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Iveco Stralis AT/AD. Manual - part 53

TRALIS

AT/AD

198

F3A ENGINE

Base - January 2003

60573

60575

Figure 185

Figure 186

Figure 187

Figure 188

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 (7) Figure 184, 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 4.44

±0.05 mm.

The camshaft is in step if at the cam lift values of 4.44

±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).

If you do not obtain the conditions illustrated in Figure 187 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 (see Figure 189) on the gear (1);

2) turn the engine flywheel appropriately so as to bring about

the conditions described in points 1 and 2 Figure 187, it
being understood that the cam lift must not change at all;

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

above.

Tighten the screws (2) to the required torque.

77259

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71778

72436

Figure 189

When the adjustment with the slots (1) is not enough to make
up the phase difference and the camshaft turns because it
becomes integral with the gear (2); as a result, the reference
value of the cam lift varies, in this situation it is necessary to
proceed as follows:

1) lock the screws (2, Figure 188) and turn the engine

flywheel clockwise by approx. 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 4.44
±0.05 mm;

3) take out the screws (2, Figure 188) and remove the gear

(1) from the camshaft.

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

- a notch (5) can be seen through the inspection window;

- the tool 99360612 (1) inserted to the bottom of the seat

of the engine speed sensor (2) and (3).

77260

Phonic wheel timing

Turn the crankshaft by taking the piston of cylinder no. 1 into
the compression phase at T.D.C.; turn the flywheel in the
opposite direction to the normal direction of rotation by
approximately 1/4 of a turn.

Again turn the flywheel in its normal direction of rotation until
you see the hole marked with the double notch (4) through
the inspection hole under the flywheel housing. Insert tool
99360612 (5) into the seat of the flywheel sensor (6).

Insert the tool 99360613 (2), via the seat of the phase sensor,
onto the tooth obtained on the phonic wheel.

Should inserting the tool (2) prove difficult, loosen the screws
(3) and adjust the phonic wheel (1) appropriately so that the
tool (2) gets positioned on the tooth correctly. Go ahead and
tighten the screws (3).

Mount the gear (2) Figure 189 with the 4 slots (1) 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 cylinder completely and then turn
the flywheel anticlockwise until the dial gauge gives a reading
of 44.4

±0,05.

Check the timing conditions described in Figure 187.

Figure 190

Figure 191

- using an appropriate wrench (4), loosen the adjustment

screw

until

the

pumping

element

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.

The adjustment of clearance between the rockers and rods
controlling the intake and exhaust valves, as well as the
adjustment of pre-loading of the rockers controlling pump
injectors, must be carried out carefully.

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

60577

Figure 192

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.

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F3A ENGINE

Base - January 2003

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 TDC

120º

Fit the blow-by case (1) within 10’ from sealer
application.

Fit the cover (3) and tighten the fastening screws (2) to the
prescribed torque.

The filter (5) operation is unidirectional, therefore it
must be assembled with the two sight supports as
illustrated in the figure.

Fit the distribution cover (1).
Fit the blow-by case (7) and its gasket and then tighten the
screws (8) to the prescribed torque.
Install the filter (5) and the gaskets (4 and 6).

60665

Figure 193

Figure 194

- Set the gasket (4) on the oil sump (1). Position the spacer

(3) and mount the sump on the engine crankcase,
screwing the screws (2) to the required torque.

Completing Engine Assembly

Complete the engine by fitting or hooking up the following
parts:

- thermostat assembly;

- automatic tensioner, water pump, alternator;

- drive belt.

ASSEMBLY DIAGRAM OF FAN — WATER PUMP —

ALTERNATOR DRIVE BELT

1. Alternator — 2. Electromagnetic coupling —

3. Water pump — 4. Crankshaft

Figure 195

60578

- damper flywheel;

- electromagnetic coupling;

Figure 196

Apply silicone LOCTITE 5699 on the blow-by case
(7) surface of engines fitted with P.T.O. according to
the procedure described in the following figure.

85480

Apply silicone LOCTITE 5699 on the blow-by case and form
a string (2) of

∅ 1,5 ±,

as shown in the figure.

85481

0.5
0.2

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