Iveco Stralis AT/AD. Manual

60593

FRONT SIDE

stage 4:

angle
inner

screws

(45º)

60592

60594

Figure 155

stage 1:

pretightening
outer screws

(30 Nm)

FRONT SIDE

stage 2:

pretightenig

inner screws

(120 Nm)

stage 5:

angle

outer

screws

(60º)

FRONT SIDE

stage 3:

angle
inner

screws

(90º)

60593

DIAGRAM OF TIGHTENING SEQUENCE OF CRANKCASE BASE FIXING SCREWS

TRALIS

AT/AD

190

F3A ENGINE

Base - January 2003

49030

Turn the cylinder block, setting it upright.

Lubricate the pistons, piston rings and inside the cylinder liners.

With the aid of the clamp 99360605 (1) mount the connecting
rod — piston assemblies (2) in the cylinder liners according to
Figure 157. Check that:

- The number of each connecting rod corresponds to the

cap coupling number.

- The symbol (2, Figure 157) punched on the top of the

pistons faces the engine flywheel or the recess in the
piston skirt tallies with the position of the oil nozzles.

60615

Figure 156

Connecting rod — piston assembly.

Area of punch marking on the top of the
piston with the symbol for the mounting
position and selection class.

Area of connecting rod punch marking.

Figure 157

60616

Fitting connecting rod - piston assemblies
in cylinder liners

Figure 158

Not finding it necessary to replace the connecting rod
bearings, you need to fit them back in exactly the
same sequence and position as in removal.
If they have to be replaced, choose the connecting
rod bearings according to the selection described
from page 161 to page 167. Lubricate the bearing
shells (1 and 3) and fit them on the connecting rod (2)
and on the cap (4).

Do not make any adjustment on the bearing shells.

The pistons are supplied as spares in class A and can
also be fitted in class B cylinder liners.

191

TRALIS

AT/AD

F3A ENGINE

47594

Figure 159

Figure 160

Figure 161

Figure 162

Figure 163

Figure 164

Connect the connecting rods to the relevant pins of the
crankshaft, mount the connecting rod caps (1) together with
the bearing shells. Tighten the screws (2) fixing the connecting
rod caps to a torque of 60 Nm (6 kgm). Using tool 99395216
(3), tighten the screws further with an angle of 60

°.

Using the centring ring 99396035 (2), check the exact position
of the cover (1). If it is wrong, proceed accordingly and lock
the screws (3).

Key on the gasket (1), mount the key 99346250 (2) and,
screwing down the nut (3), drive in the gasket (1).

Check that the pistons 1-6 are exactly at the T.D.C.
Put the gasket (2) on the crankcase.
Mount the cylinder head (1) and tighten the screws as shown
in Figs. 163 — 164 — 165.

Diagram of the tightening sequence of the screws fixing the
cylinder head.

- Pre-tightening with the torque wrench (1):

phase: 60 Nm (6 kgm).

phase: 120 Nm (12 kgm).

60563

60564

60515

60565

61270

Before reusing the screws (2), measure the diameter
of the thread; it must be no less than 13.4 mm; if it is,
change the screw.
Lubricate the thread of the screws with engine oil
before assembly.

Lubricate the thread of the screws with engine oil
before assembly.

TRALIS

AT/AD

192

F3A ENGINE

Base - January 2003

Apply LOCTITE 5699 silicone on the gear housing, using
appropriate tools (1), as shown in the figure.
The sealer string (1) diameter is to be 1,5

Using a torque wrench, tighten the highlighted screws with the
following sequence and tightening torques:

4 screws M12 x 1.75 x 35

63 Nm

10 screws M12 x 1.75 x 100

63 Nm

1 screw M12 x 1.75 x 120

63 Nm

2 screws M12 x 1.75 x 70

63 Nm

Figure 165

Figure 166

Figure 167

60566

- Closing to angle with tool 99395216 (1):

phase: angle of 120

°.

phase: angle of 60

°.

Mount the oil pump (4), the intermediate gears (2) together
with the link rod (1) and lock the screws (3) in two phases:
pre-tightening

30 Nm.

closing to angle

°.

47592

60567

60633

Figure 168

Figure 169

Key on the gasket (1), mount the keying device 99346251 (2)
and, screwing down the nut (3), drive in the gasket.

Mount the gear housing within 10 min. of applying the
sealant.

60568

2 screws M12 x 1.75 x 193

63 Nm

0.5
0.2

193

TRALIS

AT/AD

F3A ENGINE

Content .. 49 50 51 52 ..

Iveco Stralis AT/AD. Manual - part 51