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Iveco Stralis AT/AD. Manual - part 25

Apply the tool 99360321 (6) to the gearbox (3).

- Mount the engine brake lever retaining springs (3).
- Connect the pipe (2) to the engine brake cylinders (4) and

to the cylinder with the engine brake solenoid valve (1).

Figure 174

Figure 175

Figure 176

45261

Lock the screws (2) fixing the rocker-arm shaft as follows:
- 1

phase: tightening to a torque of 40 Nm (10 kgm) with

the torque wrench (1).

- 2

phase: closing with an angle of 60

° using the tool

99395216 (3).

60574

71776

71777

Figure 177

Mount the electric wiring (2), securing it on the
electro-injectors with a torque screwdriver (1) to a torque
of 1.36 - 1.92 Nm.

The arrow shows the direction of rotation of the
engine when running.
Using the above-mentioned tool, turn the engine
flywheel (1) in the direction of rotation of the engine
so as to take the piston of cylinder no.1 to
approximately the T.D.C. in the phase of combustion.
This condition occurs when the hole with one
reference mark (4), after the hole with two
reference marks (5) on the engine flywheel (1), can
be seen through the inspection window (2).

ENGINE F2B

TRALIS

AT/AD

Base - January 2003

71774

60573

60575

Figure 178

Figure 179

The exact position of piston no.1 at the T.D.C. is obtained
when in the above-described conditions the tool 99360612
(1) goes through the seat (2) of the engine speed sensor into
the hole (3) in the engine flywheel (4).
If this is not the case, turn and adjust the engine flywheel (4)
appropriately.
Remove the tool 99360612 (1).

Set the dial gauge with the magnetic base (1) with the rod
on the roller (2) of the rocker arm that governs the injector
of cylinder no.1 and pre-load it by 6 mm.

With tool 99360321 (6, Figure 177), turn the crankshaft
clockwise until the pointer of the dial gauge reaches the
minimum value beyond which it can no longer fall.

Reset the dial gauge.

Turn the engine flywheel anticlockwise until the dial gauge
gives a reading for the lift of the cam of the camshaft of 4.90
± 0.05 mm.

The camshaft is in step if at the cam lift values of
4.90

±0.05 mm there are the following conditions:

1) The hole marked with a notch (5) can be seen through

the inspection window

2) The tool 99360612 (1) through the seat (2) of the

engine speed sensor goes into the hole (3) in the engine
flywheel (4).

77259

If you do not obtain the conditions illustrated in Figure 180
and described in points 1 and 2, proceed as follows:

1) Loosen the screws (2) securing the gear (1) to the

camshaft and utilize the slots (1, Figure 182) on the gear
(2, Figure 182).

2) Turn the engine flywheel appropriately so as to bring

about the conditions described in points 1 and 2
Figure 180, it being understood that the cam lift must
not change at all.

3) Lock the screws (2) and repeat the check as described

above.

4) Tighten the screws (2) to the required torque.

Figure 180

Figure 181

ENGINE F2B

TRALIS

AT/AD

71778

77259

Figure 182

Turn the flywheel (4) again to bring about the following
conditions:

- Notch (5) visible through the lower inspection window;

- The tool 99360612 (1) inserted in the hole (3) in the

engine flywheel (4) through the seat (2) of the engine
speed sensor.

77260

Phonic wheel timing

Turn the output shaft bringing cylinder piston 1 at
compression stage to TDC.; turn the flywheel by about 1/4
turn in opposite direction than normal direction of rotation.
Turn the flywheel again according to normal direction of
rotation until the hole marked with the double notch (4) can
be seen through the inspection hole set under the flywheel
housing. Fit tool 99360612 (5) into the flywheel sensor seat
(6).
Fit tool 99360613 (2), through the timing sensor seat, on the
tooth obtained on the phonic wheel.
Should tool (2) fitting be difficult, slacken screws (3) and
direct the phonic wheel (1) properly to position the tool (2)
on the tooth. Tighten the screws (3).

Mount the gear (2, Figure 182) with the 4 slots (1,
Figure 182) centred with the fixing holes of the camshaft,
locking the relevant screws to the required tightening torque.
Check the timing of the shaft by first turning the flywheel
clockwise to discharge the cam completely and then turn the
flywheel anticlockwise until the dial gauge gives a reading of:
4.90

± 0.05 mm

Check the timing conditions described in Figure 180.

Figure 183

Figure 184

When it is not possible to adjust advance through the slots
(1) and the camshaft turns because integral with the gear (2);
thus the cam lift reference value varies and it is necessary to
proceed in the following way:

1) Fasten the screws (2, Figure 181) and rotate the engine

flywheel clockwise by ~1/2 turn;

2) Turn the engine flywheel anticlockwise until the dial

gauge gives a reading of the lift of the cam of the
camshaft of 4.90

± 0.05 mm

3) Take out the screws (2, Figure 181) and remove the gear

(2) from the camshaft.

ENGINE F2B

TRALIS

AT/AD

Base - January 2003

- Using an appropriate wrench (4), loosen the

adjustment screw until the pumping element is at the
end-of-stroke;

- Tighten the adjustment screw, with a dynamometric

wrench, to 5 Nm tightening torque (0.5 kgm);

- Untighten the adjustment screw by 1/2 to 3/4 rotation;

- Tighten the locking nut.

Adjustment of clearances between rockers and valve studs
and preloading of pump injector rockers should be carried
out with extreme care.
Take the cylinder where clearance must be adjusted to the
bursting phase; its valves are closed while balancing the
symmetric cylinder valves.
Symmetric cylinders are 1-6, 2-5 and 3-4.
In order to properly operate, follow these instructions and
data specified on the table.

Adjustment of clearance between the rockers and rods
controlling intake and exhaust valves:

- Using a polygonal wrench, loosen nut (1) locking the

adjustment screw;

- Insert the thickness gauge blade (3);

- Tighten or untighten the adjustment screw with the

appropriate wrench;

- Make sure that the gauge blade (3) can slide with a slight

friction;

- Lock the nut (1), by blocking the adjustment screw.

Pre-loading of rockers controlling pump injectors:

- Using a polygonal wrench, loosen the nut locking the

rocker adjustment screw (5) controlling the pump
injector (6);

ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS

44936A

Figure 185

FIRING ORDER 1-4-2-6-3-5

In order to properly carry out the above-mentioned
adjustments, follow the sequence specified in the
table, checking the exact position in each rotation
phase by means of pin 99360612, to be inserted in
the 11

hole in each of the three sectors with 18

holes each.

ENGINE F2B

TRALIS

AT/AD

Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors.

Clockwise

start-up and

rotation

Adjusting

cylinder

valve no.

Adjusting

clearance of

cylinder valve

no.

Adjusting

pre-loading of

cylinder

injector no.

1 and 6 at

P.M.S.

120º

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