlet valve guide (use With 99360481)Drift for fitting exhaust valve gude (use With 99360481)Crankshaft l ifting toolRings for lifting cylinder blockHOisting beam for removing and refit tmg engineRing clamp for Inserting standard and oversize pistons Into the cylindersTool for retaining cylinder linersTool for extracting cylinder linersBrackets for secunng engine to SWivel ling stand 99322230Tool for refitting Injector holder casesHandle for drifts (Interchangeable)Instal ling tool for f itt ing crankshaft f ront seal (use With 99370005)Instal ling tool for f it ting crankshaft rear seal (use With 99370005)Reaming tool for valve gurdeTap for threading Injector holder cases to be extractedReamer for reconditioning lower part of Injector holder case (use With 993940 19)Cutter for reconditioning Injector seating housmg (use With 99394019)Pliot bushPair of gaugesTee square assembly for checking connecting rod distort ionDiesel engine cyl inder compression testerBore micrometer (50 - 175 mm)Torque wrench for checking belt tension

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    8361 ENGINE p. 9.._., TIGHTENING TORQUES

    PART TORQUENm Kgm

    Cylinder head I st stage preliminary torque 118 (12)attachment bolt 2nd stage preliminary torque 118 ( 1 2)3rd stage angle 900 304th stage angle 900 305th stage angle 450 30

    Main bearing cap preliminary torque 60 (6)attachment boltsangle 120

    Big end cap preliminary torque 40 (4)attachment boltsangle 35

    Flywheel attachment preliminary torque 100 (10)boltsangle 60

    Rocker shaft preliminary torque 50 (5)pedestal securing nutangle 90

    Damper hub attach- preliminary torque 450 (45)ment screwangle 120

    Screw attaching the sump and shroud support bracket to the front cover 13 (1,5)Screw attaching the sump to the crankcase, front cover and rear cover 13 (1,5)Screw attaching the sump and bracket for heat exchanger water Inlet pipe to crankcase 13 (1,5)Screw attaching the sump and bracket for engine breather pipe to crankcase 13 (1,5)Screw attaching the all filter body mounting to the crankcase 130 ( 13)

    Lubricate the thread With engine 0 1 1

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    8361 ENGINE p. 10FAULT DIAGNOSISMain engine operating faults ,I - Engine will not start2 - Engine overheats3 - Engine lacks power4 - Engine emrts black or dark grey smoke5 - Engine -ernrts grey (whrt lsh) smoke

    I ENGINE WILL NOT START

    ~Battery terminal connections serviceable r

    YESt

    ~ NO~--------------'I--------------~

    YESt

    Battery serviceable

    Starter motor serv iceable

    YEStStarter heater serviceable

    YEStInjection pump timing correct

    YES,Fuel pump operating correctly

    6 - Engine emits blue smoke7 - Abnormal knocking from the engine8 - Engine stops9 - Engine exceeds maximum rpm10 - Orl pressure too high or too lowI I - Excessve fuel consumption

    NOClean, check. tighten clamp nuts or replace

    Carry out the checks described In the"Electrical components" repair manual

    Carry out the checks cescnoed In the_ NO ~ "Electncal components" repair manual

    NO~~_R_ep_,a_c_e ~

    Check correct timing a s d e scnbed in thet- NO ~ relevant chapter

    Check and replace If necessary- NO"

    (continued)

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    8361 ENGINE p. 11

    C heck operation and adjust as descnbedn jec to rs se rv iceab leI-NO

    YES,L_N__o_ a_I r_le _a_ ~_ln_n_u_e_lc_l_rr_u_rr~o_r_ln_J_ect_lo_n_p_u_m_p ~1- No.IL_C_h_e_c_k_a_n_d_b_ le_e_d ~

    YES,Chec k a nd c lea n fu el c ircu it, in clud ing ta nko water In fuel circuit or pump -NO

    YES,C om pression ratio as specified Overhaul the engine or lim it repairs to the parts con-

    _ NO. cerned (valves, piston rings etc)

    YES,L_F_u_e_lf i_i1t_e_rs_se_r_ v_lc_ ea_b_ le_ ~------------------~~ NO~L_R _e_p_ la_c_e ~

    YES,C heck and replace the parts concernedutom atic advance regulator and electric S TO P valve

    serviceable -NO

    (continued)

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    8361 ENGINE p. 12

    2 ENGINE OVERHEATS

    ~Coolant level correct

    !-

    YES. . .Water pump and fan belts serviceable

    YES

    Water pump serviceable

    YESjThermostat serviceable

    YES. . .

    Check for leaks and top upNO_"

    Check. adjust tension and replace parts Ifnecessary-NO

    Overhaul or replace the unrt-NO

    NO~~_R_ep_la_c_e ~

    ~ NO.L -. ~ ~ ~

    Radiator serviceable

    YES. . .Air filter and orcurt ducts serviceable

    IYES. . .

    Engine brake disengages

    Wash thoroughly. check condrtion, replace Ifnecess-ary

    Clean or replace defective parts-NO

    Check and replace Ifnecessary-NO

    (continued)

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    8361 ENGINE p. 13In jec tio n pump tim in g co rrec t C he ck co rrec t tim in g as d es cnb ed In the re lev ant

    - NO"'- section

    IYES, .~C_Y_i l_nd_e_r_h_e_ad_ga_S_ke_ t_s_e_rv~ lc_e_ab_l_e ~- N o " ' - L I _R _e_p_la_c_e ~

    YES

    I~_F_a_n_se_r_v_lc_ea_b_ le ~- NO~L_R _e_p_ la_ce ~

    3 E NG IN E LACKS POW ER

    ~Fuel f il te rs se rv iceab le

    l-

    I

    Rep lace, p roceed ing as describedNO"'-

    YES'-" , .YES,The rmosta t ser vi ce ab le

    -N 1 Replace

    YES, .Fee d p ump s er vic ea ble

    -N 1

    Replace. . . _ . . . .

    (continued)

    Fuel circurt serviceable Check and If necessary repair as required-NO'"

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    8361 ENGINE p. 14

    Check operating and adjust asdescribednjectors serviceable -NO

    Y E StInjection pump timing correct Check correct timing asdescribed Inthe relevant

    - NO. section

    Y E StCheck and adjustthe Injection pump on the benchnjection pump adjusted asspecified

    -NOY E St

    Compression ratio as specified Check USingMotometertool 99395682 and carry_ NO. out necessary repairs

    Y E S. . .Repair or replace the unrturbocharger serviceable -NO

    Y E S. . . J Check'----- __ -NO . . . - I L - - - - _ _LDA. orcutt and device serviceable

    (continued)

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    YES,Starter heater serviceable N 1 Replace,-,.

    YES,Automatic boost device cutting In Check and replace If necessary-NO

    YES,Injectors serviceable Check operation and adiust as descnbed INO

    YES'-' ,

    Injection pump timing correct Check correct timing as described In the-NO. relevant section

    YES,LDA device serviceable Adjust the L D A device uSing tool 99309002-NO.

    8361 ENGINE p. 15

    4 ENGINE EMITS BLACK OR DARK GREYSMOKE

    ~Air fitter serviceable - No~l~ _R_ep_la_ce ~

    YES,Check Injection pump and adiust on benchnject ion pump adjusted as specified

    -NO(continued)

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    8361 ENGINE p. 16

    L Coo la nt p ro ba bly e nte rin g com bu stio n c hamb er,~ - ' - - J I NO ~~re ___laC_e_CY_II_nd_e_r_h_e_a_ d_g_~_k_e_ t_o_r_o_ve_m_a_ul_t_h _e_e _n_g l_ne_ ~I

    YES. .

    IYES,

    Comp re ss io n ra tio a s s pe cifie d

    G ood q uality diesel fue l

    5 E NG IN E E MITS G RE Y (Vv'H ITIS H) S MOK E

    ~T he rm os ta t o pe ra tin g c orre ctly -

    YES, .In jec to rs serv iceab le

    YES, .In je ctio n p um p tim in g co rre ct

    YES, .Coo la nt le ve l c orre ctG oo d q ua lity d ie se l fu el

    (continued)

    C he ck u Sin g M o to me te r to ol 99395682 and r ep air asI- NO . necessary

    C le an t~ e ta nk a nd re pla ce th e d ie se l filte rsI-NO

    NO .IL _R _ep_ la_c_e ~

    C he ck o pe ra tio n a nd a dju st ~ d escn be d-NO~

    C he ck co rre ct tim in g a s d escn be d In th e re le va ntsection-NO~

    C le an th e ta nk a nd re pla ce th e d ie se l filte rs-NO.

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    8361 ENGINE p, 17

    6 ENGINE EMITS BLUESMOKE

    ~Excessive0 1 1 consumption

    I-

    7 ABNORMAL KNOCKING FROM THE ENGINE

    ~I Knocking coming from crankshaftI -I

    NO

    Knocking coming from connecting rods

    NOnockingcoming from pistonsINOnockingcoming from cylinder head Check operating clearance between rocker arms and

    _ YES. valves, Injection pump timing, valve timing AdJust.

    NO

    Knocking coming from timing gears

    (continued)

    Check 0 1 1 breather; cylinder compressionsYES. If necessary.overhaul the cylinder head or engine

    YES.Check main Journalsfor clearance and ovalrty, tight-nessof main beanng cap bolts and flywheel bolts, 0 1 1pressure Replace parts or overhaul the engine

    Check c rankpms for clearance and ovalrty tightness ofYES. connecting rod cap bolts, connecting rods for distor-t ion Replaceparts or overhaul the engine

    - YES.

    - YES.

    Check clearance between pistons and cylinder liners,piston nngs for breaks, gudgeon pin to piston bossclearances Replace parts or overhaul the engine

    Check gears and replace If necessary

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    8361 ENGINE p. 18

    K no ck in g c om in g fro m In je cto rs

    8 ENGINE STOPS

    Che ck a nd a dju st a s d es crib ed

    F ue l I n ta nk

    - YES.

    YEStRe ple nis h a nd b le ed If necessary-NO

    L_F_U_e_lf i_l lt_e_rs_s_e_r_vl_ce_a_b_le_ -. ~~ NO~k_R _e_p_ la_ce ~

    YES,En gin e b ra ke e ng ag in g

    YES,Fuel o rcur t s er vi ce ab leYESt

    I dlin g s pe ed c or re ct

    (continued)

    C he ck a nd re pla ce If necessary-NO

    C heck orcurt and ble ed-NO

    NO~k_A_d_ jU_st ~

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    8361 ENGINE p. 19

    I nje cto r p um p d eliv ery co rre ct

    IYES,

    I nje ct or p ump c on tr ols s erv ic ea b le

    I 9 ENG INE EX CEEDS MAX IMUM R PMI~

    Speed gov ern or o pe ra ti ng c or re ct lyf-

    10 O IL PR ESSUR E TOO LOW OR TOO HIGH

    Pres su re r el ie f v a lv e oper at ing

    YES,0 11 p ump a nd d eliv ery p ip es s erv ic ea bleYES,

    -NO

    -NO

    -NO

    -NO

    C he ck d elive ry o n b en ch

    R e pla ce p arts sh ow in g d ete rio ra tio n a nd a djU st

    C he ck a nd re pla ce w orn p arts If n ece ssa ry

    C he ck a nd re pla ce I f n ec ess ary

    C he ck a nd re pla ce I f n ec es sa ry

    Main and big end beanngs serviceable R eplace beanngs and If necessary recondition crank-- NO . shaft

    (continued)

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    8361 ENGINE p. 20

    Engine 01 1 VIS COS itycorrectI- NO.

    Rep lac e engine 01 1 w rth o ne o f s urta ble V ISCOS ity

    II E XCESS IV E FUEL CONSUMPT IO N

    ~F ue l ta nk a nd p ip es s erv ic ea ble

    -

    YES, .E lim in ate a ny le ak s a nd re pla ce p arts showingdeterioration

    L-A_r_ f i_~_er_s_e_N_c _e a_ b _le '- _J1- NO.L I_R _e_p_ la_c_e ~

    Y E S, .I nje cto r a dj us tment c orr ec t

    YES, .I nje cto r p um p a dju stm e nt c orre ct

    Y E S, .LDA. dev ice serv iceab leYES, .

    In je ctio n p um p tim in g co rre ct

    - NO_'

    - NO_'

    - NO_'

    - NO_'

    C he ck o pe ra tio n a nd adjust as d es crib ed In

    C he ck a nd acjust o n te st b en ch

    Adiust the L.D.A device usrng tool 99309002

    Che ck s ta tic s ettin g o f I nje ctio n p um p

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    8361 ENGINE p. 21DISMANTLING THE ENGINE ON THE BENCH

    1349681Secure the engine to the SWivell ingstand 99322230 (2) bymeansof brackets 99361034 (I) Drain the lubricating oil fromthe sump

    Detach the oil level dipstick sleeve (I)

    134970 IDetach the pipe from the starter heater the pipe (5)from the Injection pump (6), the pipe (3) from the fuel returnpipe (4) from the Injectors

    ~Detach the pipe (2) from the Inlet manifold (I) and from theL DA (3), pipes (4, 6) from the fuel fil ter support (5) and fromthe Injection pump (8), pipe (7) from the Injection pump Forremoving the fuel filters, use tool 99360314

    134m)From the Injectors (2), detach the fuel return pipe (4) andthedelivery pipes (I) Removethe Injectors (2) Removethe Inletmanifold (3)

    From the turbocharger (2), remove the air duct Removethe oil pipe (4) from the support (6) and pipe (5) from the connection on the crankcase Remove the exhaust mamfold (3)complete with turbocharger

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    8361 ENGINE p. 22

    ~~

    ~O I l l ; ].~~~-J)~

    134974 1 1Remove the pipe (3) from the 0 1 1 breather (2) and from thecrankcaseRemove the valve gear covers (I)

    1 3 4 9 7 5 1 1Remove the Inhlbrtor filter (6) uSingtool 993603 14 Detach thecoolant pipes (I) from the filter mounting (5) and from the wa-ter pump (2) and from thewater pump (2) Take off the filter mounting

    Remove the fan shroud (2),the vrscostatrc fan (3), the alternator( I) and rts dnve belt

    [ i j 2 _ 7 i ]Remove the alternator bracket (I) Remove the flange (3) fromthe water pump (4), detach the pipe (2) from the thermostathousing (5) and remove the housing

    Remove the rocker shaft ( I)Remove the caps from the ends of the valves and Withdraw thepush rods (2)

    [0-

    Remove the cylinder head bolts (2) and, uSing tool 99360595(I), hft off the cylinder head and remove the gasket

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    8361 ENGINE p. 23

    Fit the pillars 99360722 (4) for retaining the cylinder liners (5 )tothe crankcase USingtool 993 603 14 ,remove the ad filters (3 )from the heat exchanger (2 ) and remove the heat exchanger

    Mark the position (arrow) Inwhich the Injection pump (2 ) ISfitted to the support (4 ) Fittool 993 6513 6 (I) to the unionsof the Injection pump (2 ) and remove the pump

    and starter motor (3)

    1349821Remove the pipes (I and 5) and take off the water pump (4)Removethe alternator bracket (2) andthe damper fiywheel (3)with the front and rear pulleys

    1349831Prevent the flywheel (I ) from rotating byfitting tool 9936035 I(2) to the flywheel and casing(3) Unscrew the screw (5) andtake off the hub (6 ) Unlock the screws attaching the flywheeland remove the tool

    Removethe sump (I), brackets (2 and 4) and the timing gearcover (3)

    1349851Remove the pipe (3) and the 01 1 strainer (I) from thecrankcase and from the oil pump (2), then remove the oilpump

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    8361 ENGINE p. 24

    Fit surtable handles to the flywheel so that rt can be rotatedPosition the engine verticallyRemovethe big end capsandtheir beanng shellsand then takethe connecting rod/piston assemblies(I) out of the cylinderliners

    .. If on drsmantlmg the connecting rod/piston assemblies~ It ISfound that the connecting rods and their capsare

    not numbered. the numbers should be stamped onthem according to the numbering of the cylinders towhich they belong

    Remove the attachment bolts of the flywheel (I). f it SUitablehooks (2) to Itand remove the flywheel ( I) from the crankshaftusmga cable and lifting tackle

    -_

    Unscrew the screwsand remove the rear support ( I) andthecover (2) with sealfor the crankshaft

    USinga SUitablewrench. unscrew the main bearing bolts andremove the caps (I) With their bearing shellsand the thrustwasher halves -....__/

    With the help of liftingtackle andtool 99360500 (I). raisethecrankshaft (2) and remove It

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    8361 ENGINE p. 25

    USingan Allen key, unscrew the screws (I) secunng the thrustplate of the camshaft (2) and remove the shaft from thecylinder block, taking care that the beanng bushes are notdamaged dunng the operation

    Extract the tappets (I) from their housings

    Withdraw the sphned bush (3)

    Remove the cover (2) and oil pipe (I) Take off the screws (3)and the nng underneath them (4)

    o1 3 4 9 9 6 1

    Remove the shaft Withgear (2) and gear (4) Take off the orchp(2) and remove the gear (I)

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    8361 ENGINE p. 26

    o @

    Take off the adjustment shim (8)Remove the locking tab of the strip (3) from nut (4) and takeoff the nutRemove the screw (7), the union (I) and detach the pipe (2)Remove the Intermediate gear shaft (9), the support (6) for theInjection pump drive shaft and the support (5) for the powersteering pump drive shaft

    USing an appropriate extraction tool (3), extract the valve (2)for piston cooling Jets from the crankcase (I)

    When dismantling ofthe engine IScomplete, the partsdismantled must be thoroughly cleaned and checkedfor soundnessThe following pages give instructions for the mainchecks and measurements to be carried out In orderto determine whether the parts are fit for re-use onreassembly

    '--_/REPAIR OPERATIONSCYLINDER BLOCKChecks and measurements

    1349941The rnside diameter ofthe cylinder liners ISchecked to ascertainthe amount of ovalrty taper and wear by means of gauge99395687 (2) fitted with a hundredths dial gauge (I), previouslyzeroed on the nng gauge (3) 112 mm In diameter

    Where the I 12 mm diameter ring gauge IS notavailable, use a micrometer for this purpose

    135000 IThe measurements must be earned out on each mdlvldualcyl inder at three different levels and Intwo planes at nght anglesto each other; as shown In the figureMaXimum wear IS found In line with the 1st measurement onaxis B

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    8361 ENGINE p. 27

    112000 - 112022

    ~If maximum wear of more than 0150 mm ISfound or maximumovahty of 0 100 mm compared with the values shown In thefigure, the cylinder liner must be replaced since the Internalsurface of the liner has been given soft nltrldlng treatment, forwhich the operations of gnndlng, lapping or truing up are notpermitted

    120,470120,490

    \35002\The plan shown In the figure gives the outside diameters of thecylinder liner and the Internal diameters of ItShousmg aswell asthe point at which these are to be measuredThe cylinder liners may If necessary be extracted and fittedseveral t imes In di fferent housings

    [35003 !Check that the mating surface (I) for the cylinder head IS flatusmg a straight edge and a feeler gaugeAfter ascertaining the areas of distortion, true up the matingsurface, havmg first extracted the locating dowels (2 ) andcylinder liners (3), Inaccordance with the procedures IndicatedIn section "540420 REPLACING CYLINDER LINERS",removing as little material as possible and bearing In mind that.after skimming, the protrusion of the piston from the cylinderliners must be 0 I - 0 25 mm

    1 3 s 0 0 4 \When the crankcase has been skimmed, restore the depth ofthe cylinder liner seating base so that the distance X ISWithinthe ranges of the subdivrsions of the followmg classesI 90 000 - 900 I aII 9001 I - 90020III 90021 - 90030IV 90031 - 90 040V 90 04 I - 90050

    .. The dirnens.on X ISthe average ofthree measurements~ earned out at three pomts 1200 apart

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    8361 ENGINE p. 28

    IIJ,00611

    Stamp the classof measurement recorded on the crankcaseatthe points shown by the asterisks

    Bheck the condition of the machining plugs In thecylinder block, Ifthey are rusted or there ISthe leastsuspiocn of leakage,replace themReplacing cylinder liners

    135007]POSitionhe parts (2 and 3) of tool 99360723 on the crankcaseasshown Inthe figure, checkingthat the plate (3) of the tool ISresting correctly on the cylinder linerScrew up the nut (I) and withdraw the cyl inder liner from thecrankcase

    Fitthe cylinder liners, proceeding asdescribed 1350081belowThoroughly cleanthe cylinder liners and

    crankcase (3) With chlorothene sothat there ISnores.cue of the old adhesrve,Degreasethe parts to which adhesive ISto beapplied both on the crankcaseand on the cylinderliners (seefig 45), on the baSISof the classesstamped on the crankcaseat the points shown bythe arrows, fit the shim (2) of the thickness shownInthe follOWingtable

    CLASS THICKNESS (mm)IIIIIIIVV

    318~3193 19 -r- 3203 21 ~ 330331 -'- 340341 - 350

    1350091USing a SUitable tool, apply LOCTITE 576 evenly to thecrankcaseat the pomt Indicated to form a ring 5 mm high,

    I position the shim (2, fig 44) of the thickness shown Inthe tableI and Insert the cyhnder liner Into the crankcase

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    8361 ENGINE p. 29

    --lacethe component of tool 99360445 (I)on a surface plate and zero the dial gauges

    position the component of tool 99360445 (3) onthe cylinder liner,fit the compression fixture (2) tothe tool and secure It to the crankcaseby meansof the four bolts (4)

    r : : : : tighten the screw ( I) to a torque of I I0 Nm(1Ikgm)

    Tlustorque corresponds to a loadof about 4000 kg Intheseconditions read off from the dial gaugethe protrusion of thecylmderhnerwluch should be,asanaveragevalue,0 16-025m The maximum deviation of the average valuerecorded between each individual cylinder liner mustbe not more than 003 mm

    If different values are found, replace the adjustmentshim according to the procedures already described

    1350121When fitt ing IScompleted, lock the cylinder liners (I) to thecrankcase (2) by means of the pillars 99360722. (3)

    Assembly of the engine must be finished Within 10hours of the application of LOCTITE 576 to thecrankcase

    VALVE GEARCamshaftChecking cam h f t and Journalalignment

    ~Arrange the camshaft (4 ) between the centres (I) and uSingthe hundredths dial gauge (2.) check the l ift of the cams (3)which should be1- 7077 mm for the Inlet camu 7373 mm for the exhaust cam

    StillWiththe camshaft (4) arranged between centres (I), checkthe bearing Journals(3) for misalignment uSingthe hundredthsdialgauge(2), this must not be more than 0020 mm Ifalargermisalignment ISfound, replace the shaft

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    8361 ENGINE p. 30

    54,94054,970

    MAIN DATA FOR THE CAMSHAFT

    The surfaces of the bearing Journals on the shaft and those ofthe cams must be perfectly smooth,

    To check the assembly clearance, measure the Inside diametersofthe bushes (fig 54) and the diameter of the camshaft Journals(I, fig 5 I), the difference will give the actual clearance presentIf clearances of more than 0 160 mm are found, replace thebushes and the camshaft too, If necessary

    If Instead there are signs of seizing or scoring, the shaft and ItSbushes should be replaced

    R EPLACING THE CAMS HAFT G EAR

    Check thatthe teeth of the camshaft gear ( I ) are not excessive-ly damaged or worn, If they are, replace It When fitting thenew gear; It should be heated In an oven for 10' at a tempera-ture of 1800 and then shrunk onto the shaft (4), having firstfitted the plate (3) and key (2) to the shaft

    BUSHES

    MAIN DATA FOR CAMSHAFT BUSHES AND THE IR HOUS INGS IN THE CRANKCASE Dimension to be obtained after the bushes have been Installed

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    8361 ENGINE p. 31Replacing the bushes

    ?') ~

    ' (. \,

    The surfaces of the bushes must not show any signs of seizingor scoring, If they do, replace themMeasure the bush ( I) Inside diameters usmg a bore micrometer(2), If values greater than the tolerances are found. replacethem Use an appropriate tool to dismantle and assemble thebushes

    Fit the bushes so that the 01 1 feed holes are lined upwith those In the crankcase

    After fi tt ing, ream the camshaft bushes usrng the appropr iatetools to bring the Internal diameter of the bushes to thenominal value Indicated In figure 54

    Replacing tappets

    MAIN DATA FOR TAPPETS AND THEIRHOUSINGS IN THE CRANKCASE

    ,

    Replacement of the tappets due to excessive clearance In thehousings Involves fitting oversize tappets and reaming out thehousings (2) uSing a surtable reamer (I)

    Replacement tappets are supplied In standard size and 10,020, 030 mm oversize

    INJECTION PUMP DRIVEReplacing bushes

    COMPONENT PARTS OF THE INJECTION PUMPSUPPORT

    Injection pump support - 2 Shaft - 3 Adjustmentshim - 4 Bush - 5 Adjustment shim

    - 6 Washer - 7 Crchp

    Remove the retaining C1rcIJp(7) and remove the shaft (2), washer(6) and adjustment shims (4 and 5) from the support (I) Checkthe mating surfaces of the shaft (I) and of the bushes (4), thesemust not show any deterioration and the fit clearance must notbe excessiveThe nominal diameter of the shaft IS49984 - 50 000 mm

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    8361 ENGINE p . 32

    135018I fexcessive f it clearance not attnbutable to the shaft ISfound,replace the bushes (2), usmg a surtable dnft to remove and fitthem

    HZ......... The bushes must be fitted with the JOint facing the notchLlI :n the support for lubrication of the adjustment shim,

    and they must be recessed by 05 - 08 mm with respectto the faces of the support. as shown by the arrows

    When the bushes (2) have been fitted, ream them out so thattheir nominal diameter IS50025 - 50050 mmAssemble the support components by reversing thedismantling operations

    POSition a new seal on the Injection pump support (I) and fitthe support to the crankcase

    POWER STEERING PUMP DRIVEReplacing the bushes

    I J5020 ISECTIONAL VIEW OF THE POWER STEERING

    DRIVE SHAFT SUPPORTI Support. timing gear- cover Side - 2 Bush

    - 3 Shaft - 4 Support , crankcase Side - 5 BushCheck the mating surfaces of the shaft (3) and bushes (2 and5) , these must not show any deterioration and the fit clearancemust not be excessiveThe nominal diameter of the shaft IS 36984 - 37000 mmIfexcessive fit clearance not attributable to the shaft (3) IS found,replace the bushes (2 and 5), USingaSUitable dnft to remove andfit them

    m To fit the bushes (2 and 5), I t ISnecessary to chi llthem In hquid nitrogen or heat the supports (I and4) so that there ISa temperature difference of 2700C between the components MaXimumtemperature permitted for the supports 3500 C

    When the bushes (2 and 5) have been fitted, ream them outWith a reamer so that their nominal diameter IS37050 -37073 mm

    POSition a new seal (I) In the support (2) and fit thesupport to the crankcase

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    8361 ENGINE p. 33

    On the Opposite side,fit the power steering pump attachmentflange

    7

    COMPONENT PARTSOF THE PISTON COOLINGJETVALVE

    Circhp - 2 Dish - 3 Spring - 4 Valve - 5 Washer- 6 Seal - 7 Valve body

    r - - - - - - - - - - - IN 258 26,------- --

    1------- :(Y) ,,,..-----;-:-----'-:-----'1 N 270 _I~ Jgf T :: ::~ ! i ~

    i"1AIN DATA FOR CHECKING THE SPRING FORTHE PISTON COOLING JETVALVE

    Fita new sealto the valve body (6) and fi t It to the crankcaseSecurethe oil pipe (2) to the crankcaseby means of the screw(5) Bend over the locking tabs onto the screws (3 and 5)

    Fitthe tappets (I) Into their housings

    Lubricate the bearingsof the camshaft(I) and Insert theshaft Into the crankcase

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    8361 ENGINE p.34

    Tighten the screws (I) secunng the camshaft retainingplate (2)

    CRANKSHAFT

    [2,477 - 72,500j~-r- -- --

    I~~ F F F r= / t-t--r Z ~ r-"" ' ',, IT - 1\I- ..... 1--1-- I--f-- . . . . . , Ir- I"- ~ \~~~~1-' I / , 1 \ / , I--~

    , , I , ,~ , n :' 1 \ J :!I I-- f-- I,I I " '\.\ I t--~ - - ' , I 1 I i' e--- :. I :- - ".-- 1-1- l- i--' P- , I - ' r - I ) l-I- I--l-r L ' I ~I-\..1- I-L_.,. !- ,I-- L i-LJ '---l.o l.o '-'-- L- '-- L-

    ---- ~-~-1-;9,777 -7 - 79,780 !L~~ J

    MAIN DATA FOR THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS

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    8361 ENGINE p, 35Measuring the main bearing journals and crankplns

    Before regrinding the Journals, measure the main Journals (2)with a micrometer ( I) and establish on the basts of the scaleof beanng undersizes (7) the diameter to which the Journalsmust be reground

    The classesof undersize are 0 254 , 0 508 , 0 762, I 016mmforthe main beanngshellsand 0 1 2 7, 02 5 4,0 5 08mm for the big end shells

    MEASUR ING THE MAIN BEAR ING JOUR NALS

    Main bearing Journals and crankpms are always allreground to the same undersize class so as not toImpair crankshaft balance

    ~ - - - - - 135091 1M EA SU RIN G TH E CR AN KP IN SDunng the grinding operation, take great care to comply Withthe values for the main Journal and crankpin blend radiusesgiven In the following figures

    fl Regrinding earned out on main Journals or c rankpmsmust be Indicated by appropriate markings stampedon the side of crankweb no IFor undersize crankpms the letter MFor undersize main Journals the letter BFor undersize crankpms and main Journals the let tersMB

    Rett = ground

    cRett 0,4 .~

    DETAIL OF MAIN JOUR NAL BLEND RADII

    Rett = ground

    DETAIL OF CR ANKP IN BLEND R ADII

    Rett = ground

    c : : t" -I,'-- _ _ t'V l_ _

    DETAIL OF CENTRE MAIN JOUR NAL BLENDRADI I

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    8361 ENGINE p. 36Checking main journal alignment

    c o

    I 3S033 IThis check must be earned out after regrinding, Ifany,of theJournalson the crankshaft (3) by positioning the crankshaft be-tween centres (2) and uSingahundredths dialgauge (I) forthechecko Main Journal alignment maximum tolerance> 0 f 0 mm (total reading on the dial gauge)

    STANDARD POSITIONEXTREMEPOSITION 025 mm if- EXTREMEPOSITION 0 2S rnm

    '~+-'---t - -} . CRANKPIN\ ', MAIN JOURNAL

    o Alignment of the o ankprns With the mainJournals the centreline of each pair of rrankpmsand the centreline of the main Journalsmust beInthe sameplane the maximum tolerancepermitted at right anglesto this plane IS 025 mm

    fJ For the distance between the axis of rotation ofthe shaft and the outer surface of the crankpms,the maximum tolerance permitted IS 0 10mm

    Replacing camshaft and oil pumpdrive gears

    Check that the teeth ofthe gear ( I ) are not damagedor worn,Ifthey are, remove them usmg a surtable extractor (3 )

    ... When fitting the gear (I ) to the shaft (2), there must be~ a temperature difference of 120 - 1500 C between thetwo parts

    Fitting main bearingsReplacement main bearings are supplied In rnsrde diameterundersrzes of 0 254, 0508, 0762, I 0 I 6 mm

    Do not carry out f it ting operations on thebearings

    I 3272S IPosition the bearing shells (I) Inthe main bearing housings Inthe crankcase

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    8361 ENGINE p. 37

    134990 IUSing tool 99360500 (I) fit the crankshaft (2) onto the beanngshells

    Measuring main bearmgassembly clearances

    The clearance between the crankshaft Journals and the rele-vant beanngs ISchecked by the plastigage method, proceedingas followso thoroughly clean the parts and remove all traces

    of 011o arrange a strip of plasngage (3) on the mainJournals (2), parallel With the lengthwise axso fit the caps (I) together With the bearing shells tothe relevant housmgs

    o tighten the main bearing cap secunng bolts ( I ),havmg first lubricated them, to the prescnbedtorque of 60 Nm (6 kgm)

    1350371o f it tool 99395216 (2) to the angle gauge wrench and

    tighten the bolts (I) a further 1200

    Checking crankshaft end float

    1350381USing a dial gauge With magnetic base (I), check the end floatof the crankshaft, thrs should be 0068 - 0294 mmIf a larger end float IS found, replace the thr ust washer halvesWith new ones of standard thickness or If necessary 0 127,o 254 or 0 508 oversize

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    8361 ENGINE p. 38

    [; remove the main beanng caps (I)The clearance between the main beanng shells and their respe -trve Journals ISmeasured by comparing the width of the plastigag(3) at the point of greatest flattening with the scale drvisions giveon the package (2) containing the plastigageThe numbers given on the scale show the fit clearance In mwhich should be 0068 - 0794 mm

    1 3 2 6 0 3 1Position the thrust washer halves (I) on the 6th housing withthe surface covered with antr-fnction alloy towards the faongon the crankshaft

    1 32731 IFit the main bearing caps with beanng shells, before fitting thecap (I). position the halves of the thrust washer (2) with thesurface covered with antr-fncnon alloy towards the facmg onthe crankshaft

    40+60

    ... To re-use the main beanng attachment bolts, check~ that at the pomt shown, the diameter d IS 13 5 mm

    If not, replaceLubncate the thread and the head underside (--) with engineoil, fit and tighten to a torque of 60 Nm (6 kgm)

    Further tighten the screws (I) by 1205, usmg tool 99395216(2 )

    Crankshaft rear cover

    USing Installing tool 99374195 (2) and handle 99370005 (I),fit the seal (3) to the rear cover (4)

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    8361 ENGINE p. 39

    Lubricate the seal(2) and.havingfirst fitted the gasket.fittherear cover ( I )

    Fitthe clutch bell housing (I) andtighten the securing screwsto the prescribed torque

    x

    1350441Check the seating surface for the clutch plate If scoring ISpresent. the flywheel must be skimmed... Checkthat there are nocuts,swellingsor stampingon~ the circular zone (X), If there are, replace the

    flywheel

    Replace the flywheel ring gear

    If the teeth of the ring gear (I) fitted to the flywheel are badlydamaged, replace the ring gear Before fitting. the ring gearmust be heated to a temperature of 80 C

    Fit the flywheel (I) to the crankshaft

    f l S d

    i""""-o~r-- ~---J

    25+30:~

    To re-use the flywheel attachment bolts, checkthat atthe point shown, the diameter d IS155 mm If not,replace

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    8361 ENGINE p. 40

    Preventthe flywheel (I) from rotating usingtool 9936035 I (3)and tighten the bolts (2), having first lubricated them withengine oil, to a torque of 100 Nm (10 kgm)

    USingtool 99395216 (2), t ighten the bolts (I) further for 60,remove tool 9936035 I (3)

    CONNECTING RODIPISTONASSEMBLY

    COMPONENT PARTSOF THE PISTON/CONNECTINGROD ASSEMBLY

    Retaining clips - 2 Gudgeon pin - 3 Piston - 4 Piston rings -5 Bolt - 6 Bearing shells - 7 Connecting - rod - 8 Bush

    0,---~!-"-----.;...____r

    Remove the piston rings (2) from the piston (3) usingtongs99360183 (I)

    The gudgeon pm ( 1) r et ain i ng cl ips (2) a re r emovedusmq pliers (3)

    Piston

    The diameter of the piston (I) ISmeasured usmg amicrometer (2) to determine the assemblyclearance

    .. The diameter must be measured 22 mm from the~ base of the skirt

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    8361 ENGINE p. 41

    The clearance between the piston and cylinder liner can alsobe measured usmg a feeler gauge (I)

    Gudgeon pin

    The pinsarefitted with clearance both Inthe small end and Inthe piston

    ----------]--- -- - c--- - - -- - I

    * 3,200 I 2,540 I l 4,030 jl3,230 I 2,560 I 4,050-- - ---- --- - -- -----~

    Conditions for correct gudgeon pin topiston fit

    When fitting new pins,checkthe correct fit with the housingInthe piston by carrying out the following checko lubricate the pin and Its housing In the piston

    bosseswith engine 011o holding the pin Ina vertical position, Insert ItInto the bossesIn the piston

    U It should be possible to Insert the pin simply bypressingon Ito the pin should not drop out of the bossesbyItself

    *

    MAIN DATA FOR THE PISTON, PISTON RINGS AND GUDGEON PIN"' The dimension ISmeasured on the 0 I175 mm

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    8361 ENGINE p. 42Piston rings

    l_I6552jCheck the thickness of the piston ring (2) uSinga micrometer(I)

    Check the clearance between the piston nngs (3) and thegrooves on the piston (2) uSinga feeler gauge (I)

    [Jill]The compression ring (2) Inthe first slot ISwedge shaped Theclearance X between the compression nng and the groove ISmeasured by posit ioning the piston (I) with the relevant nngInthe cylinder liner (3) In suchaway that the compression nnghalf projects from the cylinder liner

    ~----2

    Connecting rods

    t r m ~2020 4200042035 '42,0062007020080

    76,698 06,718[35059j

    MAIN DATA FOR THE CONNECTING ROD, BUSH,GUDGEON PIN AND BEARING SHELLS

    Dimension to be obtained after Installingthe bushChecking connecting rod for distortion

    1 3 2 7 3 8 1Check that the connecting rod axesare parallel The tolerancepermitted IS0 08 mm measuredat 125mm from the lengtbwrseaxis of the rod

    Eachconnecting rod ISmarked on the body andcap with a number Indicatingthat they frt togetherMoreover, It may be stamped with the number ofthe cylinder In which It ISfi tted In caseofreplacement, It IStherefore necessaryto numberthe new connecting rod with the samenumber asthe one replaced

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    8361 ENGINE p. 43Bushes

    135061 I Fitthe bearing shells(I) to the connecting rod and to the capPositionthe piston (4) on the connecting rod (3) so that thewords "LATO PUNTERIE" (TAPPETSIDE) (I) on the crownare on the opposite sideto the number stamped on the con-necting rod Insertthe gudgeon plr (2) and fit the retainer or-chps

    [35060 IThe bush(2) ISremoved and refitted usmg the appropriate drift(I)

    After Installingthe bush In the connecting rod smallend, remove the part which protrudes atthe sideandthen ream the bush to the specified diameter uSingreamer 9930 I044

    ASSEMBLING THE CONNECTINGRODIPISTON ASSEMBLYAssembling connecting rod to piston

    Checking connecting rod/piston for distortion

    Check the connecting rod-piston assemblyfor distortion uSingfixture 99395363 (I) and a feeler gauge (2 ) The planeof thepiston crown must be exactly at right anglesto the plane of thefixture 99395363Fitting piston rings

    The piston rings (2) are fi tted to the pistons (3) usmgtongs99360183 (I) The ringsmustbe fitted with the word TOP fac-Ingupwards, andalsothe ring gapsmust be located sothat theyare 1200

    Do not carry out any fitting operations on thebearing shells

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    8361 ENGINE p. 44

    The connecting rod/piston assembly(I) ISfitted Into the cylin-der liner usmg ring clamp 99360605 (2)Lubricate the parts concerned before fitting

    When fitting the connecting rod/pistonassembliesInto the liners, check that

    : : : : : J the connecting rod number correspondsto the number of Its cylinder

    [J the words "LATO PUNTERIE" (TAPPETSIDE) stamped on the piston crowns arefacmg the camshaft

    [J the numbers on the connecting rods arefacmg away from the camshaft Sideo the piston nng gapsare staggered I20apart

    Measuring crankpin assemblyclearance

    1 3 5 066JTo measure the clearance, carry out the followingoperationso thoroughly clean the parts and remove all traces

    of 01 1o POSitiona strip of plastigage(2) on the crankshaftJournals (I)

    [J lubricate the threads and undersides of the headsof the big end attachment bolts (I)

    o f it the connecting rod caps (2 ) and, uSingatorquewrench, tighten the bolts ( I ) to atorque of 40 Nm

    usmg tool 99395216 (2), tighten the bolts (I)a further 35

    o remove the connecting rod cap and determinethe clearance by comparing the Width of thep las ng ag e (2 ) With the scale drvtsrons given onthe package (I) containing the plastigage

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    8361 ENGINE p.45Fitting big end caps

    x

    ... Tore-use the bigend capattachment bolts, checkthatLi.J atthe point shown, the diameter X IS135 mm If not.replace

    Lubricate the bigend bearingshells,the threads andundersidesof the headsof the securing bolts (2)Fit the big end caps (3) and tighten the bolts (2), having firstlubricated then Nlth engine 011, to a torque of 40 Nm, thentighten further, b/ mean~of tool 99395216 (I), to an angleof35" I

    Checking piston position

    When fittmg IScomplete, check the protrusion of the pistons(3) at TDC With respect to the cylinder liner face uSinga dialgauge ( I) With magnetic base (3)The top landsof the pistons must project 0 I - 0 25 mm abovethe face of the cylinder liners (2)

    TIMING GEARS

    Checking and replacing theidler gear

    Check the Idler gear for damageand excessivetooth wear re-placmgIt If necessaryCheck the contact surfacesof the bush (I) for scoring or signsof seizing,or excessive playon the bearing Journal, Ifthese arefound, replace the bush (I) uSinga SUitabledrift

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    8361Replacement of idler gear bush

    ENGINE p. 46

    50,05050,075

    0,5 - 0,8 0,5 - 0,8

    \35073\Fit the bush (I) so that It IS recessed with respect to the faceofthe gear by 05 - 08 mmAfter f it tmg, ream the bush to obtain the nominal diametershown In the figure

    L49,97550,000

    Check the surface of the Idler gear pin for damage or excessivewear Check that the 01 1 feed holes are not blocked

    F r t t he pin ( 4) and posit ion the adjustment shim ( 5) on It F i t t h eInjection pump drive gear (I), the power steering pump drtvespindle and the support (3)Fitting the idler gear and setting the timing

    Turn the flywheel ( I) until the 0 stamped on It Indicating TDCIS In hne with the pointer (2)

    Uo o

    o \35077Instal l the Idler gear (2), locating rt so that the numbers I, 2 anc3 stamped on It Itne up with the same numbers engraved on th ecrankshaft gear (3), the camshaft gear (4) and the Inject ion purnrgear (I)

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    8361 ENGINE p. 47

    Fit the washer (I) and crchp (2), Insert the oi l pipe (4) Inthesupport (3 ) and secure thrs to the pin (5 ) bymeansof the union(6)

    FITTING THE INJECTION PUMPAND SETTING THE TIMING

    Turn the flywheel until the mark corresponding to15 30' of Injection advance ISexactly lined up with thereterence pointer (I)

    Installthe connection coupling (I) on the dnve shaft housedIn the support (2) remembenng that It engagesvia a doubledog and a double recess

    Removethe Inspection plug (2) from the Injection pump,turnthe shaft until the tappet relating to the above hole ISInthestart of delivery positionUSingtool 99365 I 36 (I), fit the Injection pump, liningup themarks previouslymadewhen dismantling,andthen securetheInjection pump to Its support

    Ifthe engagement dogs of the coupling JOintand theInjection pump shaft are found to be 1800 out ofphase,turn the crankshaft one revolution

    1350821Fittool 99365134 (I) t it ted with a dial gaugeto the Injectionpump and rest the stylus (2) of the tool on the crown of thetappetZero the dial gaugewhen the tappet ISat BDCTurn the flywheel backwards about half a turnThen turn the flywheel Inthe opposite direction and checkthat when the mark corresponding to 15:1: 30'of Injection advance on the flywheel IS l ined up with thereference pointer (2, tig 133), the plunger hastravelled a startof delivery pre-stroke, read off from the dial gauge, of 3 55 0 05 mmIf a different value ISfound, loosen the screws (3) and adjustthe cam so asto achievethe prescribed pre- stroke Repeatthe check and tighten the screws (3)

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    8361 ENGINE p. 48CYLINDER HEADHydraulic leak test

    I135083 I I

    Before dismantling the cylinder head, carry out the hydraulicleak test 1Fit the appropriate equipment to the cylinder head Pump Iwater heated to approx 90 C and at a pressure of 4 - 5 bars 1Into the cylinder head Under these conditions, no leaksshould be found, If they are, replace the cylinder head

    DISMANTLING OF VALVES

    1350841Rest the cylinder head on the workbench and, uSing too99360357 (6), apply pressure to the spring cup (2) so that bcompressing the spnng (3) the valve collets (I) can be removedThen take off the upper cup (2), the spring (3) and the lowercu(4)Repeat the operation on all the valvesTurn the cylinder head upside down and withdraw the valves (5)

    Checking the mating surface of the headwith the cylinder block

    1350861The mating surface of the head with the cylinder block ISchecked usiog a straight edge and a feeler gauge If values ofmore than 0 15mm are found overthe whole length of the sur-face, true up the head on a SUitable surface grinder; removingas l it tle material as possible

    VALV~SRemoving deposits and checking valves

    @ill]Remove carbon deposits from the valves uSing a SUitable wirebrushCheck the valves for signs of seizing or cracking and also, usmga micrometer; check that the diameter ofthe valve stem ISwithinthe specified limits (see fig 141) If not, replace the valves

    Refacing the valvesI f necessary, reface the seat ings on the valvesusmg grinding machine 9930 I0 14, setting an angle of 45 15' 5' for exhaust valves and 65 15' 5' for Inlet valves remov-Ing as l itt le material as possible

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    8361 ENGINE p. 49

    INLET EXHAUST13 50871

    M AIN D ATA FO R VALVE S AN D VALVE G UID ES Drmension to be obtained after Install ingthe valve guides

    Checking valve stem to valve guide clearance

    ~ r-:

    I 350SS 1USing a dial gauge (2) with magnetic base (I), check the play be-tween the valve stem (3) and Its gUide If excessive play ISfound,replace the valve and If necessary the valve guide

    VALVE GUIDE

    FITTING VALVE GUIDESA Inlet valve guide B Exhaust valve guide

    135089]The valve guides are removed uSing drift 99360481 (I)They are fitted usmg dnft 9936048 I (I) equipped With theadaptor (2)L 99360495, for Inlet valve gurdes (3)L 99360496, for exhaust valve gurdes (4)Adaptors 99360495 and 99360496 determine the correctf it ting POSition forthe valve guides Inthe cyl inder head, If theyare not available, the guides must be Installed In the cylinderhead so that they protrude from It by the amounts shown Infigure 143

    Replacement valve guides are also suppl iedWith the outside diameter 0 2 mm oversize

    Reaming the valve guides

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    8361 ENGINE p. 50Recutting the valve seats

    The valve seats In the cylinder head are recutwhenever the valves or valve guides arereconditioned or replaced

    1350921RECESSING OF THE INLET AND EXHAUST VALVES

    FROM THE CYLINDER HEAD FACE

    After recutting the valve seats, check that the recessing of theInlet and exhaust valves with respect to the cylinder head faceIsOO-03 mm

    Valve leakage test

    CD-

    1350461The leakage test on the valves In the cyh nder head ( I) IScarriedout uSing the appropriate equipment (2 and 3)

    Replacing injector holder cases

    Inthe second Instance, the case must be replaced, proceedingas followso tap a thread In the case usmg tool 9 93 90 42 5 (I)

    ... The stop bush (2 ) must be posmoned about 9 mmLJ from the end of the tool (I)

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    8361 ENGINE p. 51

    using extractor99342145 (I), extract the casing fromthe cylinder head

    USing a surtable tool ( I). remove any copper residue left In thesplines In the cylinder head

    Lubricate the seals (2). fit them to the case ( I ) and Insert thelatter Into the housing In the cylinder head

    Spread the lower seating of the case (3) In the cylinder headusmg spreading tool 99365063 (I) and bush 99394019 (2)

    Ream the hole In t he case (2) using reamer 993940 17 (3) andbushes 99394019 (I)Checking injector protrusion

    /35100 ICheck the protrusion of the Injector (I) from the cylinder headface If necessary. adjust the Injector protrusion with respectto the cylinder head face by recutting the seating usmg cutter99394018 (4) and bush 99394019 (I). the value should be I 04mm

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    8361 ENGINE p. 52VALVE SPRINGS

    ! 165871

    Before fitting, the characteristics of the valve springs must bechecked usmg tool 99305049, and the data on load and elasticdeformation compared with those given for new springs Inthefollowing figure

    618 24N

    MAIN D ATA FOR CHE CK IN G TH E V AL VE S PR IN GSFitting the valves

    Lubricate the valve stems (3) and Insert them Into their valveguides. using Installing tool 99360292 (I), fit the seals (2) tothe exhaust valve guides (4)

    On the cylinder head arrange the lower spring cup (4), thespring (3) and the upper spring cup (2), uSingtool 99360357(6), compress the spnng (3) and secure the parts to the valvewith the spilt collets ( I )

    The part of the spring with the more closely space:coils (marked with paint) must face towards the heac

    To fitand tighten down the cylinder head, proceed as de-scribed belowo arrange the gasket (I) on the crankcase with

    the word ALTO (TOP) (2) facing the operator

    To re-use a cylinder head bolt, check that at the pomX shown, the diameter IS 155 mm If not, replace th:bolt

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    8361 ENGINE p. 53

    C i ? J O (~

    o position the cylinder head on the crankcase,lubricate the bolts and screw them down

    23 19 15 18 22 2611CID 7CQ) 3CID 1CID 4CO] 8@'2O~f.;\0G\00~O~O~O~O~O~~13 0 9 0 5 0 2 0 6 0 10 0 14

    25 21 17 16 20 24

    o tighten the bolts In the order shown In the figureand uSing the procedure described belowstage I, usmg a torque wrench (fig 164), carry outInitial tightening to a torque of I 18 Nmstage 2, retighten to a torque of I 18 Nm

    oo

    o stage 3, f it tool 99395216 (I) to the angle gaugewrench and tighten by an angle of 90 3stage 4, tighten by an angle of 90 3stage 5, for bol ts I to 14 only, tighten by an angleof 45 3

    oo

    PUSHRODS

    The valve push rods must be free from distortion, the cup seat-1ngsfor the adjustment screws and the ball ends locating In thetappets must not show any signs of seizing or wear, If t hey do,replace the rodsPushrods for In let and exhaust valves are Ident ical and thereforeInterchangeable

    Fit the pushrods ( I) Into their seatings

    ROCKER SHAFTROCKERS

    COMPONENT PARTS OF THE ROCKER SHAFTI Circlip - 2 Adjustment shims - 3 Rockers - 4 Pedestal forshaft - 5 Spring - 6 Shaft

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    8361 ENGINE p.54

    24,03624,015

    I l E F @ @ @ @ @ @ i 1 D

    MAIN DATA FOR ROCKER SHAFT PEDESTALS , ROCKER SHAFT AND ROCKERS

    '--;~~040-24,061L _

    Check that the contact surfaces of the rockers with theshaft and of the shaft with the pedestals are not excess-ively worn or showing deter iorationCheck that the plugs fitted to the ends of the shaft pro-vide a perfect seal

    Fitting the rocker shaft andadjusting the operating clearancebetween the valvesand rockers

    Fit the caps onto the valve stemsFit the rocker shaft assembly ( I )Tighten the nuts (2) secunng the pedestals (3) to atorque of 50Nm, then tighten them a further 90, uSingtool 99395216 to check this

    USing wrench 99350 I08 (I), a feeler gauge (2) and a b--hexa-gon wrench (3), adjust the clearance between the valves androckers as Indicated belowo rotate the crankshaft until the valves of no I

    cylinder are rocking and adjost the valves markedWith an asterisk as shown In the table

    _:c,,-,ylc:._ln:_::dc:::e:_r_no=--_ c _ _ _ - - ' 2 . , _ _ _ _ _ _ _ - : 3 _ _ 4 ... 5 6Inlet * * *exhaust ., . , *o rotate the crankshaft until the valves of no 6

    cylinder are rocking and adiust the valvesmarked With an asterisk as shown In the table

    cylinder no 2 3 4 5 6Inlet . , . , . ,exhaust * .)j(

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    8361 ENGINE p. 55LUBRICATION

    Enginelubrication ISobtained by means of a gear type pump(fig 173) fit ted to the lower part of the crankcase In linewiththe front main bearing It ISdnven bythe crankshaftgear

    OIL PUMP

    SECTIONAL VIEW OF THE OIL PUMPI Pump body - 2 Dnving gear - 3 Cover- 4 Oil pump drive gear - 5 Dnven gear

    Check that the gears (2, 4 and 5) are not worn or show-Ingdeterioration and that their shaftsdo not haveex-cessiveplay Inthe housingsInthe body (I) orthe cover(3)Ifany fault ISfound, replace the oil pump complete

    HEAT EXCHANGER

    Remove the attachment screws (I) and take off thecover (2)Remove the attachment screws (3) and take off theheat exchanger (4)

    The following components are housed In the heatexchanger mounting the pressure relief valve, set-t ing 75 bars,the fine filtered oil delivery regulationvalve, setting pressure 4 bars

    Pressure relief valve

    Removethe screw (2) secunngthe bracket (3) retainingthe pressure relief valve ( I) and remove the valve fromthe heat exchanger mounting (4)

    COMPONENT PARTSOF THE PRESSURERELIEFVALVE

    I Valve body - 2 Seal- 3 Spnng - 4 Valve- 5 Circbp

    Remove the circhp (5) and Withdraw the spnng (3) and thevalve (4) from the valvebody ( I)Checkthatthevalve (4) slidesfreely Inthe valvebody (I) With-out excessiveplay

    MAIN DATA FOR CHECKING THE RELIEFVALVESPRING

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    8361 ENGINE p. 58

    /L~~;'7JPosition the gasket on the crankcase and fit the sump (I)Fit the brackets

    Fr t the alternator bracket (2), the water pump (4) and pipes (4and 5), fit and adjust the pulse transmitter as followso screw Inthe transmitter (3) until contact occurso unscrew one turn, corresponding to a gap of I mrno tighten the lock nut to a torque of 40 12 Nm

    Then fit the heat exchanger (2) and the compressor (I)

    I I

    I Fit the thermostat housmg (5) and attach the pipe (2)to ItRefit the flange (3) to the water pump (4)Fit the alternator to the alternator bracket ( I) with thednve belt

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    8361 ENGINE p. 59

    Ifa different value ISfound, adjustthe tension of the belt ( I) bymeans of the tensioner (2).. After the engine has run for a period of I h, again~ check that the tension IS40 - 50 daN, If not. adjust the

    belt tension once again

    Fit the viscostatrc fan (3) and secure It to the pulley (4) bymeans of the nuts (5)

    F it the fa n s hro ud (1)

    C F 9 Y 5 JFitthe mounting (5) and screw the Inhibitor fi lter (6) onto ItConnect pipes (3 and 4) to the water pump (2)

    and pipe (I) to the mounting (5) and to the waterpump (2)

    ! 35133JTo clean the oil breather filter. mark the position In which thecover (4) ISfitted to the rocker cover ( I) and remove the filterRemovethe orchp and take out the filter components (2)

    Fitthe valve gear covers (I )Connect the 01 1 breather pipe (3) to the breather (2) and se-cure Itto the crankcase

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    8361 ENGINE p. 60

    Fit the Inlet manifold (3) andthe Injectors (2)Connect the fuel delivery (I) and fuel return (4) pipes to the

    i : 1Fr t the fuel filters Connect pipes (4 and 6) to the filter mount-IIng (5) and to the injection pump (8), pipe (2) to the Inletmanifold (I) and to the LDA device (3), pipe (7) to the Injec-Inon pump (8)

    Connect pipe (5) tothe uuectionpump (6), pipe (3) to the fuelrecovery pipe (4), pipe (I) to the therrnostarter

    [i4~Fitthe air duct (2) and the sleeve (I) for the ad level dipstick

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    a361 ENGINE. 61OVERHAULING THE TURBO-

    ..,_" CHARGER TYPE KKK,K27.2Preliminary checks

    21---------..

    Thoroughly clean the outside of the turbocharger uSing anti-corrosion and anti-oxidising liquidsMark the assembly position of the compressor body (3) to theflange (2) and of the flange to the centre body (I) Separatethe compressor body (3 ) from the flange (2 ) by removing theretaining screws (4 )

    1351381

    Mark the assembly posrtion of the turbine body (2) on thecentre body (I)Remove the securing screws and separate the centre body ( I )from the turbine body (2)

    After detaching the turbine and compressor bodiesand before proceeding to check the play In the bear-mgs, check that the above components and thecentre body are free from wear or erosion or foreignobject Impacts, also, there should be no carborused0 1 1 present In the 0 1 1 outlet portIf even one of these pomts IS f ound, replace theturbocharger complete

    i 3 5 1 3 7 1 1

    Checking bearing play

    [D-

    The end and radial play In the beanngs should bemeasured on the shaft at the turbine rotor (2) end

    Position the stylus of the dial gauge ( I)with magnetic base onthe spindle (2) and zero the dial gaugePress the spindle (2) In the directions shown by the arrows andcheck that the end play In the bearings ISno more than 0 I 6mm

    L3~lj iJPosition the stylus of the dial gauge (I) on the spindle (2) atthe pomt shown In the figure USing a spring balance (3), pulldown on the spindle with a force of 50 N and zero the dialgauge In t hese conditions Stili with a f orce of 50 N, pull up onthe spindle and measure the spindle deflection on the dialgaugeThis should be not more than 042 mmRepeat the check at one other point at least on the spindle

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    8361 ENGINE p. 64Assembling

    I 32802JUSing pliers (4), fit the Inner circhps (3) to the centre body (5),Insert the bushes (2 ) lubricated With engine oil and secure themWith the outer c ir chp s ( I)

    OJ------~~-=~[IJ.----~

    Position the orchp (2 ) In Its housing on the turbine rotorshaft ( I)

    Lubricate the turbine rotor shaft (2), fitthe heat shield (3), fitthecentre body (I)vvhen compressing the circhp (4), make sure that the openingIS90 away from the 0 1 1 feed hole.. The circhp (4) IScorrectly positioned In ItS housing If the~ heat shield (3) and centre body ( I) rotate freely

    Position the washer (3), spacer (2 ) and axial bear ing ( I )In the centre body (4 )

    Fit the thrust washer (2) and the oil thrower (I)

    @ 1 4 6 JFit the bush (2) complete With orclp (3) to the flange (I)

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    8361 ENGINE p. 65

    Fitthe Inner seal (2) to the flange(I) and fit thisto the centrebody (3), lining up the marks made when dismantling

    .. The seal (2) must be coated with NEVER-SEEZ~ compound

    --r 1351481Apply LOCTITE 640 to the threads of the screws (I) andtighten them to a torque of 6 Nm (06 kgm)

    (J]------~[I)----____,,_~r n >..--=---+-~~~F

    [ 3 2 8 " @Heat the compressor rotor ( I) to 1300C Lubncatethe rotorshaft (3) and frt the compressor rotor ( I) to this Screw on anew securing nut and tighten Itto atorque of7 + 2 Nm, (05

    Position a new seal(3) Inthe housingon the Intermediate drsc(2) and fit the compressor body (I) to the centre body (4),taking careto line up the marks made when dismantlingTighten the screws secunng the compressor body to the

    @ill]Fit the centre body (I) complete Into the turbine body (2),taking care to line up the marks made when dismantlingTighten the screws secunng the centre body to the turbinebody to a torque of 20 Nm (2 kgm)

    The threads of the turbine body secunng screwsmust be coated with NEVER-SEEZ compound be-forehand

    .:TJ------~[I]---~~~W\~S:-ITJ-_~~-~~(I]------+---t"f-~