Iveco Stralis AT/AD. Manual — part 53
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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
199
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F3A ENGINE
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
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.
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
th
hole
in each of the three sectors with 18 holes each.
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AT/AD
200
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
6
1
5
120º
3
4
1
120º
5
2
4
120º
1
6
2
120º
4
3
6
120º
2
5
3
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
.
201
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F3A ENGINE
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