STRALIS AT/AD

REPAIR MANUAL
MECHANICAL
ELECTRIC
ELECTRONIC
STRALIS AT/AD
REPAIR MANUAL
This publication describes the characteristics, the data, the
correct methodology of the repairs that can be made on each
individual component of the vehicle.
By complying with the instructions supplied and using the
specific tools it is possible to perform any repair intervention
correctly, within the specified time frames, while protecting the
technicians against incidents.
Before starting any repair work, make sure that all accident
prevention devices are ready at hand.
Check and wear the protective personal equipment provided
for by the safety standards: goggles, helmet, gloves, shoes.
Check the efficiency of all processing, lifting and transport tools
before using them.

The data contained in this publication might fail to reflect the

latest changes which the Manufacturer may introduce at any
time, for technical or sales purposes, or to meet the
requirements of local legislation.
Copy, even partial, of text and drawings is forbidden.

Produced by:

Publication Edited by:

IVECO S.p.A.
T.C.O. - B.U. Customer Service
Lungo Stura Lazio, 15/19
10156 Torino (Italy)
B.U. TECHNICAL PUBLISHING
C.so Svizzera, 185
Printed 603.93.141 - 1st Ed. 2003 10149 Torino (Italy)
 SPECIAL REMARKS
The workshop manuals for mechanical parts have been divided into Sections, each of which has a number and its relevant contents
are indicated in the General Specifications. Each section features a main Unit (e.g. engine, gears etc.).
The subjects usually dealt with in each section are:
Technical data table, Driving torques, Equipment, Diagnostic, Removal and Fitting in place, Repair operations.
Where possible, the same sequence of procedures has been followed for easy reference.
Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.

Example

∅1 Ø 1 = housing for connecting rod small end bush

Tighten to torque
Tighten to torque +
Ø 2 = housing for connecting rod bearings α angular value
∅2

Furthermore, within each section, every heading or sub-heading concerning the operations to be carried out is preceded by a six
digit number. This number is the Product Code that is to be found in the repair operation described in the REPAIR TIMES CHARTS
and in the FAULT CODES.
For quick reference the indication of how to read this code is described below (see the Repair time charts also).

Product Code: 5 0
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT

Example:
Product 50 = Frame;
Product 52 = Axles;
Product 53 = Gears etc.

Unit Code: 0 1
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT

Figures three and four identify the ASSEMBLY within the PRODUCT
Example:
Product 50 = Frame;
Unit 01 = Chassis;
Unit 02 = Bumpers etc .

Sub-assembly Code: 4 0
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT

Example:
Product 50 = Frame;
Unit 01 = Chassis;
Sub-assembly 40 = Chassis cross members etc.

Print 603.93.141 Base - January 2003

Graphs and symbols

Removal
Intake
Disconnection

Refitting
Exhaust
Connection

Removal
Operation
Disassembly

Fitting in place
Assembly ρ Compression ratio

Tolerance
Tighten to torque
Weight difference

Tighten to torque + angle value Rolling torque

α

Replacement
Press or caulk
Original spare parts

Regulation
Rotation
Adjustment

Warning Angle
! Note Angular value

Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check

Equipment Temperature

Surface for machining

Pressure
Machine finish bar

Oversized
Interference
Higher than….
Strained assembly
Maximum, peak
Undersized
Thickness
Less than….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0°
Sealant
Cold
Adhesive
Winter
Temperature > 0°
Air bleeding Hot
Summer

Base - January 2003 Print 603.93.141

Print 603.43.671/A

STRALIS AT/AD

Print 603.93.141 — 1st edition

Base — January 2003

UPDATE DATA

Section Description Page Revision date

Print 603.93.141 Base - January 2003

Base - January 2003 Print 603.93.141
 INDEX OF SECTIONS

Section

General information 1

Engine 2

Clutch 3

Gearbox 4

Hydraulic retarder 5

Propeller shafts 6

Rear axles 7

Front axle 8

Front and rear suspensions 9

Wheels and tyres 10

Steering system 11

Pneumatic system - brakes 12

Bodywork and chassis frame 13

Maintenance 14

Print 603.93.141 Base - January 2003

Base - January 2003 Print 603.93.141
STRALIS AT/AD GENERAL 1

SECTION 1
General

Page

VEHICLE IDENTIFICATION DATA . . . . . . . . . . 3

- Vehicle identification plate . . . . . . . . . . . . . . . . 4

- Production identification plate . . . . . . . . . . . . . 4

COMPOSITION OF MODELS . . . . . . . . . . . . . . 5

P.I.C. NUMBER CODING . . . . . . . . . . . . . . . . . . 9

REPLENISHING FLUIDS . . . . . . . . . . . . . . . . . . . 13

Print 603.93.141 Base - January 2003

2 GENERAL STRALIS AT/AD

Base - January 2003 Print 603.93.141

 STRALIS AT/AD GENERAL 3

Print 603.43.671

VEHICLE IDENTIFICATION DATA

The type and number of engine, type and

number of chassis and manufacturer’s plate
comprise the vehicle identification data.

Manufacturer’s
plate
To identify the vehicle in accordance with the
E.E.C. directive
(under the front radiator cowling).

Chassis frame Engine

Punching (front on right side member of Plate on the left rear side of the crankcase
chassis frame).

Print 603.93.141 Base - January 2003

 4 GENERAL STRALIS AT/AD

Vehicle Identification Plate

Plate legend IVECO MAGIRUS AG
a)
a) Type-approval number marking (if applicable).
b) Vehicle identification code number (V.I.N.). b)
c) Total tractor weight. c) Kg
d) Total weight of tractor + trailer (if applicable). d) Kg
e) Permissible weight limit on 1st axle. e) 1- Kg
f) Permissible weight limit on 2nd axle (if applicable).
g) Permissible weight limit on 3rd axle. f) 2- Kg
h) Permissible weight limit on 4th axle (if applicable). g) 3- Kg
i) Specific identification of type. h) 4- Kg
l) Wheelbase in mm. Type No of axles
i) o)
m) Engine type.
n) Engine power. Wheelbase Corrected

l) absorption
value
o) No. of axles.
Engine type Engine power KW
p) Place of manufacture. m) n)
Made in

p)

Production identification plate Permissible

Unit No grade of
This plate shows the P.I.C. (production identification code
Part No smoke
number), which is needed when referring to the spare
parts catalogue (electronic and/or microfiche catalogue).
Serial No
The P.I.C. is also given on the vehicle warranty card.
Note: When consulting the catalogues, use only the first P.I.C. No
8 digits of the product identification code number. Made in Germany-Iveco Magirus AG

9843 8247

Base - January 2003 Print 603.93.141

STRALIS AT/AD GENERAL 5

COMPOSITION OF MODELS
CHASSIS CABS - 4x2 MODELS

AT 190 S 40/FP-CT

AT 190 S 43/FP-CT
AD 190 S 27/FP-D

AD 190 S 31/FP-D

AD 190 S 35/FP-D

AD 190 S 40/FP-D

AD 190 S 43/FP-D
T = 4x2 tractor

AT 190 S 27/FP-D

AT 190 S 31/FP-D

AT 190 S 35/FP-D

AT 190 S 40/FP-D

AT 190 S 43/FP-D
AD 190 S 27/P

AD 190 S 30/P

AD 190 S 31/P

AD 190 S 35/P

AD 190 S 40/P

AD 190 S 43/P
AT 190 S 27/P

AT 190 S 31/P

AT 190 S 35/P

AT 190 S 40/P

AT 190 S 43/P
TX = 6x2 C tractor (central added axle cannot

AT 190 S S31
AD 190 S 27

AD 190 S 30

AD 190 S 31

AD 190 S 35

AD 190 S 40

AD 190 S 43
AT 190 S 27

AT 190 S 35

AT 190 S 40

AT 190 S 43
be lifted)
TY = 6x2 P tractor (rear added axle can be
lifted)
ASSEMBLIES TN = 6x2 vehicles with mechanical rear
f f f f f f suspensions and raisable rigid rear added
F2BE0681F (270 CV)
axle
F2BE0681E (300 CV) f f
TZ = 6x4 tractor (bogie rear axle)
F2BE0681B (310 CV) f f f f f f
P = 4x2 — 6x2P — 6x2C vehicles with air
F2BE0681A (350 CV) f f f f f f suspension on rear axle and 6x2P vehicles
F3AE0681B (400 CV) f f f f f f f with rigid rear axle that can be lifted with
F3AE0681D (430 CV) f f f f f f f single wheels
PT = 6x2P vehicles with air suspension on rear
Single disc 16” f f f f f f f f f f f f f f f f f f f f axle and rigid rear added axle that can be
lifted with twin wheels
Single disc 17” f f f f f f f f f f f f f f
PS = 6x2P vehicles with air suspension on rear
ZF 9 S 109 D.D. f f f f f f f f f f f f axle and on steering rear added axle that
can be lifted with single wheels
ZF 16 S 151 D.D. f f f f f f
FP = 4x2 — 6x4 — 6x2P — 6x2C vehicles with
ZF 16 S 181 O.D. front and rear air suspensions
ZF 16 S 181 D.D. f f f f f f f f f f f f f f
FS = 6x2P vehicles with front and rear air
ZF 16 S 221 O.D. suspensions, steering rear added axle can
EuroTronic Automated 12 AS 2301 O.D. be lifted with single wheels
EuroTronic Automated 12 AS 2301 D.D. f f f f f f f f f f f f f f f f f f f f f f 4x2 = Vehicles with two axles with rear driving
Allison MD 3060 P - MD 3066 P f f f f axle
FRONT AXLE: 5876/4 (F 8021) ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ 6x2P = Vehicles with three axles with rear driving
axle and rear added third axle that can be
5876/5 (F 8021) F F F F F F F F F F F F F F F F F F F F F F F F lifted
5886/5 (F 9021) f f f f f f f f f f 6x2C = Vehicles with three axles with rear driving
ADDED AXLE: axle and central added third axle that
Steering central 5876/4 (F 8021) cannot be lifted
Rigid rear 55080/D1 (N 8071) * 6x4 = Vehicles with three axles with two rear
Rigid rear 56082/D1 (N 9171) * driving axles (in tandem)
Steering rear 57080/D1 (N 8072) * CM = Movable Boxes
MERITOR MS 13-175/T - MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f LT = Tractor with lowered chassis frame
MERITOR RT 160/1 CT = Chassis cab with lowered chassis frame
451391 HR RR = Rough Roads
D = Distribution
ZF 8098 f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f
HR = Hub Reduction
AT = Active Time
FRONT MECHANICAL Front j j j j j j j j j j j j j f j j j j j j j j
AD = Active Day
Rear j j j j j j j j j j j
PNEUMATIC Front f f f f f f f f f f f f
Rear f f f f f f f f f f f f f f f f f f f f f f f
Added axle
⊗ = With brake calliper assembly at 57° without parking brake j = With parabolic leaf springs
F = With brake calliper assembly at 0° with parking brake * = TI with drum brakes
Z = With longitudinal and transversal bars

Print 603.93.141 Base - January 2003

6 GENERAL STRALIS AT/AD

COMPOSITION OF MODELS
CHASSIS CABS - 6x2 P MODELS
T = 4x2 tractor

AD 260 S 35Y/FP-D
AD 260 S 31Y/FP-D

AD 260 S 31Y/FS-D

AD 260 S 35Y/FS-D
AD 260 S 27Y/FS-D

AT 260 S 31Y/FP-D

AT 260 S 35Y/FP-D
AD 260 S 27Y/FP-D

AT 260 S 27Y/FS-D

AT 260 S 30Y/FS-D

AT 260 S 31Y/FS-D

AT 260 S 35Y/FS-D
AT 260 S 27Y/FP-D

AD 260 S 27Y/TN

AD 260 S 31Y/TN

AD 260 S 35Y/TN
AT 260 S 27Y/TN

AT 260 S 31Y/TN

AT 260 S 35Y/TN
AD 260 S 27Y/PT

AD 260 S 31Y/PT

AD 260 S 35Y/PT
AT 260 S 31Y/PT
AT 260 S 27Y/PT

AT 260 S 35Y/PT
AD 260 S 31Y/PS

AD 260 S 35Y/PS
TX = 6x2 C tractor (central added axle cannot

AD 260 S 27Y/PS

AD 260 S 30Y/PS
AT 260 S 27Y/PS

AT 260 S 31Y/PS

AT 260 S 35Y/PS
AT 260 S 30Y/PS

AD 260 S 31Y/P

AD 260 S 35Y/P
AD 260 S 27Y/P

AT 260 S 35Y/P
AT 260 S 27Y/P

AT 260 S 31Y/P
be lifted)
TY = 6x2 P tractor (rear added axle can be lifted)
TN = 6x2 vehicles with mechanical rear
suspensions and raisable rigid rear added
ASSEMBLIES axle
F2BE0681F (270 CV) f f f f f f f f f f f f TZ = 6x4 tractor (bogie rear axle)
F2AE0681E (300 CV) f f f P = 4x2 — 6x2P — 6x2C vehicles with air
F2BE0681B (310 CV) f f f f f f f f f f f f suspension on rear axle and 6x2P vehicles
F2BE0681A (350 CV) f f f f f f f f f f f f with rigid rear axle that can be lifted with
single wheels
F3AE0681B (400 CV)
F3AE0681D (430 CV) PT = 6x2P vehicles with air suspension on rear
axle and rigid rear added axle that can be
Single disc 16” f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f lifted with twin wheels
PS = 6x2P vehicles with air suspension on rear
Single disc 17” axle and on steering rear added axle that
can be lifted with single wheels
ZF 9S 109 D.D. f f f f f f f f f f f f f f f f f f f f f f f f f
FP = 4x2 — 6x4 — 6x2P — 6x2C vehicles with
ZF 16S 151 O.D. f f f f f f f f f f f f front and rear air suspensions
ZF 16S 181 O.D. FS = 6x2P vehicles with front and rear air
ZF 16S 181 D.D. suspensions, steering rear added axle can
ZF 16S 221 D.D. be lifted with single wheels
EuroTronic Automated 12 AS 2301 D.D. 4x2 = Vehicles with two axles with rear driving
EuroTronic Automated 12 AS 2301 O.D. f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f axle
Allison MD 3060 P - MD 3066 P f f f f f f f f f f f 6x2P = Vehicles with three axles with rear driving
axle and rear added third axle that can be
FRONT AXLE: 5876/4 (F 8021) ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗
lifted
5876/5 (F 8021) F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F
6x2C = Vehicles with three axles with rear driving
5886/5 (F 9021) f f f f f f f f axle and central added third axle that
cannot be lifted
ADDED AXLE:
Steering central 5876/2 (F 8021) 6x4 = Vehicles with three axles with two rear
driving axles (in tandem)
Rigid rear 55080/D1 (N 8071) * f f f f f f f f f f f f
CM = Movable Boxes
Rigid rear 56082/D1 (N 9171) * f f f f f f f f f f f f
HM = Heavy Mission
Steering rear 57080/D1 (N 8072) * f f f f f f f f f f f f f f f
LT = Tractor with lowered chassis frame
MERITOR MS 13-175/T - MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f
CT = Chassis cab with lowered chassis frame
MERITOR RT 160/1
RR = Rough Roads
451391 HR
D = Distribution

ZF 8098 f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f AT = Active Time

AD = Active Day
FRONT MECHANICAL Front j j j j j j j j j j j j j j j j j j j j j j j j j j
Rear j j j j j j
PNEUMATIC Front f f f f f f f f f f f f f
Rear f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f
Added axle f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f
⊗ = With brake calliper assembly at 57° without parking brake j = With parabolic leaf springs
F = With brake calliper assembly at 0° with parking brake * = TI with drum brakes
Z = With longitudinal and transversal bars

Base - January 2003 Print 603.93.141

STRALIS AT/AD GENERAL 7

COMPOSITION OF MODELS
CHASSIS CABS - 6x2 P MODELS

AD 260 S 43Y/FS-CM
AD 260 S 40Y/FS-CM

AT 260 S 43Y/FS-CM
T = 4x2 tractor

AT 260 S 40Y/FS-CM

AD 260 S 43Y/FP-D

AD 260 S 43Y/FS-D
AD 260 S 40Y/FS-D

AT 260 S 43Y/FP-D
AD 260 S 40Y/FP-D

AT 260 S 40Y/FS-D

AT 260 S 43Y/FS-D
AT 260 S 40Y/FP-D

AD 260 S 40Y/TN

AD 260 S 43Y/TN
AT 260 S 40Y/TN

AT 260 S 43Y/TN
AD 260 S 40Y/PT

AD 260 S 43Y/PT
AT 260 S 40Y/PT

AT 260 S 43Y/PT
AD 260 S 43Y/PS
TX = 6x2 C tractor (central added axle cannot

AD 260 S 40Y/PS
AT 260 S 40Y/PS

AT 260 S 43Y/PS
AD 260 S 43Y/P
AD 260 S 40Y/P
AT 260 S 40Y/P

AT 260 S 43Y/P
be lifted)
TY = 6x2 P tractor (rear added axle can be lifted)
TN = 6x2 vehicles with mechanical rear
suspensions and raisable rigid rear added
ASSEMBLIES axle
F2BE0681F (270 CV) TZ = 6x4 tractor (bogie rear axle)
F2AE0681E (300 CV) P = 4x2 — 6x2P — 6x2C vehicles with air
F2BE0681B (310 CV) suspension on rear axle and 6x2P vehicles
F2BE0681A (350 CV) with rigid rear axle that can be lifted with
single wheels
F3AE0681B (400 CV) f f f f f f f f f f f f f f
F3AE0681D (430 CV) f f f f f f f f f f f f f f PT = 6x2P vehicles with air suspension on rear
axle and rigid rear added axle that can be
Single disc 16” lifted with twin wheels
PS = 6x2P vehicles with air suspension on rear
Single disc 17” f f f f f f f f f f f f f f f f f f f f f f f f f f f f axle and on steering rear added axle that
can be lifted with single wheels
ZF 9S 109 D.D.
FP = 4x2 — 6x4 — 6x2P — 6x2C vehicles with
ZF 16S 151 O.D. front and rear air suspensions
ZF 16S 181 O.D. FS = 6x2P vehicles with front and rear air
ZF 16S 181 D.D. f f f f f f f f f f f f f f f f f f f f f f f f f f f f suspensions, steering rear added axle can
ZF 16S 221 D.D. be lifted with single wheels
EuroTronic Automated 12 AS 2301 D.D. 4x2 = Vehicles with two axles with rear driving
EuroTronic Automated 12 AS 2301 O.D. f f f f f f f f f f f f f f f f f f f f f f f f axle
Allison MD 3060 P - MD 3066 P 6x2P = Vehicles with three axles with rear driving
axle and rear added third axle that can be
FRONT AXLE: 5876/4 (F 8021) ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗
lifted
5876/5 (F 8021) F F F F F F F F F F F F F F F F F F F F F F
6x2C = Vehicles with three axles with rear driving
5886/5 (F 9021) f f f f f f axle and central added third axle that
cannot be lifted
ADDED AXLE:
Steering central 5876/4 (F 8021) 6x4 = Vehicles with three axles with two rear
driving axles (in tandem)
Rigid rear 55080/D1 (N 8071) * f f f f f f
CM = Movable Boxes
Rigid rear 56082/D1 (N 9171) * f f f f f f f f
LT = Tractor with lowered chassis frame
Steering rear 57080/D1 (N 8072) * f f f f f f f f f f f f f f
CT = Chassis cab with lowered chassis frame
MERITOR MS 13-175/T - MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f
RR = Rough Roads
MERITOR RT 160/1
D = Distribution
451391 HR
HR = Hub Reduction

ZF 8098 f f f f f f f f f f f f f f f f f f f f f f f f f f f f AT = Active Time

AD = Active Day
FRONT MECHANICA0L Front j j j j j j j j j j j j j j j j
Rear j j j j
PNEUMATIC Front j j j j Z Z j j j j Z Z
Rear f f f f f f f f f f f f f f f f f f f f f f f f
Added axle f f f f f f f f f f f f f f f f f f f f f f f f
⊗ = With brake calliper assembly at 57° without parking brake j = With parabolic leaf springs
F = With brake calliper assembly at 0° with parking brake * = TI with drum brakes
Z = With longitudinal and transversal bars

Print 603.93.141 Base - January 2003

8 GENERAL STRALIS AT/AD

COMPOSITION OF MODELS
TRACTORS - MODELS 4x2 6x2 C 6x4
T = 4x2 tractor

AT 440 S 40T/FP-CT

AT 440 S 43T/FP-CT
AD 440 S 40T/P-HR

AD 440 S 43T/P-HR
AT 440 S 40T/FP-LT

AT 440 S 43T/FP-LT
TX = 6x2 C tractor (central added axle cannot

AD 440 S 43T/P-RR

AT 440 S 43T/P-HR
AD 440 S 35T/P-HR

AD 440 S 40T/P-RR
AT 440 S 35T/P-HR

AT 440 S 43T/P-RR
AT 440 S 40T/P-HR
AT 440 S 40T/P-RR

AD 440 S 40TX/P

AD 440 S 43TX/P
AT 440 S 40TX/P

AT 440 S 43TZ/P
be lifted)

AT 440 S 43TXP
AD 440 S 43T/P
AD 440 S 31T/P

AD 440 S 35T/P

AD 440 S 40T/P
AT 440 S 35T/P

AT 440 S 40T/P

AT 440 S 43T/P
AT 440 S 31T/P
TY = 6x2 P tractor (rear added axle can be lifted)
TN = 6x2 vehicles with mechanical rear
suspensions and raisable rigid rear added
axle
ASSEMBLIES
TZ = 6x4 tractor (bogie rear axle)
F2BE0681F (270 CV)
F2AE0681E (300 CV) P = 4x2 — 6x2P — 6x2C vehicles with air
F2BE0681B (310 CV) f f suspension on rear axle and 6x2P vehicles
with rigid rear axle that can be lifted with
F2BE0681A (350 CV) f f f f single wheels
F3AE0681B (400 CV) f f f f f f f f f f
F3AE0681D (430 CV) f f f f f f f f f f f PT = 6x2P vehicles with air suspension on rear
axle and rigid rear added axle that can be
Single disc 16” lifted with twin wheels
PS = 6x2P vehicles with air suspension on rear
Single disc 17” f f f f f f f f f f f f f f f f f f f f f f f f f f f axle and on steering rear added axle that
can be lifted with single wheels
ZF 9S 109 D.D.
ZF 16S 151 O.D. f f f f f f FP = 4x2 — 6x4 — 6x2P — 6x2C vehicles with
ZF 16S 181 O.D. f f f f f f f f front and rear air suspensions
ZF 16S 181 D.D. f f f f f f f f f f f f FS = 6x2P vehicles with front and rear air
ZF 16S 221 D.D. f suspensions, steering rear added axle can
EuroTronic Automated 12 AS 2301 D.D. f f f f be lifted with single wheels
EuroTronic Automated 12 AS 2301 O.D. f f f f f f f f f f f f f f f f f f f f 4x2 = Vehicles with two axles with rear driving
Allison MD 3060 P - MD 3066 P axle
FRONT AXLE: 5876/4 (F 8021) ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ 6x2P = Vehicles with three axles with rear driving
5876/5 (F 8021) F F F F F F F F F F F F F F F F F F F F F F F F F F F axle and rear added third axle that can be
lifted
5886/5 (F 9021)
6x2C = Vehicles with three axles with rear driving
ADDED AXLE: axle and central added third axle that
Steering central 5876/4 (F 8021) f f f f cannot be lifted
Rigid rear 55080/D1 (N 8071) * 6x4 = Vehicles with three axles with two rear
driving axles (in tandem)
Rigid rear 56082/D1 (N 9171) *
CM = Movable Boxes
Steering rear 57080/D1 (N 8072) *
HM = Heavy Mission
MERITOR MS 13-175/T - MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f
LT = Tractor with lowered chassis frame
MERITOR RT 160/1 f
451391 HR f f f f CT = Chassis cab with lowered chassis frame
RR = Rough Roads
ZF 8098 f f f f f f f f f f f f f f f f f f f f f f f f f f f D = Distribution
AT = Active Time
FRONT MECHANICAL Front j j j j j j j j j j j j j j j j j j j j j j j AD = Active Day
Rear j
PNEUMATIC Front f f f f
Rear f f f f f f f f f f f f f f f f f f f f f f f f f f f
Added axle
⊗ = With brake calliper assembly at 57° without parking brake j = With parabolic leaf springs
F = With brake calliper assembly at 0° with parking brake * = TI with drum brakes
Z = With longitudinal and transversal bars

Base - January 2003 Print 603.93.141

STRALIS AT/AD GENERAL 9

P.I.C. NUMBER CODING

CAB LIVEABILITY

A A A B B C C D

M = Stralis AD (Active Day)

N = Stralis AT (Active Time)

TOTAL WEIGHT ON GROUND - AXLES CONFIGURATION

A A A B B C C D
C = 4x2; 18-20 ton.

D = 4x2T; 19-20 ton.

E = 6x2C; 26 ton.
F = 6x2P; 26 ton.
G = 6x2P; 26 ton.
H = 4x2T; 19-20 ton.

J = 6x2C; 26 ton.
K = 6x4; 26 ton.
L = 4x2P; 19-20 ton.
M = 6x2P; 26 ton.
N = 6x2P; 26 ton.

ENGINE

A A A B B C C D

H E 270

L E 400

K E 430

P E 310

Q E 300

R E 352

Print 603.93.141 Base - January 2003

10 GENERAL STRALIS AT/AD

SUSPENSION TYPE - REAR AXLE TYPE - TYPE OF ADDITIONAL AXLE

A A A B B C C D

A Mechanical - SR - TWIN

B Pneumatic - SR - CENT/SING/TWIN

C - SR - CENT/SING

E Pneumatic - HR (Tractor 4x2)

E Pneumatic - HR - SR - STER (Chassis cab 6x2P)

F - SR - STER

G (*) - SR - SING

H (*) - SR - STER

* = Suspensions with 5886/D front axle

TWIN = Twin rear wheels
CENT = Middle axle (6x2C vehicles)
SING = Added axle with rear single wheels
STER = Added axle with rear steering single wheels
HR = Double reduction rear axle
SR = Simple reduction rear axle

VERSION COMBINATION - USE

A A A B B C C D

1 = Chassis cab - STD

2 = Tractor - STD

H = Tractor - GRAV

M = Cartran - STD -Tractor

N = Cartran - STD - Chassis cab

T = LOW TR - STD

Cartran = Car transport

LOW TR = Lowered tractor
STD = Standard use
GRAV = Heavy duty use

Base - January 2003 Print 603.93.141

STRALIS AT/AD GENERAL 11

WHEELBASE

A A A B B C C D

VERSION WHEELBASE VERSION WHEELBASE VERSION WHEELBASE VERSION WHEELBASE

1
T6x2C 3800 T4x2 3650 6x2P 3120 T6x4 2800

T6x4 3200 2

6x2P T 4x2
3805 3800 3
C 4x2 C 6x2C

C 4x2
C 6x2C 4200 4
6x2P

C 4x2
C 6x 2 4500 5
6 x 2P

C 4x2
6x2P
4800 6

C 4x2
6x2P
5100 7

C 4x2 8
5700
6x2P

C4x2 6300 6x2P 6050 9

C4x2 5500 L

C4x2 6300 M

Print 603.93.141 Base - January 2003

12 GENERAL STRALIS AT/AD

GEARBOX - BRAKES COMBINATION

A A A B B C C D

BRAKES
GEARBOX
NO YES

Mechanical Disc Disc A

Mechanical Disc Drum B

ALLISON Disc Drum

D

EuroTronic 12 A S 2301 Disc Disc

E

EuroTronic 12 A S 2301 Disc Drum F

CAB - DRIVE - BRAKES COMBINATION

A A A B B C C D

DRIVE

Left 1

Right A

Base - January 2003 Print 603.93.141

STRALIS AT/AD GENERAL 13

REPLENISHING FLUIDS
LUBRICANTS RECOMMENDED BY IVECO PARTS TO BE FILLED UP Quantity
Litres Kg
Urania FE 5W30(1)
Urania LD5 Engine F2B
Urania Turbo LD
Total capacity for first filling
28 25,2

Capacity:
- engine sump min level 12.5 11,2
- engine sump max level 23 21
- quantity in circulation that 5 4.5
does not flow back to the en-
gine sump
2.5 2.3
- quantity contained in the car-
tridge filter (which has to be
added to the cartridge filter re-
fill)

Urania FE 5W30(1) Engine F3A

Urania LD5
Urania Turbo LD
Total capacity 1st filling 30 29.8
Capacity:
- engine sump at minimum level 17 15.3
- engine sump at maximum level 25 22.5
- quantity in circulation that does not re-
turn to sump 7 6.3
- quantity contained in cartridge filter (to
add when changing the cartridge filter) 2.5 2.3
Gearbox
ZF 9 S 109 * 8 7.2
ZF 16 S 151 * 11 10
ZF 16 S 151 + Intarder * 18.5 16.65
Tutela Truck FE-Gear1 ZF 16 S 181 * 13 12
Tutela ZC 90 ZF 16 S 181 + Intarder* 21.5 19.35
ZF 16 S 221 * 13 12
ZF 16 S 221 + Intarder* 21.5 19.35
* Quantity 1st filling EuroTronic automated 12 AS 2301* 12 11
EuroTronic automated 12 AS 2301* + intarder 23 21

Tutela GI/A Allison MD 3060 P - MD 3066 P 18 16

Tutela Truck FE-Gear1

Power take off (Multipower) 2.5
Tutela ZC 90

(1) IVECO recommends using these oils for reasons of fuel economy. IVECO provides new vehicles already with these types of
lubricants. Also suited for cold climates (minimum temperature down to -30ºC)
These quantities are not decisive. An exact check must be made by verifying the levels

Print 603.93.141 Base - January 2003

14 GENERAL STRALIS AT/AD

REPLENISHING FLUIDS

Quantity
LUBRICANTS RECOMMENDED BY IVECO PARTS FOR REPLENISHING Litres kg
Front hubs (single)
FRONT AXLE 5876/4-/5 (F8021) 0.35 0.32
FRONT AXLE 5886/5 0.35 0.32
Tutela Truck FE-Axle(2) ADDED AXLE::
Tutela W140/M-DA Steering central 5876/4 (F 8021) 0.35 0.32
Tutela W90/M-DA3 Rigid rear 55080/D1 (N 8071) 0.35 0.32
Rigid rear 56082/D1 (N 9171) 0.35 0.32
Steering rear 57080/DI (N 8072) 0.35 0.32
Bridge Meritor MS 13-175/T - MS 13-175/D:
V (mechanical suspension) 18.5 16.5
Tutela Truck 15.5
V (pneumatic suspension) 17
FE-Axle(2) Bridge 451391 HR 16 14.5
Tutela W140/M-DA
W140/M DA
Tutela W90/M-DA3 Rear axle Meritor in tandem RT 160E/1
- middle 18.5 16.6
- rear 16.5 14.8

Power steering 2.7* 2.4

Tutela GI/A
13.5** 12
* Excluding vehicles with steering rear axle
** For vehicles with steering rear axle only
Tutela TRUCK Clutch circuit
DOT SPECIAL 0.5 0.45
(excluding vehicles with Euro Tronic gearbox)

Cooling system
Engine F2B Total capacity* µ34 µ23.4
Water+Paraflu11 Engine F2B with Intarder Total capacity* µ50 µ27
Engine F3A Total capacity* µ38 µ39.6
Engine F3A with Intarder Total capacity* µ58 µ57.6
* = Protective anti-freeze
(concentration 50% freezing point —35°C)

Tutela LHM Cab tilting system 0.6 0.54

(2) Only on axles with disc brakes, IVECO recommends using these oils for reasons of fuel economy. IVECO provides new vehicles
already with these types of lubricants. Also suited for cold climates (minimum temperature down to -30ºC)
(3) Specific for cold climates
These quantities are not decisive. An exact check must be made by verifying the levels

Base - January 2003 Print 603.93.141

STRALIS AT/AD GENERAL 15

International lubricant designation FL products

Engine oil
Meets the specifications:
ACEA E4 with a totally synthetic base SAE 50W 30 URANIA FE 5W30
ACEA E5 with a mineral base SAE 15W 40 Urania LD5
ACEA E3 with a mineral base SAE 15W 40 Urania Turbo LD
Oil for differential gear and wheel hubs
Meets the specifications:
API GL5, MT-1 with a totally synthetic base SAE 75W 90 Tutela Truck FE-Axle
API GL5 with a mineral base SAE 85W 140 Tutela W140/M-DA
API GL5 with a mineral base SAE 80W 90 Tutela W90/M-DA
Oil for mechanical gearboxes
Containing non-EP anti-wear additives
Meets the specifications:
API GL4 with a totally synthetic base SAE 75W 85 Tutela Truck FE-Gear
API GL3 with a mineral base SAE 80W 90 Tutela ZC90
Oil for power steering and hydrostatic transmissions
A.T.F. DEXRON II D Tutela GI/A
Grease for general greasing
Tutela MR 2
based on lithium soaps, N.L.G.I. consistency no. 2
Specific grease for bearings and wheel hubs
Tutela MR 3
based on lithium soaps, N.L.G.I. consistency no. 3
Clutch drive fluid
Conforming to N.H.T.S.A. standards 116, ISO 4925, Std. SAEJ 1703, Tutela TRUCK DOT SPECIAL
IVECO STANDARD 18-1820
Mineral oil for hydraulic circuits
Tutela LHM
In compliance with IVECO STANDARD 18-1823
Windscreen washer fluid, mixture of spirit, water and surfactants
Tutela PROFESSIONAL SC 35
CUNA NC 956-11
Grease for central lubrication systems based on lithium soaps,
with synthetic base, N.L.G.I. no. 2. Tutela COMAR 2
Working temperatures: from —30°C to +140°C
Concentrated protective fluid for radiators
based on ethylene glycol containing corrosion inhibitors, conforming to the Paraflu11
standard: IVECO-STANDARD 18-1830

Print 603.93.141 Base - January 2003

 16 GENERAL STRALIS AT/AD

Print 603.43.671

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE 1

SECTION 2
Engine

Page

- F2B Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

- F3A Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

- Hidrocar pressure take-off on timing system

(P.T.O. - Optional) . . . . . . . . . . . . . . . . . . . . . 223

Print 603.93.141 Base - January 2003

2 ENGINE STRALIS AT/AD

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 3

Print 603.43.671

F2B Engine

Page

VIEWS OF THE ENGINE . . . . . . . . . . . . . . . . . . 8

GENERAL CHARACTERISTICS . . . . . . . . . . . . . 13

ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . 16

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 22

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

DISMANTLING THE ENGINE ON THE BENCH 40

REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 47

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 47

- Checks and measurements . . . . . . . . . . . . . . . 47

CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . 48

- Fitting and checking protrusion . . . . . . . . . . . . 49

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

- Replacing cylinder liners . . . . . . . . . . . . . . . . . . 49

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 50

- Measuring main journals and crank pins . . . . . . 51

PRELIMINARY MEASUREMENT OF MAIN AND BIG

END BEARING SHELL SELECTION DATA . . 52

- Replacing the timing control gear and

the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 59

- Checking main journal installation clearance . . . 59

- Checking crankshaft end float . . . . . . . . . . . . . 60

PISTON-CONNECTING ROD ASSEMBLY . . . . 61

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

- Measuring the diameter of the pistons . . . . . . . 62

- Conditions for correct gudgeon pin-piston

coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . 64

- Checking connecting rod alignment . . . . . . . . . 65

Print 603.93.141 Base - January 2003

4 ENGINE F2B STRALIS AT/AD

Page Page
- Mounting the connecting rod-piston assembly . 65 - Fitting the connecting rod-piston assembly into
the cylinder liners . . . . . . . . . . . . . . . . . . . . . . . 80
- Mounting the piston rings . . . . . . . . . . . . . . . . . 65
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . 83
- Fitting the connecting rod-piston assembly into
the piston liners . . . . . . . . . . . . . . . . . . . . . . . . 66
- Fitting engine flywheel . . . . . . . . . . . . . . . . . . . 83
- Piston protrusion check . . . . . . . . . . . . . . . . . . 66
- Fitting camshaft . . . . . . . . . . . . . . . . . . . . . . . . . 84
- Checking assembly clearance of big end pins . . 67
- Fitting pump-injectors . . . . . . . . . . . . . . . . . . . . 85
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 67
- Fitting rocker-arm shaft assembly . . . . . . . . . . . 85
- Valve removal . . . . . . . . . . . . . . . . . . . . . . . . . . 67
- Camshaft timing . . . . . . . . . . . . . . . . . . . . . . . . 86
- Checking the planarity of the head on
the cylinder block . . . . . . . . . . . . . . . . . . . . . . . 67 - Phonic wheel timing . . . . . . . . . . . . . . . . . . . . . 88
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 - Intake and exhaust rocker play adjustment and
pre-loading of rockers controlling pump injectors. 89
- Removing deposits and checking the valves . . . 67
ENGINE COMPLETION . . . . . . . . . . . . . . . . . . 90
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . 68

- Replacing of valve guides . . . . . . . . . . . . . . . . . 69 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 93

- Replacing - Reaming the valve seats . . . . . . . . . 69 - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

REPLACING INJECTOR HOLDER CASES . . . . . 69 - Overpressure valve . . . . . . . . . . . . . . . . . . . . . 95

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 - Oil pressure control valve . . . . . . . . . . . . . . . . 96

- Checking protrusion of injectors . . . . . . . . . . . . 71 - Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 96

TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 - By-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . . 97

- Checking cam lift and pin alignment . . . . . . . . . 72 - Thermostatic valve . . . . . . . . . . . . . . . . . . . . . . 97
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 - Engine oil filters . . . . . . . . . . . . . . . . . . . . . . . . 97
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
- Replacing camshaft bushes using
beater 99360487 . . . . . . . . . . . . . . . . . . . . . . . 74 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 - Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 101

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 75 - Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

- Fitting the valves and oil seal ring . . . . . . . . . . . 75 - Electromagnetic coupling . . . . . . . . . . . . . . . . . 101
ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 76 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . 102
- Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . 102
- Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
TURBO COMPRESSOR HOLSET HX 40V . . . . . 104
ASSEMBLING THE ENGINE ON THE BENCH . 77
- Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
DIAGRAM SHOWING THE UNDERBLOCK FIXING
SCREWS TIGHTENING ORDER . . . . . . . . . . 79 - Solenoid valve for VGT control . . . . . . . . . . . . 107

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 5

Page

FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

- Replacing injectors-pump . . . . . . . . . . . . . . . . . 109

- Injector-pump . . . . . . . . . . . . . . . . . . . . . . . . . . 109

- Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

- Injector Phases . . . . . . . . . . . . . . . . . . . . . . . . . 110

Print 603.93.141 Base - January 2003

6 ENGINE F2B STRALIS AT/AD

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 7

Figure 1

78840

F2B ENGINE

Print 603.93.141 Base - January 2003

 8 ENGINE F2B STRALIS AT/AD

VIEWS OF THE ENGINE

ENGINE

TYPE PART NUMBER

F 2 B E 0 6 8 1 A * A 0 0 1 -

Progressive production number

Version number within the B.o.M.

Only for exhaust gas level with

the same torque and power curves
Engine power output or torque level

Use (eg I = truck)

Fuel feed + injection (TCA, direct injection diesel engine)

Number of cylinders
A 352 CV 131 kgm
Number of strokes and cylinders’ position (eg 0 = 4 strokes,
vertical) B 310 CV 114 kgm

Engine E 301 CV 113 kgm

F 273 CV 114 kgm
Engine family evolution (also irrespective of the
displacement)
Indicates the engine family

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 9

Figure 2

rpm

52244

F2BE0681F: POWER-TORQUE CURVES

Max OUTPUT 200 kW 273HP at 2400 rpm

Max TORQUE 1115 Nm 114 kgm at 1000 to 1770 rpm

Print 603.93.141 Base - January 2003

 10 ENGINE F2B STRALIS AT/AD

Figure 3

rpm

52243

F2BE0681E: POWER-TORQUE CURVES

Max OUTPUT 221 kW 301HP at 2400 rpm

Max TORQUE 1110 Nm 113 kgm at 1000 rpm

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 11

Figure 4

rpm

47531

F2BE0681B: POWER-TORQUE CURVES

Max OUTPUT 228 kW 310HP at 2400 rpm

Max TORQUE 1100 Nm 114 kgm at 1000 to 1950 rpm

Print 603.93.141 Base - January 2003

 12 ENGINE F2B STRALIS AT/AD

Figure 5

rpm

47532

F2BE0681A: POWER-TORQUE CURVES

Max OUTPUT 259 kW 352HP at 2400 rpm

Max TORQUE 1280 Nm 131 kgm at 1080 to 1930 rpm

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 13

GENERAL CHARACTERISTICS

Type F2BE0681A F2BE0681B F2BE0681E F2BE0681F

Cycle Diesel 4 strokes

Feeding Turbocharged with aftercooler

Injection Direct

N. of cylinders 6 on-line

∅
Diameter mm 115

Stroke mm 125

+ + +.. = Total displacement cm3 7790

ρ Compression ratio 16 ± 0.8

Max. power KW 259 228 221 200

(HP) (352) (310) (301) (273)

rpm 2400 2400 2400 2400

Max. torque Nm 1280 1115 1115

1110 (113)
(Kgm) (131) (114) (114)

1080 to 1930 1000 to 1950 1000 1000 to 1770

rpm
Engine idling speed,
no load
rpm 525 ± 25
Maximum engine
speed, no load
rpm 2760 ± 20

Print 603.93.141 Base - January 2003

 14 ENGINE F2B STRALIS AT/AD

Type F2B

A
VALVE TIMING

opens before T.D.C. A 17°

closes after B.D.C. B 31°

B

opens before B.D.C. D

48°
closes after T.D.C. C 9°
D

For timing check

mm _
X
X mm _

Running

mm 0.35 to 0.45
X
mm 0.35 to 0.45

FEED Through fuel pump - Filters

Injection With electronically regulated injectors PDE 30
type Bosch pump injectors controlled by overhead camshaft

Nozzle type _

Injection order 1-4-2-6-3-5

ba Injection pressure bar 1500

r
Injector calibration bar

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 15

Type F2B

SUPERCHARGING
Holset with variable geometry
Holset,
Turbocharger

type: HY 40 V
LUBRICATION Forced by gear pump, pressure control valve, oil filter
Oil pressure, engine hot
bar
(100 oC ± 5 oC): 1.5
at idling speed bar 5
at maximum speed bar
By centrifugal pump, regulating thermostat, viscostatic fan,
COOLING
radiator and heat exchanger
Water pump control By belt
Thermostat: N. 1
starts to open: ~85 ºC
fully open: _
OIL FILLING
Total capacity at 1st filling
liters 28
kg 25.5
Capacity:
- engine sump min level
liters
kg
Fiat lubricants 12.5
12 5
Urania Turbo LD - engine sump max level
E3-96
(according to E3 96 liters 11.2
standard) kg
Urania Turbo 23
(according to E2-96 - quantity in circulation that
does not flow back to the 21
standard)
engine sump
liters
5
kg
- quantity contained in the
cartridge filter (which has to
be added to the cartridge filter
refill)
liters
2.5
kg 2.3

Print 603.93.141 Base - January 2003

 16 ENGINE F2B STRALIS AT/AD

ASSEMBLY CLEARANCE DATA

Type F2B

CYLINDER BLOCK AND CRANK

mm
MECHANISM COMPONENTS
∅1
Cylinder sleeve bore
upper 130.200 to 130.225
∅1
lower 128.510 to 128.535

Cylinder liners:
outer diameter:
L upper 130.161 to 130.186
∅2
lower 128.475 to 128.500
∅2 length L
Cylinder sleeve -
crankcase bore
upper 0.014 to 0.064
lower 0.010 to 0.060

Outside diameter ∅2

Cylinder sleeve
∅3 A* 115.000 to 115.012

X inside diameter ∅3
B* 115.010 to 115.022
Protrusion X 0.035 to 0.065
* Available dia. class
Pistons:
∅1
measuring dimension X 18
X
outside diameter ∅ 1 A• 114.888 to 114.900
∅2 outside diameter ∅ 1 B•• 114.898 to 114.910
46.010 to 46.018
outside diameter ∅ 2
114.898 to 114.910
• Class A pistons supplied as spares.
•• Class B pistons are fitted in production only and
are not supplied as spares.
Piston - cylinder sleeve 0.100 to 0.124

Piston diameter ∅1 _

X
Pistons protrusion X 0.32 to 0.99

∅3 Gudgeon pin ∅3 45.994 to 46.000

Gudgeon pin - pin housing 0.010 to 0.024

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 17

F2B
Type
mm
X1* 2.71 to 2.74
X1
Piston ring grooves X 2 2.55 to 2.57
X2
X3 X3 4.02 to 4.04
*measured on ∅ of 112 mm
Piston rings:
trapezoidal
p seal S1* 2.575 to 2.595
S1 2 470 tto 2.490
2.470 2 490
lune seal S2
S2
S3 milled scraper ring
rin
with slits and internal
spring S3 3 975 to 3.990
3.975 3 990
*measured on ∅ of 112 mm
1 0.115 to 0.165
Piston rings - 0.060 to 0.100
grooves 2
3 0.030 to 0.065

Piston rings _

X1 Piston ring end gap in

cylinder liners:
X2
X1 0.35 to 0.50
X3
X2 0.70 to 0.96
X3 0.30 to 0.60
Small end bush housing
∅1 Ø1 49.975 to 50.000
Big end bearing
housing Ø2 Rated value 77.000 to 77.030

∅2 1 77.000 to 77.010
Selection classes Ø2 2 77.010 to 77.020
3 77.020 to 77.030
∅4 Small end bush diameter
outside ∅4 50.055 to 50.080
∅3
inside ∅3 46.015 to 46.030
Big end bearing shell S
S Red 2.000 to 2.010
Green 2.011 to 2.020
Yellow 2.021 to 2.030
Small end bush - housing 0.055 to 0.105
Piston pin - bush 0.015 to 0.036

Big end bearing shells 0.127 - 0.254 - 0.508

Connecting rod weight

g. 2890 to 2920
A
Class B g. 2921 to 2950
C g. 2951 to 2980

Print 603.93.141 Base - January 2003

 18 ENGINE F2B STRALIS AT/AD

F2B
Type
mm
X
Measuring dimension X 125

Max. connecting rod

axis misalignment
tolerance 0.08

Main journals ∅ 1 Rated value 82.910 to 82.940

1 82.910 to 82.919
Selection class 2 82.920 to 82.929
3 82.930 to 82.940
∅1 ∅2 Crankpins ∅ 2 Rated value 72.915 to 72.945
1 72.915 to 72.924
Selection class 2 72.925 to 72.934
3 72.935 to 72.945
Main bearing
shells S1
S1 S 2 Red 3.000 to 3.010
Green 3.011 to 3.020
Yellow D 3.021 to 3.030
Big end bearing
shells S2 2.000 to 2.010
Red
2.011 to 2.020
Green
2.021 to 2.030
Yellow D
Main bearing housings ∅ 3 Rated value 89.000 to 89.030
∅3 1 89.000 to 89.009
Selection class 2 89.010 to 89.019
3 89.020 to 89.030
Bearing shells -
0.040 to 0.080
main journals
Bearing shells -
0.035 to 0.075
big ends
Main bearing shells 0.127 - 0.254 - 0.508
Big end bearing shells 0.127 - 0.254 - 0.508

Main journal,
thrust bearing X1 39.96 to 40.00
X1

Main bearing housing,

thrust bearing X2 32.94 to 32.99
X2

X3 Thrust washer
halves X3 3.38 to 3.43

Driving shaft shoulder 0.11 to 0.30

1 2 1 ≤ 0.05
Alignment
2 _
Ovality 1-2 0.010

Taper 1-2 0.010

D Fitted in production only and not supplied as spares

Base - January 2003 Print 603.93.141

 STRALIS AT/AD ENGINE F2B 19

11

Type F2B

CYLINDER HEADS - VALVE TRAIN mm

∅ 1

Valve guide housings

in cylinder head
∅1 12.980 to 12.997

∅ 2

∅2 8.023 to 8.038
Valve guide
∅3 13.012 to 13.025
∅ 3

Valve guides - housings

0.015 to 0.045
in the cylinder heads

Valve guide _

∅ 4 Valves:
7.985 to 8.000
∅4
α 60° 30′ ± 7′ 30″

∅4 7.985 to 8.000
α α 45° + 15′
Valve stem and its guide 0.023 to 0.053
Housing in head for valve
seat

∅1 41.985 to 42.020

∅ 1 ∅1 40.985 to 41.020
Outside diameter of valve
seat; angle of valve seat in
∅ 2 cylinder head:

∅2 42.060 to 42.075
α 60° - 30’
α ∅2 41.060 to 41.075
α 45° - 30′
Recessing of 0.5 to 0.8
valve X
X 1.6 to 1.9

Between valve
seat and head 0.040 to 0.090

Print 603.93.141 Base - January 2003

 20 ENGINE F2B STRALIS AT/AD

Type F2B

mm
Valve outside spring
height:
free height H 62.6
H H1 under a load of:
H 2 N 454 ± 22 H1 48.5
N 840 ± 42 H2 36.5

Injector protrusion X 0.7

X

Camshaft bush housing

fitted in the cylinder head:
1⇒7 Ø 80.000 to 80.030
∅ ∅ ∅
∅ 2

Camshaft journal diameter:

1⇒7 Ø 75.924 to 75.940
∅ 1 ∅ 3

Camshaft bushing outer

∅ diameter: ∅ 80.090 to 80.115

Camshaft bushing
∅ inner diameter: ∅ 75.990 to 76.045

Bushings and housings in

0.060 to 0.115
engine block
Bushings and journals 0.050 to 0.121
Cam lift:
8.07

H 7.63

8.80 to 8.82

∅ 1
Rocker shaft ∅1
37.984 to 38.000

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 21

Type F2B

mm
Bushing housing in rocker
arms
41.000 to 41.016

53.000 to 53.019

∅
42.000 to 42.016

Bushing outer diameter

for rocker arms:
41.097 to 41.135

∅ 53.105 to 53.156

42.066 to 42.091

Bushing inner diameter

for rocker arms:
38.025 to 38.041

∅ 50.025 to 50.041

38.015 to 38.071

Between bushings and

housings
0.081 to 0.135

0.086 to 0.156

0.050 to 0.091

Between rocker arms and

shaft
0.025 to 0.057

0.225 to 0.057

0.015 to 0.087

TURBOCHARGER
Type HOLSET, variable geometry
End float _
Radial play _

Print 603.93.141 Base - January 2003

 22 ENGINE F2B STRALIS AT/AD

TIGHTENING TORQUES

PART TORQUE
Nm kgm
Under-basement fastening screws to cylinder block (see Figure 6) ♦
Outer screws First stage : pre-tightening M10x1.25 25 2.5
Inner screws Second stage : pre-tightening M16x2 140 14
Inner screws Third stage : angle closing M16x2 60°
Inner screws Fourth stage : angle closing M16x2 60°
Outer screws Fifth stage : angle closing M10x1,5 90°
Pipe union for piston cooling nozzle M12X1.5 35 ± 2 3.5 ± 0.2
Intercooler fastening screws to cylinder block ♦ (see Figure 10)
pre-tightening 11.5 ± 3.5 1.15 ± 0.35
tightening 19 ± 3 1.9 ± 0.3
Plug 125 ± 15 12.5 ± 1.5
Spacer and oil sump fastening screws (see Figure 11) 41.5 ± 3.5 4.1 ± 0.3
Gearcase fastening screws to cylinder block 41.5 ± 3.5 4.1 ± 0.3
63 ± 7 6.3 ± 0.7
9±3 1.9 ± 0.3
Cylinder head fastening screw: (see Figure 7) ♦
First stage pre-tightening 50 5
Second stage pre-tightening 100 10
Third stage angle closing 90°
Fourth stage angle closing 75°
Rocker arm shaft fastening screw ♦
First stage pre-tightening 40 4
Second stage pre-tightening 60°
Locknut for rocker arm adjusting screw ♦ 39 ± 5 3.9 ± 5
Screws for injector fastening brackets ♦ 36.5 3.65
Shoulder plate fastening screws to head ♦ 23.5 2.35
Engine support bracket fastening screws to cylinder head 74 ± 8 7.4 ± 0.8
Gear fastening screws to camshaft: ♦
First stage pre-tightening 50 5
Second stage pre-tightening 50°
Phonic wheel fastening screws to distribution gear 8.5 ± 1.5 0.8 ± 0.1
Exhaust pipe fastening screws • (see Figure 8)
pre-tightening 32.5 ± 7.5 3.2 ± 0.7
tightening 47 ± 2.5 4.7 ± 0.2
Engine brake actuator cylinder fastening screws 24.5 ± 2.5 2.4 ± 0.2
Connecting rod cap fastening screws: ♦
First stage pre-tightening 50 5
Second stage pre-tightening 40°
Engine flywheel fastening screws: ♦ M16x1.5x58
First stage pre-tightening 100 10
Second stage pre-tightening 60°
Engine flywheel fastening screws: ♦ M16x1.5x110
First stage pre-tightening 100 10
Second stage pre-tightening 120°
Flywheel pulley fastening screws to crankshaft : ♦
First stage pre-tightening 70 7
Second stage pre-tightening 50°
♦ Lubricate with oil MOLYKOTE before assembly
• Lubricate with graphitized oil before assembly

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 23

TIGHTENING TORQUES

PART TORQUE
Nm kgm
Damper flywheel fastening screws: ♦ 115 ± 15 11.5 ± 1.5
Idler gear pin fastening screws: ♦
First stage pre-tightening 30 3
Second stage pre-tightening 90°
Idle gear link rod fastening screw 24.5 ± 2.5 2.4 ± 0.2
Oil pump fastening screw 24.5 ± 2.5 2.4 ± 0.2
Oil pump suction rose fastening screw 24.5 ± 2.5 2.4 ± 0.2
Front cover fastening screw to cylinder block ♦ 19 ± 3 1.9 ± 0.3
Control unit fastening screw to cylinder block ♦ 19 ± 3 1.9 ± 0.3
Supply pump fastening screw to gearcase ♦ 19 ± 3 1.9 ± 0.3
Fuel filter support fastening screw to cylinder head ♦ 37 ± 3 3.7 ± 0.3
Turbo-compressor fastening screws and nuts • (see Figure 9)
pre-tightening 32.5 ± 7.5 3.2 ± 0.7
tightening 46 ± 2 4.6 ± 0.2
Water pump fastening screw to cylinder block 24.5 ± 2.5 2.4 ± 0.2
Pulley fastening screw to hub 55 ± 5 5.5 ± 0.5
Rocker arm cover fastening screws (see Figure 12) 9 0.9
Thermostat box fastening screws to cylinder head 24.5 ± 2.5 2.4 ± 0.2
Automatic tightener fastening screws to cylinder block 45 ± 5 4.5 ± 0.5
Fixed tightener fastening screws to cylinder block 105 ± 5 10.5 ± 0.5
Fan support fastening screws to cylinder block 24.5 ± 2.5 2.4 ± 0.2
Starter fastening screws 44 ± 4 4 ± 0.4
Air heater on cylinder head 30 ± 3 3 ± 0.3
Air compressor fastening screw to cylinder head 74 ± 8 7.4 ± 0.8
Air compressor control gear fastening nut 170 17 ± 1
Hydraulic power steering pump gear fastening nut 46.5 ± 4.5 4.6 ± 0.4
Air conditioner compressor fastening screw to support 24.5 ± 2.5 2.4 ± 2.5
Air conditioner compressor support fastening screw to cylinder block 44 ± 4 4.4 ± 0.4
Alternator support fastening screw to cylinder block 44 ± 4 4.4 ± 0.4
Alternator bracket fastening screw to cylinder block 24.5 ± 2.5 2.4 ± 0.2
Water pipe unions 35 3.5
Water temperature sensor 32.5 ± 2.5 3.2 ± 0.2
♦ Lubricate with oil MOLYKOTE before assembly
• Lubricate with graphitized oil before assembly

Print 603.93.141 Base - January 2003

 24 ENGINE F2B STRALIS AT/AD

TIGHTENING TORQUES

PART TORQUE
Nm kgm
Engine brake solenoid valve fastening screws 32.5 ± 2.5 3.2 ± 0.2
Flywheel rev sensor fastening screw 8±4 0.8 ± 0.2
Camshaft rev sensor fastening screw 8±2 0.8 ± 0.2
P.D.E solenoid connector fastening screw 1.62 ± 0.3 0.1 ± 0.3
Overboost pressure sensor fastening screw 8±2 0.8 ± 0.2
Absolute pressure sensor fastening screw 22.5 ± 2.5 2.2 ± 0.2
P.W.M. control valve fastening screw/nut 8±2 0.8 ± 0.2
Fuel/coolant temperature sensor 35 3.5
Coolant temperature indicator 23.5 ± 2.5 2.3 ± 0.2
Filter clogging sensor 10 1
Oil temperature switch 25 ± 1 2.5 ± 0.1
Oil pressure sensor 25 ± 1 2.5 ± 0.1
Oil clogging sensor 55 ± 5 5.5 ± 0.5
Electric wire fastening screw 8±2 0.8 ± 0.2
Heater fastening screw 12.5 ± 2.5 1.2 ± 0.2

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 25

UNDERBLOCK FIXING SCREWS TIGHTENING SEQUENCE

Figure 6

First phase:
FRONT SIDE preliminary tightening
of outer screws
(25 Nm)

44897

Second phase:
FRONT SIDE
preliminary
tightening of
inner screws
(140 Nm)

44898

Third phase:
FRONT SIDE
angle tightening
of inner screws
60º

44898

Front phase:
FRONT SIDE angle tightening
of inner screws
60º

44898

Fifth phase:
FRONT SIDE angle tightening
of outer screws
90º

44899

Print 603.93.141 Base - January 2003

 26 ENGINE F2B STRALIS AT/AD

Figure 7

44900

DIAGRAM OF CYLINDER HEAD FIXING SCREWS TIGHTENING SEQUENCE

Figure 8

8 1 4 5 8 1 2 5 8 1 4 5

6 3 2 7 6 3 4 7 6 3 2 7
45359

DIAGRAM OF EXHAUST MANIFOLD FIXING SCREWS TIGHTENING SEQUENCE

Figure 9

45360

DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE

SEQUENCE: Preliminary tightening 4-3-1-2
Tightening 1-4-2-3

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 27

Figure 10

455361

DIAGRAM OF HEAT EXCHANGER FIXING SCREWS TIGHTENING SEQUENCE

Figure 11

1 12 11 10 3

13 9

14 8

4 5 6 7 2 45362

DIAGRAM OF ENGINE OIL SUMP FIXING SCREWS TIGHTENING SEQUENCE

Figure 12
17 14 13 1 4 5 8
18 9

19 10

20 11
16 15 12 2 3 6 7 45363

DIAGRAM OF ROCKER ARM CAP FIXING SCREWS TIGHTENING SEQUENCE

Print 603.93.141 Base - January 2003

 28 ENGINE F2B STRALIS AT/AD

TOOLS

TOOL NO. DESCRIPTION

Full-optional tool-kit to rectify valve seat

99305019

99305047 Equipment for spring load check

99322230 Rotary telescopic stand

99340051 Extractor for crankshaft front gasket

99340052 Extractor for crankshaft rear gasket

99340205 Percussion extractor

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 29

TOOLS

TOOL NO. DESCRIPTION

99342148 Injector extractor

99342149 Extractor for injector-holder

99346245 Tool to install the crankshaft front gasket

99346246 Tool to install the crankshaft rear gasket

99348004 Universal extractor for 5 to 70 mm internal components

99350072 Box wrench for transmission gear support fixing screws

Print 603.93.141 Base - January 2003

 30 ENGINE F2B STRALIS AT/AD

TOOLS

TOOL NO. DESCRIPTION

99350074 Box wrench for block junction bolts to the underblock

Skid retaining tools (12+6) for rocker arm adjusting screws during
99360144 rocker arm shaft removal/ refitting

99360177 Injector housing plug

Pincers for removing and refitting circlips and pistons

99360184 (105-160 mm)

99360264 Tool to take down-fit engine valves

99360288 Tool to remove valve guide

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 31

TOOLS

TOOL NO. DESCRIPTION

99360292 Tool to install gasket on valve guide

99360294 Tool to drive valve guide

99360314 Tool to remove cartridge filters

99360321 Tool to rotate engine flywheel

99360334 Tool for checking cylinder barrel projection.

99360335 Cylinder barrel compression cap (to be used with 99360334)

Print 603.93.141 Base - January 2003

 32 ENGINE F2B STRALIS AT/AD

TOOLS

TOOL NO. DESCRIPTION

99360351 Tool to stop engine flywheel

Tool to take down and fit back camshaft bushes

99360487

99360500 Tool to lift crankshaft

99360551 Bracket to take down and fit engine flywheel

99360558 Tool to lift and transport rocker shaft

99360585 Balance for lifting and handling engine

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 33

TOOLS

TOOL NO. DESCRIPTION

Belt to insert piston in cylinder liner (60 - 125 mm)

99360605

99360612 Engine flywheel timing pin

99360613 Tool for timing of phonic wheel on timing gear

99360703 Tool to stop cylinder liners

99360706 Tool to extract cylinder liners

99360724 Tool to extract the cylinder liners (to be used with 99360723)

Print 603.93.141 Base - January 2003

 34 ENGINE F2B STRALIS AT/AD

TOOLS

TOOL NO. DESCRIPTION

99361035 Brackets fixing the engine to rotary stand 99322230

99365054 Tool for injector holder heading

Tool to detect cylinder liner projections

99370415 (use with 99395603)

Tool for printing engine identification plates (to be used with

99378100 special punches)

Punches (A) for printing engine identification plates (to be used

99378101 with 99378100)

Punches (B) for printing engine identification plates (to be used

99378102 with 99378100)

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 35

TOOLS

TOOL NO. DESCRIPTION

Punches (E) for printing engine identification plates (to be used

99378105 with 99378100)

Punches (F) for printing engine identification plates (to be used

99378106 with 99378100)

Dynamometric screwdriver to calibrate screws for injector

99389834 solenoid valve

99390310 Valve guide sleeker

99390772 Tool to remove residues from injector holder

99390804 Tool to thread injector holders to be extracted

Print 603.93.141 Base - January 2003

 36 ENGINE F2B STRALIS AT/AD

TOOLS

TOOL NO. DESCRIPTION

99394014 Guide bush (to be used with 99394041 or 99394043)

Cutter to rectify injector holder housing (to be used with

99394041 99394015)

Reamer to rectify injector holder lower side (to be used with

99394043 99394015)

Gauge for centre distance check between camshaft and idle gear
99395215

Measuring pair for angular tightening with 1/2” and 3/4” square
99395216 couplings

99395363 Complete square to check connecting rod squaring

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 37

TOOLS

TOOL NO. DESCRIPTION

99395603 Dial gauge (0 - 5 mm)

99395687 Reaming gauge (50-178 mm)

99396033 Centering ring of crankshaft front cap

Print 603.93.141 Base - January 2003

 38 ENGINE F2B STRALIS AT/AD

Figure 13

78839

ENGINE - LONGITUDINAL SECTION

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 39

Figure 14

78841

ENGINE - CROSS SECTION

Print 603.93.141 Base - January 2003

40 ENGINE F2B STRALIS AT/AD

54010 DISMANTLING THE ENGINE

ON THE BENCH Figure 16
Figure 15

47562 47563

Before dismantling the engine on the rotary stand 99322230, Remove the soundproofing shield (1) and plug (2)
remove the following components:
- starter (2)
- turbocharger soundproofing shield (1)

Figure 17

1
1

1
1
47601

Fix the engine to the rotary stand 99322230, by means of

brackets 99361035 (1), remove the fan.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 41

Figure 18 Figure 20

73579 60490

Using an appropriate tool (2), operate in the direction of the Fit the extractor 99340053 (2) and remove the engine
arrow, and remove the belt (1) driving the water pump, crankshaft seal gasket (1), remove the cover (3).
alternator and fan.
Take out the screws and remove the electromagnetic
coupling (3).
Figure 19 Figure 21

60489
60491
Remove the following components: Remove the following components:
- thermostat unit (6) fitted with turbine actuator pressure - water outlet line (2);
sensor (7);
- oil delivery line (4);
- alternator (2);
- actuator air line (3);
- pulley support (1);
- water delivery line (6);
- water pump (8) and piping;
- oil return line (7);
- automatic belt tightener support (3);
- turbocharger (5);
- fixed belt tightener (9);
- exhaust manifold (1).
- damping flywheel (4) and pulley underneath it;
- automatic belt tightener (5);
- disconnect all the electric connections and the sensors.

Print 603.93.141 Base - January 2003

42 ENGINE F2B STRALIS AT/AD

Figure 22 Figure 24

45254

Install extractor 99340051 (2) and remove the seal gaskets

47564 (1). Unscrew the screws and remove the cover.
Load the belt tensioner spring by tool (4), acting in the Disconnect all electric connections and sensors.
direction shown by the arrow, on the head of the screw fixing
the roller. The screw cannot be untightened as the thread is Figure 25
counterclock-wise. Remove the belt (3). By tool (2), act in the
direction shown by the arrow and remove the fan, alternator
and water pump control belt (1).

Figure 23

47566

Remove the following components: oil supply lines (1); water

cooling supply lines (3); water discharge lines (2); oil return
lines (4); turbocharger (5); exhaust manifold (6).

Figure 26

47565

Remove the following components:

- alternator (1);
- belt tightener support (2);
- air conditioner compressor (3);
- flywheell (4);
- water pump and piping (5);
47567
- fan pulley spacer (6);
- thermostat unit (7). Unscrew the oil filter (1) by tool 99360314 (2).
Unscrew the screws and remove the entire heat exchanger
(3).

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 43

Figure 27 Figure 30

47587

Remove the following components: intake manifold (6); 45661

support for fuel filter (1); fuel lines (2); fuel pump Unscrew the screws (2), by using the proper wrench and
(3);compressor (4); control unit (5). remove the gear (1) with the phonic wheel.
Figure 31
Figure 28

70708
To remove the P.T.O. (if applicable): 45265
- Disconnect the oil pipe (1). Unscrew the screws (1); tighten a screw in a reaction hole and
- Unscrew the 4 screws (2) and (3).
remove the shoulder plate (3), remove the sheet gasket.
Figure 29
Figure 32

84377
47568
Remove the rocker arm cover (1), take off the screws (2) and
remove: the cover (3), the filter (5) and the gaskets (4 and 6). By means of a properly splined wrench, untighten screws (2)
Take off the screws (8) and remove the blow-by case (7). and remove the transmission gear (1)

Print 603.93.141 Base - January 2003

44 ENGINE F2B STRALIS AT/AD

Figure 33 Figure 36

In sequence, take out the:

47568
- if the P.T.O. control gear (1) is present;
Stop the engine flywheel (3) rotation by means of tool - idle gear (2);
99360351 (1), untighten the fixing screws (2) and remove the - oil pump gear (3).
engine flywheel.
Figure 37
Figure 34

45259
45257
- Remove the check springs (2) of the exhaust brake lever;
Apply extractor 99340052 (2) and pull out the seal gasket (1).
- Untighten the fixing screws (1) of rocker arm shaft.

Figure 38
Figure 35

73533
47569 - Using tool 99360144 (3), constrain the blocks (4) to the
rockers (2).
Untighten the screws (1) and take down the gear box (2). - Apply tool 99360553 (1) to the rocker holder shaft (5)
and remove the shaft (5) from the cylinder head.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 45

Figure 39 Figure 42

3
4

45262
47573
- Remove the piping (1) for exhaust brake pins; Untighten screws (2) and remove the engine oil sump (1) with
- Untighten screws and remove electric connections (2) spacer (3) and seal .
from solenoid valves;
- Untighten fixing screws (3) of injector brackets (4).
Figure 40
Figure 43

45263

- Remove injectors (2)

If this operations is difficult, use extractor 99342148 (1). Install 47572
plugs 99360177 instead of injectors.
Untighten screws and remove suction rose (1).

Figure 41 Figure 44

45266
Remove the camshaft and the fixing screws on cylinder heads
- By means of wire ropes, lift the cylinder head (1) and 47574
remove seals (2). Rotate the block (1) to the vertical position.

Print 603.93.141 Base - January 2003

46 ENGINE F2B STRALIS AT/AD

Figure 45 Figure 48

47575
47571
Remove the crankshaft half-bearings (1), untighten the screws
Untighten screws (2) fixing the connecting rod cap (3) and
and remove oil spray nozzles (2).
remove it. Remove the connecting rod-piston assembly from
Take down cylinder liners as specified in the relative paragraph
the upper side. Repeat these operations for the other pistons.
on page 49.

Figure 46

After disassembling the engine, thoroughly clean

! disassembled parts and check their integrity.
Instructions for main checks and measures are given
in the following pages, in order to determine whether
the parts can be re-used.

47576

By means of proper and splined wrenches, untighten the

screws (1) and (2) and remove the under-block (3).

Figure 47

47570

Remove the crankshaft (2) with tool 99360500 (1).

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 47

REPAIR OPERATIONS
540410 CYLINDER BLOCK Figure 51
540420 Checks and measurements
Figure 49 (Demonstration)

34994 47440

Internal diameter of the cylinder liners is checked for A = Selection class Ø 115 to 115.012 mm
ovalization, taper and wear, using a bore dial (1) centesimal B = Selection class Ø 115.010 to 115.022 mm
gauge 99395687 (2) previously reset to ring gauge (3),
diameter 115 mm. In case of maximum wear max 0.150 mm or maximum
ovalization max 0.100 mm compared to the values indicated
in the figure, the liners must be replaced as they cannot be
ground, lapped or trued.
If a 115 ring gauge is not available use a micrometer
! caliper.
! Cylinder liners are equipped with spare parts with
“A“ selection class.

Figure 50
Figure 52

47441

47439 A = Ø 130.200 to 130.225 mm

B = Ø 128.510 to 128.535 mm
1 = 1st measuring C = Ø 130.161 to 130.186
2 = 2nd measuring D = Ø 128.475 to 128.500 mm
3 = 3rd measuring
The figure shows the outer diameters of the cylinder liners
and the relative seat inner diameters.
Carry out measurings on each cylinder liner at three different
levels and on two (A-B) surfaces, to one another The cylinder liners can be extracted and installed several
perpendicular, as shown in Figure 50. times in different seats, if necessary.

Print 603.93.141 Base - January 2003

 48 ENGINE F2B STRALIS AT/AD

CYLINDER LINERS
Figure 53

45150 45150a

BLOCK WITH CYLINDER LINERS

Figure 54

47533

Selection class A mm 115.000 to 115.012

B mm 115.010 to 115.022
CYLINDER LINERS MAIN DATA

Figure 55 A

47534

DETAIL “X”
“A“ = Selection class marking area

Base - January 2003 Print 603.93.141

 STRALIS AT/AD ENGINE F2B 49

540420 Replacing cylinder liners

Removal
Figure 56 Figure 58

77812

Check cylinder barrel protrusion with tool 99360334

47577 (1-2-3-4) and tighten screw (1) to 170 Nm.
With dial gauge 99395603 (5) placed on base 99370415 (6).
Place details 99360706 (1 and 2) and plate 99360724 (4) as Measure the cylinder barrel protrusion compared to the
shown in the figure, by making sure that the plate (4) is cylinder head supporting plane, it must be 0,035 to 0,065 mm
properly placed on the cylinder liners. (Figure 59); otherwise replace the adjusting ring (1,
Tighten the screw nut (1) and remove the cylinder liner (3) Figure 57) fitted with spare parts having different thickness.
from the block.

Figure 59
Fitting and checking protrusion
Figure 57

49017

CYLINDER LINER PROTRUSION

Figure 60 (Demonstration)

16798

Always replace water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2);
lubricate lower part of liner and install it in the cylinder unit
using the proper tool.

! The adjustment ring (1) is supplied as spare parts in

the following thicknesses: 0.08 mm - 0.10 mm - 0.12
mm.

35012

When the installation is completed, block the cylinder liners

(1) to the block (2) with studs 99360703 (3).

Print 603.93.141 Base - January 2003

 50 ENGINE F2B STRALIS AT/AD

5408 CRANKSHAFT
Figure 61

Upper main journal half bearing

Lower main journal half bearings

49018

MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
The data given refer to the normal diameter of the pins.

Figure 62 Figure 63

BUFF
BUFF

47537 47538

X. Detail of main journals connections Y. Detail of crank pins connections

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 51

540812 Measuring main journals and crank pins

Before grinding the crank pins using a micrometer (1), Figure 65
measure the main journals and the crank pins (2) and decide,
on the basis of the undersizing of the bearings, the final
diameter to which the pins are to be ground.

Figure 64

47536

MEASURING CRANK PINS

During grinding, pay attention to journal and crank pins values
47535
specified in figures 62 and 63.
MEASURING THE MAIN JOURNALS

It is advisable to enter the values found in a table All journals and crank pins must also be ground to
! (Figure 66). ! the same undersizing class, in order to avoid any
alteration to shaft balance.

Figure 66

Fill in this table with the measurements of the main journals and the crank pins.

MAIN JOURNALS

Ø MIN.
Ø MAX.

Ø MIN.
Ø MAX.

CRANK PINS 36061

Print 603.93.141 Base - January 2003

 52 ENGINE F2B STRALIS AT/AD

PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA

For each of the journals of the crankshaft, it is necessary to carry out the following operations:
MAIN JOURNALS: CRANKPINS:
- Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the
crankcase. connecting rod.
- Determine the class of diameter of the main journal. - Determine the class of diameter of the crankpin.
- Select the class of the bearing shells to mount. - Select the class of the bearing shells to mount.

DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure 67 at top).
- The first set of digits (four) is the coupling number of the crankcase with its base.
- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure 67 at bottom).
- Each of these digits may be 1, 2 or 3.

CLASS MAIN BEARING HOUSING

Figure 67 NOMINAL DIAMETER

89.000 to 89.009

89.010 to 89.019

89.020 to 89.030

47535

Base - January 2003 Print 603.93.141

 STRALIS AT/AD ENGINE F2B 53

Selecting the main and big end bearing shells

To obtain the required assembly clearances, the main and big end bearing shells need to be selected as described
! hereunder.

This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary,
can have different classes from one journal to another).
Depending on the thickness, the bearing shells are selected The following tables give the specifications of the main and
in classes of tolerance marked by a coloured sign (red-green big end bearing shells available as spares in the standard sizes
— red/black — green/black). (STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).

Figure 68

STD +0.127 +0.254 +0.508

red 2.000 to 2.010 2.127 to 2.137 2.254 to 2.264

red/black 2.063 to 2.073

green 2.011 to 2.020 2.138 to 2.147 2.265 to 2.274

green/black 2.074 to 2.083

yellow* 2.021 to 2.030

yellow/black* 2.084 to 2.093

STD +0.127 +0.254 +0.508

red 3.000 to 3.010 3.127 to 3.137 2.254 to 3.264

red/black 3.063 to 3.073

green 3.011 to 3.020

green/black 3.074 to 3.083

yellow* 3.021 to 3.030

yellow/black* 3.084 to 3.093 * Fitted in production only and not supplied as spares

Print 603.93.141 Base - January 2003

 54 ENGINE F2B STRALIS AT/AD

DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter)
Main journals and crankpins: determining the class of diameter of the journals.
Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 69 at top):
- The first number, of five digits, is the part number of the shaft.
- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status
of the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins
they refer to (Figure 69 at top).
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the
status of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of the
main journals they refer to (Figure 69 at bottom).

Figure 69

CRANKPIN
CLASS
NOMINAL DIAMETER

72.915 to 72.924

72.925 to 72.934

72.935 to 72.945

CLASS MAIN JOURNALS

NOMINAL DIAMETER

82.910 to 82.919
82.920 to 82.929
82.930 to 82.940

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 55

Selection of main half-bearings (nominal diameter pins)

After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in
compliance with the following table:

Figure 70

STD.

1 2 3

green green green

1
green green green

red green green

2
red green green

red red red

3
red red red

Print 603.93.141 Base - January 2003

 56 ENGINE F2B STRALIS AT/AD

Selection of main half-bearings (rectified pins)

If the journals have been rectified, the procedure described cannot be applied.
In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing type
required for this undersizing.
Figure 71

red/black = -0.127
mm 3.063 to 3.073

green/black =
mm 3.063 to 3.073
1 2 3
82.784 green/black green/black green/black
1
82.793 green/black green/black green/black

82.794 red/black green/black green/black

2
82.803 red/black green/black green/black

82.804 red/black red/black red/black

3
82.814 red/black red/black red/black

-0.254

red =
mm 3.127 to 3.137
1 2 3

red red red

82,666
82,686 red red red

-0.508

red =
mm 3.254 to 3.264
1 2 3

red red red

82.412
82.432 red red red

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 57

SELECTING THE BIG END BEARING SHELLS Figure 72

(JOURNALS WITH NOMINAL DIAMETER)
There are three markings on the body of the connecting rod
in the position shown in the view from ”A”:

1 Letter indicating the class of weight:

VIEW FROM “A”
A = 2890 to 2920 g.
B = 2921 to 2950 g.
C = 2951 to 2980 g.
2 Number indicating the selection of the diameter of the
big end bearing seat:
1 = 77.000 to 77.010 mm
2 = 77.011 to 77.020 mm
3 = 77.021 to 77.030 mm
3 Numbers identifying the cap-connecting rod coupling.

The number, indicating the class of diameter of the bearing

shell seat may be 1, 2 o 3.
Determine the type of big end bearing to fit on each journal
by following the indications in the table (Figure 73). 47557

Figure 73

STD.

Class 1 2 3

green green green

1
green green green

red green green

2
red green green

red red red

3
red red red

Print 603.93.141 Base - January 2003

 58 ENGINE F2B STRALIS AT/AD

Selection of connecting rod half-bearings (rectified pins)

If pins have been rectified, the procedure described must be applied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the half-bearings
identified according to the relative table.
Figure 74
red/black =
mm 2.074 to 2.083 -0.127
green/black =
mm 2.063 to 2.073
1 2 3
72.789 green/black green/black green/black
1
72.798 green/black green/black green/black

72.799 red/black green/black green/black

2
72.808 red/black green/black green/black

72.809 red/black red/black green/black

3
72.818 red/black red/black green/black

-0.254
red
mm 2.127 to 2.137
green =
1 2 3
mm 2.138 to 2.147

72.671 red green green

72.680 red green green

72.681 red red green

72.691 red red green

-0.508
red =
mm 2.254 to 2.264
green =
1 2 3
mm 2.265 to 2.274

red green green

72.417
72.426 red green green

72.427 red red green

72.437 red red green

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 59

540815 Replacing the timing control gear and

the oil pump
Check that the teeth of the gears are not damaged or worn, Figure 77
otherwise remove them using the appropriate extractor.

Figure 75

47578

Using the hoist and hook 99360500 (1) mount the driving
shaft (2).
49020

After fitting the gear (1) on the crankshaft (2), heat it for
~15 minutes in an oven at temperature not higher than
180°C.
Let them cool down after the installation.
If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.

540811 Checking main journal installation

clearance

Figure 78
Figure 76

49021
47579

Install the half-bearings (1) on the main bearings in the

Install the oil spray nozzles (2) and have the dowel coincide underblock (2).
with the block hole (3). Check the installation clearance between the main journals
Install the half-bearings (1) on the main bearings. and the relative bearings as follows:

Print 603.93.141 Base - January 2003

 60 ENGINE F2B STRALIS AT/AD

Figure 79 Figure 80

49022 47578

Place a piece of calibrated wire on the journal of the - Lubricate inside screws (1) con UTDM oil, and tighten
crankshaft (2), parallel to the longitudinal axis; install the them by dynamometric wrench to 140 Nm torque, thus
underblock (1), by hoist and appropriate hooks. with 60º angle closing, following the diagram in Figure 81.

Figure 81

FRONT SIDE

44898

Diagram showing the tightening order of the screws fixing the lower under-block to the block

Figure 82 Checking crankshaft end float

Figure 83

47579
- Remove the under-block
The clearance between the main bearings and the journals
is obtained by comparing the calibrated wire length (2) at the 47588
maximum deflection point, with the calibrated scale on the
coating (1) containing the calibrated wire (1). End float is checked by placing a magnetic dial gauge (1) on
Numbers shown on the scale specify the clearance in the crankshaft (2), as shown in the figure. If the value obtained
coupling millimeters. If the clearance obtained is different is higher than specified, replace the rear thrust half-bearings
from the clearance required, replace the half-bearings and and repeat this check.
repeat this check.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 61

5408 PISTON-CONNECTING ROD ASSEMBLY

Figure 84

47580

PISTON CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6. Scraper ring with
spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston

Make sure the piston does show any trace of seizing, scoring, Pistons are equipped with three elastic rings: a sealing ring, a
cracking; replace as necessary. trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.

Removal
Figure 85 Figure 86

49023 49024

Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin split rings (2) using the round tipped
(1). pliers (1).

Print 603.93.141 Base - January 2003

 62 ENGINE F2B STRALIS AT/AD

Figure 87 Figure 89

49025 32618

Remove the piston pin (1). Measuring the gudgeon pin diameter (1) with a micrometer
If removal is difficult use the appropriate beater. (2).

Measuring the diameter of the pistons

Figure 88

Conditions for correct gudgeon pin-piston

coupling
47584

Using a micrometer (2), measure the diameter of the piston

(1) to determine the assembly clearance; the diameter should Figure 90
be measured at the specified value.

49026

Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight
finger pressure and it should not come out by gravity.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 63

Figure 91

Drawing No. 500388370

77816

MAIN DATA ON PISTONS, AND PISTONS RINGS

* Values are determined on ∅ of 112 mm.

540842 Piston rings Figure 94

Figure 92

3513

The sealing ring (2) of the 1º cavity is trapezoidal. Clearance

“X” between the sealing ring and its housing is measured by
placing the piston (1) with its ring in the cylinder barrel (3),
16552
so that the sealing ring is half-projected out of the cylinder
barrel.
Check the thickness of the piston ring (2) using a micrometer
(1).
Figure 95
Figure 93

36134

Check the opening between the ends of the sealing rings (1),
using a thickness gauge (2), entered in the cylinder barrel (3).
16552
If the distance between ends is lower or higher than the value
Check the clearance between the sealing rings (2) and the required, replace split rings.
relative piston housings (1) using a thikness gauge (3).

Print 603.93.141 Base - January 2003

 64 ENGINE F2B STRALIS AT/AD

540830 CONNECTING ROD

Figure 96

Data concerning the class section of connecting rod

housing and weight are stamped on the big end.

When installing connecting rods, make sure

! they all belong to the same weight class. VIEW FROM “A”

DIAGRAM CONNECTING ROD MARKS

1 Letter indicating the weight class:

A = 2890 to 2920 g.
B = 2921 to 2950 g.
C = 2951 to 2980 g.
2 Number indicating the selection of diameter for
the big end bearing housing:
1 = 77.000 to 77.010 mm
2 = 77.011 to 77.020 mm
3 = 77.021 to 77.030 mm

3 Numbers identifying cap-connecting rod coupling

47557

Figure 97

44927

MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS

* Values to be obtained after installing the bush

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 65

Checking connecting rod alignment Checking bending

Figure 98 Figure 100

61695

Check the bending of the connecting rod (5) by comparing

two points C and D of the pin (3) on the vertical plane of the
axis of the connecting rod.
61696 Position the vertical mount (1) of the dial gauge (2) so that this
rests on the pin (3) at point C.
Swing the connecting rod backwards and forwards seeking the
Checking axis alignment highest position of the pin and in this condition zero the dial
Check the alignment of the axes of the connecting rods (1) gauge (2).
with device 99395363 (5), proceeding as follows: Shift the spindle (4) with the connecting rod (5) and repeat
the check on the highest point on the opposite side D of the
- Fit the connecting rod (1) on the spindle of the tool pin (3). The difference between point C and point D must be
99395363 (5) and lock it with the screw (4). no greater than 0.08 mm.
- Set the spindle (3) on the V-prisms, resting the connecting
rod (1) on the stop bar (2).
Mounting the connecting rod - piston assembly
Carry out the steps for removal described on page 61 in
Checking torsion reverse order.

Figure 99 The connecting rod screws can be reused as long as

! the diameter of the thread is not less than 13.4 mm.

Mounting the piston rings

Figure 101

61694

Check the torsion of the connecting rod (5) by comparing

two points (A and B) of the pin (3) on the horizontal plane
of the axis of the connecting rod.
49029
Position the mount (1) of the dial gauge (2) so that this
pre-loads by approx. 0.5 mm on the pin (3) at point A and To fit the piston rings (1) on the piston (2) use the pliers
zero the dial gauge (2). Shift the spindle (4) with the 99360184 (3).
connecting rod (5) and compare any deviation on the The rings need to be mounted with the word ”TOP” (4)
opposite side B of the pin (3): the difference between A and facing upwards. Direct the ring openings so they are
B must be no greater than 0.08 mm. staggered 120° apart.

Print 603.93.141 Base - January 2003

 66 ENGINE F2B STRALIS AT/AD

Fitting the connecting rod-piston assembly into

the piston liners Figure 104
Figure 102

47593
49030

Install half-bearings (1), selected as specified on page 66, on - all pistons belong to the same class, A or B;
both the connecting rod and the cap.
- ideogram stamped on the piston crown is placed toward
the engine flywheel, or the cavity, on the piston cover,
As spares, class A pistons are provided and can be corresponds to the position of the oil spray nozzles.
! fitted also to cylinder barrels belonging to class B.

Piston protrusion check

Fit the connecting rod-piston assemblies (1) into the piston Once assembly is complete, check piston protrusion from
liners (2) using band 99360605 (1, Figure 104). Check the cylinder barrels: it must be 0.32-0.69 mm.
following:
- the openings of the split rings are offset by 120°;

Figure 103

1 Connecting rod-piston assembly

2 Marking area on the piston crown of ideogram

specifying the assembly position and the
selection class

3 Connecting rod marking area (see fig. 96).

61831

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 67

540831 Checking assembly clearance of big Checking the planarity of the head on the
end pins cylinder block
To check the clearance proceed as follows: Figure 107 (Demonstration)
Connect the connecting rods to the relative main journals,
place a length of calibrated wire on the latter.

Figure 105

36159

The planarity (1) is checked using a ruler (2) and a thikness

gauge (3). If deformations exist, surface the head using
proper surface grinder; the maximum amount of material to
47594 be removed is 0.2 mm.
Install the connecting rod caps (1) with half-bearings; tighten
the connecting rod cap fixing screws (2) to 50 Nm (5 kgm)
torque. By tool 99395216 (3), tighten the screws further at
40° angle. After leveling, make sure that valve sinking and
Remove the caps and check the clearance by comparing the ! injector protrusion are as described in the relative
width of the calibrated wire with the scale calibration on the paragraph.
envelope containing the wire.

540610 CYLINDER HEAD

Before taking down the cylinder head, check the seal using
the appropriate tool; in case of leakage replace the cylinder
head.
540622 VALVE
Removing deposits and checking the valves
Valve removal

Figure 106 Figure 108

48625
47583
Remove carbon deposits using the metal brush supplied.
Install and fix tool 99360264 (2) with bracket (4); tighten by Check that the valves show no signs of seizure or cracking.
lever (1) until cotters are removed (3); remove the tool (2) Check the diameter of the valve stem using a micrometer
and the upper plate (5), the spring (6) and the lower plate (7). (see fig. 109) and replace if necessary.
Repeat the operation on all the valves. Turn the cylinder head
upside down and remove the valves (8).

Print 603.93.141 Base - January 2003

 68 ENGINE F2B STRALIS AT/AD

Figure 109 Check, by means of a micrometer, that valve stem diameters

are as specified; if necessary, grind the valves seat with a
grinder, removing the minimum quantity of material.

47584

MAIN DATA - VALVES AND VALVE GUIDES

* Values to be obtained after installing the valve guides

540667 VALVE GUIDES

Figure 110

47509
INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES
* Values to be obtained after installing the guide valves

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 69

540613 REPLACING INJECTOR HOLDER

CASES
Replacing of valve guides Removal
Remove valve guides by means of tool 99360288.
Install by means of tool 99360288 equipped with part Figure 112
99360294, which determines the exact installation position
of valve guides into the cylinder heads; if they are not
available, install the valve guides in the cylinder head so that
they project out by mm 16.3 to 16.7 (fig. 110).
After installing the valve guides, smooth their holes with
sleeker 99390310. A

Replacing - Reaming the valve seats 1

To replace the valve seats, remove them using the
appropriate tool.

Figure 111
2

45634

To replace the injector case (2), act as follows:

- thread the case (2) with tool 99390804 (1).
Carry out operations described in figs. 112-115-116-117
by fixing tools to the cylinder head by means of braket A.
41032

Ream the valve seats (2) on cylinder head using tool

99305019 (1).

Valve seats must be reamed whenever valves or

! valve guides are replaced or ground.

After reaming the valve seats, use tool 99370415, to make

sure that the valve position, with respect to the cylinder head
surface, is the following:
- -0.5 to -0.8 mm (recessing) of exhaust valves;
- -1.6 to 1.9 mm (recessing) of discharge valves.

Print 603.93.141 Base - January 2003

 70 ENGINE F2B STRALIS AT/AD

Figure 113 Figure 115

1

1
2

4
3

45635

- Lubricate sealing rings (3) and fit them to the case (4);
fix tool 99360554 (2) to the cylinder head by means of
bracket A, install the new case, tighten the screw (1),
45631
upsetting the case lower part.
- fasten extractor 99342149 (2) to case (3), by tightening
the nut (1), and pull out the case from cylinder head.
Figure 116

Figure 114

2
1

3
45633

- Remove any residue (1), with tool 99390772 (2), from

45632
the cylinder head groove.
- Adjust the casing hole (3) with borer 99394043 (1) and
guide bushing 99394014 (2).

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 71

Figure 117 Figure 119

3 44909

INSTALLATION DIAGRAM FOR

INJECTOR CASE
45636

- Through miller 99394041 (1) and bushing 99394014 (2),

ream the injector seat in the case (3), check the injector
protrusion from the cylinder head plane which must be
0.7 mm.

Checking protrusion of injectors

Figure 118

47585

Using dial gauge (1), check the protrusion of the injector (2)
which must be 0.7 mm.

Print 603.93.141 Base - January 2003

 72 ENGINE F2B STRALIS AT/AD

5412 TIMING GEAR

541211 Checking cam lift and pin alignment
Figure 120

47506

Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2); values are shown in table on page
20.

Figure 121

47507

When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not exceed
0.030 mm. If misalignment exceeds this value, replace the shaft.

Figure 122
1

47505

In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.
If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 73

541210 Camshaft
Figure 123

47504

MAIN DATA - CAMSHAFT AND TOLERANCES

The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring, replace the
shaft and the relative bushes.

TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL

ORIENTATION Perpendicularity ⊥
POSITION Concentricity or coaxial alignment
OSCILLATION Circular oscillation ↗
IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝
541213 Bushes
Figure 124

47508

MAIN DATA - CAMSHAFT BUSHES AND RELATIVE BLOCK SEATS

* Bush inner diameter after installation

The bush surfaces must not show any sign of seizing or Measure the bush inner diameters with a baremeter and replace
scoring; if they do replace them. them, if the value measured exceeds the tolerance value.
To take down and fit back the bushes, use the proper tool
99360487.

Print 603.93.141 Base - January 2003

 74 ENGINE F2B STRALIS AT/AD

541213 Replacing camshaft bushes using beater 99360487

Figure 125

A B C D E F D L G H D I 71721

A. Drift with seat for bushings to insert/extract. - B. Grub screw for positioning bushings. - C. Reference mark to insert
seventh bushing correctly. - D. Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (red marks). - E. Guide bushing. -
F. Guide line. - G. Guide bushing to secure to the seventh bushing mount. - H. Plate fixing yellow bushing to cylinder head.
- I. Grip. - L. Extension coupling.

Removal
Figure 126 1 Position the bushing to insert on the drift (A) making the
grub screw on it coincide with the seat (B) (Figure 125)
on the bushing.
2 Position the guide bushing (E) and secure the guide
bushing (G) (Figure 125) on the seat of the 7th bushing
with the plate (H).
3 While driving in the bushing, make the reference mark (F)
match the mark (M). In this way, when it is driven home,
the lubrication hole on the bushing will coincide with the
oil pipe in its seat.
The bushing is driven home when the 1st red reference
mark (D) is flush with the guide bushing (G).

Rear
71725
Figure 128
The sequence for removing the bushings is 7, 6, 5, 4, 3, 2, 1.
The bushings are extracted from the front of the single seats.
Removal does not require the drift extension for bushings 5,
6 and 7 and it is not necessary to use the guide bushing.
For bushings 1, 2, 3 and 4 it is necessary to use the extension
and the guide bushings.
Position the drift accurately during the phase of removal.

Assembly
Figure 127

Rear

71723

To insert the bushing (6), proceed as follows:

- Unscrew the grip (I) and the extension (N).
- Position the extension (N) and the guide bushing (E) as
shown in the figure.
- Repeat steps 1, 2, 3.
77795
Assemble the drift together with the extension.
To insert bushings 1, 2, 3, 4 and 5, proceed as follows:

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 75

Figure 129 Fitting the valves and oil seal ring

Figure 132

Rear 71724

To insert bushing (7), proceed as follows:

- Unscrew the grip (I) and the extension (N).
- Refit the guide (G) from the inside as shown in the figure.
- Position the bushing on the drift (A) and bring it close
up to the seat, making the bushing hole match the
lubrication hole in the head. Drive it home.
The 7th bushing is driven in when the reference mark (C)
is flush with the bushing seat.

540665 VALVE SPRINGS

Figure 130

49033

Lubricate the valve stem and place the valves in the relevant
valve guides; install the lower plates (3) using tool 99360292,
fit the oil seal ring (1) on valve guides (2), then install the
valves as shown:

70000

Before assembly, the flexibility of the valve springs has to be Figure 133
checked with the tool 99305047.
Compare the load and elastic deformation data with those
of the new springs given in the following figure.
Figure 131
Free spring height

Valve closed

Valve open
47583

- fit springs (6) and the upper plate (5);

49034
- apply tool 99360264 (2) and block it with bracket (4);
tighten the lever (1) until cotters are installed (3),
MAIN DATA TO CONTROL EXHAUST AND remove tool (2).
DISCHARGE VALVE SPRING

Print 603.93.141 Base - January 2003

 76 ENGINE F2B STRALIS AT/AD

5412 ROCKER SHAFT

Figure 134

44925
The camshaft cams directly control rockers: 6 for injectors and 12 for valves.
Rockers slide directly on the cam profiles via rollers.
The other end acts on a bar directly supported by the two valves stems.
A pad is placed between the rocker adjusting screw and the bar.
Two lubrication holes are obtained inside the rockers.
The rocker shaft practically covers the whole cylinder head; remove it to have access to all the underlying components.

Shaft
Figure 135

79171

MAIN DATA OF THE ROCKER ARM SHAFT

Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.

Rocker
Figure 136

SECTION A-A SECTION B-B

The bush surfaces must not show any trace of scoring of

excessive wear; otherwise, replace bushes or the whole
rocker.
44914

PUMP INJECTOR ROCKER

Figure 137 Figure 138

SECTION A-A SECTION B-B

SECTION A-A SECTION B-B

44912 44913

EXHAUST VALVES ROCKER DISCHARGE VALVE ROCKER

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 77

ASSEMBLING THE ENGINE ON THE BENCH

Fix the engine block to the stand 99322230 by means of Figure 141
brackets 99361035.
Install the cylinder liners as described in page 49.

Figure 139

49021

Place the half-bearings (1) on the main bearings in the

underblock (2).

Figure 142
47586

Fit the oil spray nozzles (2), so that the dowel coincides with
the block hole (3).
Place the half bearings (1) on the main bearings.

47595

By means of suitable equipment (1) apply silicone LOCTITE

5699 to the block, as shown in the figure.
Figure 140

Figure 143

47596

Sealant application diagram

47570
Fit the underblock within 10’ of the application of the
Lubricate the half bearings, then install the crankshaft (2) by sealant.
means of hoist and hook 99360500 (1). !

Print 603.93.141 Base - January 2003

 78 ENGINE F2B STRALIS AT/AD

Figure 144

49022

Fit the underblock by means of a suitable hoist and hooks (1).

Figure 145

47581

Fit the underblock and, using a dynamometric wrench (2),

close the splined outer (1) screws to 25 Nm torque,
according to the diagram shown on page 79.

Figure 146

47579

Close the inner screws (1) to 140 Nm torque by means of

a dynamometric wrench (3), then with two further angular
phases 60° + 60°, using tool 99395216 (4). Tighten again the
outer screws (1, Figure 145) with 90° angular closing, using
tool 99395215 (3, Figure 145).

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 79

DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER

Figure 147

First phase: outer

FRONT SIDE screws preliminary
tightening
(25 Nm)

44897

Second phase:
FRONT SIDE
inner screws
preliminary
tightening
(140 Nm)

44898

Third phase:
FRONT SIDE inner screws
angle closing
(60º)

44898

Fourth phase:
FRONT SIDE inner screws
angle closing
(60º)

44898

Fifth phase:
FRONT SIDE outer screws
angle closing
(90º)

44899

Print 603.93.141 Base - January 2003

 80 ENGINE F2B STRALIS AT/AD

Figure 148 Figure 150

49030

Rotate the cylinder assembly placing it vertically. 47593

Lubricate the half-bearings (1) and fit them in the connecting Fit the connecting rod-piston assemblies (2) into the piston
rod and the cap. liners, using the band 99360605 (1, Figure 150). Check the
following:
Not finding it necessary to replace the connecting
rod bearings, you need to fit them back in exactly the - the openings of the split rings are offset by 120º;
!
same sequence and position as in removal. - all pistons belong to the same class, A or B;
If the big end bearings need to be replaced, choose
them according to the description given from page - ideogram (2, Figure 149), stamped on the piston crown,
52 to page 58. is placed toward the engine flywheel, or the cavity, on the
piston skirt, corresponds to the position of the oil spray
nozzles

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.

Fitting the connecting rod-piston assembly

into the cylinder liners
Figure 149

1 Connecting rod-piston assembly

2 Marking area of ideogram on the piston

crown

3 Connecting rod marking area

61831

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 81

Figure 151 Figure 154

47594
45266
Connect the connecting rods to the relative journals, fit the
connection rod caps (1) with half bearings; tighten the fixing Make sure that pistons 1-6 are exactly at the TDC Place the
screws (2) of the connecting rod caps to 50 Nm torque (5 sealing gasket (2) on the block. Fit the cylinder head (1) and
kgm). Using tool 99395216 (3), further tighten screws with tighten screws as shown in figs. 155, 156 and 157.
40° angle.

Figure 152 Figure 155

44900

Diagram showing the cylinder head fixing screws tightening

45255 order
By means of centering ring 99396033 (2), check the exact
cover position (1), otherwise act as necessary and tighten the
screws.
Figure 156
Figure 153

45267
45256
- Preliminary tightening by means of a dynamometric
Fit the sealing gasket (1), install the fitting tool 99346245 (2) wrench (1):
and drive the sealing gasket (1) by screwing nut (3). 1st phase: 50 Nm (5 kgm:
2nd phase: 100 Nm (10 kgm)

Print 603.93.141 Base - January 2003

 82 ENGINE F2B STRALIS AT/AD

Figure 157 Tighten the screws shown in the figure by means of a

dynamometric wrench, in compliance with the following order
and tightening torque:
Figure 160

45268

- Angle closing by means of tool 99395216 (1):

3rd phase: 90° angle
4th phase: 75° angle
Figure 158

α
47598
Engines without power take-off
no. 13 screws M12 x 1.75 x 80 tightening torque 63 Nm
: no. 3 screws M10 x 1.5 x 35 tightening torque 42 Nm
no. 1 screw M10 x 1.5 x 100 tightening torque 42 Nm
no. 1 screw M10 x 1.5 x 180 tightening torque 42 Nm
no. 2 screws M18 x 1.25 x 125 tightening torque
24 Nm
47597 Figure 161
Fit the oil pump (4), intermediate gears (2) with rod (1) and
tighten screws (3) in two phases:
preliminary tightening 30 Nm
angle closing 90°
Figure 159

84390

Engines with power take-off

47592
no. 10 screws M12 x 1.75 x 80 tightening torque 63 Nm
Apply sealant LOCTITE 5699 to the gear box using the
proper equipment (1). ¬ no. 3 screws M10 x 1.5 x 35 tightening torque 42 Nm
no. 1 screw M10 x 1.5 x 170 tightening torque 42 Nm
The sealer string (1) diameter is to be 1,5 ± 0.5
0.2
no. 1 screw M10 x 1.5 x 180 tightening torque 42 Nm
no. 2 screws M12 x 1.75 x 125 tightening torque 63
Install the gear box within 10’ of the application of Nm
the sealant. d no. 8 screw M10 x 1,5 x 120
! ◊ no. 2 screw M10 x 1,5 x 120 (apply to the thread
LOCTITE 275)
Base - January 2003 Print 603.93.141
STRALIS AT/AD ENGINE F2B 83

Figure 162 Figure 164

49037

45258 Position the flywheel (1) on the crankshaft, lubricate the

Fit the sealing gasket (1), install the fitting tool 99346246 (2) thread of the screws (2) with engine oil and screw them
and drive the sealing gasket by screwing the nut (3). down. Lock rotation with tool 99360351 (3). Lock the
screws (2) in three phases.
First phase: pre-tightening with torque wrench (4) to a
torque of 100 Nm (10 kgm).
540850 ENGINE FLYWHEEL Figure 165

If the teeth of the ring gear mounted on the engine

flywheel, for starting the engine, are very damaged,
! replace the ring gear. It must be fitted after heating
the ring gear to a temperature of approx. 200°C.
α

Fitting engine flywheel

The crankshaft has a locating peg that has to couple

! with the relevant seat on the engine flywheel.
49036

Second phase: closing to angle of 60° with tool 99395216 (1).

Figure 163

VIEW OF HOLES: VIEW OF HOLES:

A-B-C D 60668

DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS

A. Hole on flywheel with one reference mark, corresponding to the TDC of pistons 3-4. - B. Hole on flywheel with one reference
mark, corresponding to the TDC of pistons 1-6. - C. Hole on flywheel with one reference mark, corresponding
to the TDC of pistons 2-5. - D. Hole on flywheel with two reference marks, position corresponding to 54°.

Print 603.93.141 Base - January 2003

 84 ENGINE F2B STRALIS AT/AD

Fitting camshaft
Figure 166 Figure 168

45376

- Apply gauge 99395215 (1), check and record the

72436 position of the rod (3) for the transmission gear, tighten
the screw (2) to the prescribed torque.
Position the crankshaft with the pistons 1 and 6 at the top
dead centre (T.D.C.).
This situation occurs when:
1. The hole with reference mark (5) of the engine flywheel
(4) can be seen through the inspection window.
2. The tool 99360612 (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the engine flywheel (4).
If this condition does not occur, turn the engine flywheel (4)
appropriately.
Remove the tool 99360612 (1).

Figure 169

Figure 167

45269

- Remove the transmission gear (1) and tighten screws (2)

73843 by means of proper splined wrench, to the prescribed
torque.
Fit the camshaft (4), positioning it observing the reference
marks (→) as shown in the figure.
Lubricate the seal (3) and fit it on the shoulder plate (2). Replace the idle gear bushing (1) when wear is
Mount the shoulder plate (2) with the sheet metal gasket (1) detected. After installing the bushing, adjust it to j
and tighten the screws (5) to the required torque.
! 58.010 ± 0.10 mm.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 85

Figure 170 Figure 172

71775

Mount:
45270 - The injectors (2) and, using a torque wrench, lock the
bracket fixing screws to a torque of 26 Nm.
Position the gear (2) on the camshaft so that the 4 slots are
- The exhaust brake cylinders (1) and (4) and, using a
centred with the holes for fixing the camshaft, without fully
torque wrench, fix them to a torque of 19 Nm.
locking the screws (5).
Using the dial gauge with a magnetic base (1), check that the - The crosspieces (3) on the valve stem, all with the largest
clearance between the gears (2 and 3) is 0.073 — 0.195 mm; hole on the same side.
if this is not so, adjust the clearance as follows:
- Loosen the screws (4) fixing the idle gear (3).
- Loosen the screw (2, Figure 168) fixing the link rod. Shift
the link rod (3, Figure 168) to obtain the required Fitting rocker-arm shaft assembly
clearance.
- Lock the screw (2, Figure 168) fixing the link rod and
screws (4, Figure 170) fixing the idle gear to the required Figure 173
torque.

Before refitting the rocker-arm shaft assembly, make

Fitting pump-injectors ! sure that all the adjustment screws have been fully
unscrewed.
Figure 171

73533

Using tool 99360144 (3), fasten the blocks (4) to the rocker
arms (2).
44908
Apply the tool 99360553 (1) to the rocker arm shaft (5) and
mount the shaft on the cylinder head.
Fit the seals (1) (2) (3) on the injectors.

Print 603.93.141 Base - January 2003

 86 ENGINE F2B STRALIS AT/AD

Camshaft timing
Figure 174 Figure 177

45261

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

- 1st phase: tightening to a torque of 40 Nm (10 kgm) with
the torque wrench (1).
- 2nd phase: closing with an angle of 60° using the tool
99395216 (3).

Figure 175

71776

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

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
60574 so as to take the piston of cylinder no.1 to
- Mount the engine brake lever retaining springs (3). approximately the T.D.C. in the phase of combustion.
- Connect the pipe (2) to the engine brake cylinders (4) and This condition occurs when the hole with one
to the cylinder with the engine brake solenoid valve (1). reference mark (4), after the hole with two
reference marks (5) on the engine flywheel (1), can
Figure 176 be seen through the inspection window (2).

71777

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.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 87

Figure 178 Figure 180

71774

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
77259
the hole (3) in the engine flywheel (4).
If this is not the case, turn and adjust the engine flywheel (4) The camshaft is in step if at the cam lift values of
appropriately. 4.90±0.05 mm there are the following conditions:
Remove the tool 99360612 (1). 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).
Figure 179

Figure 181

60573

Set the dial gauge with the magnetic base (1) with the rod
60575
on the roller (2) of the rocker arm that governs the injector
of cylinder no.1 and pre-load it by 6 mm.
If you do not obtain the conditions illustrated in Figure 180
With tool 99360321 (6, Figure 177), turn the crankshaft and described in points 1 and 2, proceed as follows:
clockwise until the pointer of the dial gauge reaches the
minimum value beyond which it can no longer fall. 1) Loosen the screws (2) securing the gear (1) to the
camshaft and utilize the slots (1, Figure 182) on the gear
Reset the dial gauge. (2, Figure 182).
Turn the engine flywheel anticlockwise until the dial gauge 2) Turn the engine flywheel appropriately so as to bring
gives a reading for the lift of the cam of the camshaft of 4.90 about the conditions described in points 1 and 2
± 0.05 mm. 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.

Print 603.93.141 Base - January 2003

 88 ENGINE F2B STRALIS AT/AD

Figure 182 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.

Phonic wheel timing

Figure 184
71778

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.

Figure 183

77260

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).
77259
Fit tool 99360613 (2), through the timing sensor seat, on the
Turn the flywheel (4) again to bring about the following tooth obtained on the phonic wheel.
conditions: Should tool (2) fitting be difficult, slacken screws (3) and
- Notch (5) visible through the lower inspection window; direct the phonic wheel (1) properly to position the tool (2)
on the tooth. Tighten the screws (3).
- The tool 99360612 (1) inserted in the hole (3) in the
engine flywheel (4) through the seat (2) of the engine
speed sensor.

Base - January 2003 Print 603.93.141

 STRALIS AT/AD ENGINE F2B 89

Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors.
Figure 185

44936A

ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS

Adjustment of clearances between rockers and valve studs - Using an appropriate wrench (4), loosen the
and preloading of pump injector rockers should be carried adjustment screw until the pumping element is at the
out with extreme care. end-of-stroke;
Take the cylinder where clearance must be adjusted to the - Tighten the adjustment screw, with a dynamometric
bursting phase; its valves are closed while balancing the wrench, to 5 Nm tightening torque (0.5 kgm);
symmetric cylinder valves.
Symmetric cylinders are 1-6, 2-5 and 3-4. - Untighten the adjustment screw by 1/2 to 3/4 rotation;
In order to properly operate, follow these instructions and - Tighten the locking nut.
data specified on the table.
FIRING ORDER 1-4-2-6-3-5
Adjustment of clearance between the rockers and rods
controlling intake and exhaust valves:
Clockwise Adjusting Adjusting Adjusting
- Using a polygonal wrench, loosen nut (1) locking the start-up and cylinder clearance of pre-loading of
adjustment screw; rotation valve no. cylinder valve cylinder
no. injector no.
- Insert the thickness gauge blade (3);
1 and 6 at 6 1 5
- Tighten or untighten the adjustment screw with the P.M.S.
appropriate wrench; 120º 3 4 1
- Make sure that the gauge blade (3) can slide with a slight 120º 5 2 4
friction; 120º 1 6 2
- Lock the nut (1), by blocking the adjustment screw. 120º 4 3 6
Pre-loading of rockers controlling pump injectors: 120º 2 5 3

- Using a polygonal wrench, loosen the nut locking the In order to properly carry out the above-mentioned
rocker adjustment screw (5) controlling the pump ! adjustments, follow the sequence specified in the
injector (6); table, checking the exact position in each rotation
phase by means of pin 99360612, to be inserted in
the 11th hole in each of the three sectors with 18
holes each.

Print 603.93.141 Base - January 2003

 90 ENGINE F2B STRALIS AT/AD

ENGINE COMPLETION
Figure 186 Complete the engine by installing or connecting the following
components:
- thermostatic unit;
- belt tensioner, water pump, alternator;
- control belt;
- belt tensioner, conditioner compressor;
- control belt.

Figure 188

84377
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).

The filter (5) operation is unidirectional, therefore it

! must be assembled with the two sight supports as
illustrated in the figure.

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

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.
44921

DIAGRAM FOR THE INSTALLATION OF FAN BELTS -

Figure 187 WATER PUMP - ALTERNATOR AND CONDITIONER
COMPRESSOR
1. Alternator - 2. Fan - 3. Water pump - 4. Crankshaft - 5.
Conditioner compressor

Figure 189

84392

Apply silicone LOCTITE 5699 on the blow-by case and form

a string (2) of ∅ 1.5 ±, 0.5
0.2 as shown in the figure.
47564

Fit the blow-by case (1) within 10’ from sealer To install belts (1-3), use the appropriate tools (2-4,) to work
! application. on the tensioners, as shown by arrows.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 91

Figure 190
Automatic tensioners do not require further
! adjustments after the installation.

- damping flywheel;
- fan;
- compressor;
- fuel pump;
- fuel filter and piping;
- pre-heating resistance;
- intake manifold;
- soundproof shields;
- heat exchanger;
- oil filter, lubricating the gasket;
- rockers caps;
- exhaust manifold;
- turbocharger and its oil and water piping;
- power take-off (P.T.O.) (if any) and related pipes;
- oil level stick and oil vapor vent;
- rotate the engine and install the oil rose pipe.
47573

- place the gasket (4) on the oil sump (1), position the
spacer (3) and fit the sump to the engine block by
tightening screws (2) to the prescribed torque;
- electric connections and sensors;
- remove the engine from the stand and fit the starter;
- fill the engine with the oil quantity required.

Print 603.93.141 Base - January 2003

 92 ENGINE F2B STRALIS AT/AD

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 93

5430 LUBRICATION
Engine lubrication is obtained with a gear pump driven by the
crankshaft via gears.
A heat exchanger governs the temperature of the lubricating
oil.
The oil filter, signalling sensors and safety valves are installed
in the intercooler.

Figure 191

Dropping oil
Pressure oil

Lubrication circuit

Dropping oil
Pressure oil

DETAIL A
44918

Print 603.93.141 Base - January 2003

 94 ENGINE F2B STRALIS AT/AD

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 95

543010 Oil pump

Figure 192 Overpressure valve
Figure 194

190 ± 6N
324 ± 9N

43,65
33,5

22,95
77820
60560

The oil pump (1) cannot be overhauled. On finding any MAIN DATA TO CHECK THE OVERPRESSURE
damage, replace the oil pump assembly. VALVE SPRING
See under the relevant heading for replacing the gear (2) of
the crankshaft.

Figure 193

77817

OIL PUMP CROSS-SECTION

1. Overpressure valve — Start of opening pressure 10.1 ± 0.7 bars

Print 603.93.141 Base - January 2003

 96 ENGINE F2B STRALIS AT/AD

Oil pressure control valve Figure 196

Figure 195
168 ± 9
308 ± 15

63
51

36,4
73542 88819

The oil pressure control valve is located on the left-hand side MAIN DATA TO CHECK THE OIL PRESSURE
of the crankcase. CONTROL VALVE SPRING
Start of opening pressure 5 bars.
543110 Heat exchanger
Figure 197

77818

HEAT EXCHANGER
The following elements are fitted on the intercooler: 1. Transmitter for low pressure warning lamp - 2. By-pass valve - 3. Oil
temperature sensor - 4. Oil pressure sensor for single gauge - 5. Heat valve. Number of intercooler elements: 7

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 97

By-pass valve This is a new generation of filters that permit much more
Figure 198 thorough filtration as they are able to holder back a greater
amount of particles of smaller dimensions than those held
back by conventional filters with a paper filtering element.
These high-filtration devices, to date used only in industrial
processes, make it possible to:
- reduce the wear of engine components over time;
- maintain the performance/specifications of the oil and
thereby lengthen the time intervals between changes.

External spiral winding

The filtering elements are closely wound by a spiral so that
each fold is firmly anchored to the spiral with respect to the
73545 others. This produces a uniform use of the element even in
the worst conditions such as cold starting with fluids with a
The valve quickly opens at a pressure of: 3 bars. high viscosity and peaks of flow. In addition, it ensures
Thermostatic valve uniform distribution of the flow over the entire length of the
Figure 199 filtering element, with consequent optimization of the loss of
load and of its working life.

Mount upstream
To optimize flow distribution and the rigidity of the filtering
element, this has an exclusive mount composed of a strong
mesh made of nylon and an extremely strong synthetic material.

Filtering element
73546 Composed of inert inorganic fibres bound with an exclusive
Start of opening: resin to a structure with graded holes, the element is
- travel 0.1 mm at a temperature of 82 ± 2°C. manufactured exclusively to precise procedures and strict
End of opening: quality control.
- travel 8 mm at a temperature of 97°C.
Engine oil filters Mount downstream
A mount for the filtering element and a strong nylon mesh
Figure 200
make it even stronger, which is especially helpful during cold
starts and long periods of use. The performance of the filter
remains constant and reliable throughout its working life and
from one element to another, irrespective of the changes in
working conditions.

Structural parts
The o-rings equipping the filtering element ensure a perfect
seal between it and the container, eliminating by-pass risks
and keeping filter performance constant. Strong
corrosion-proof bottoms and a sturdy internal metal core
complete the structure of the filtering element.
When mounting the filters, keep to the following rules:
- Oil and fit new seals.
- Screw down the filters to bring the seals into contact
with the supporting bases.
- Tighten the filter to a torque of 35÷40 Nm.

47447

Print 603.93.141 Base - January 2003

 98 ENGINE F2B STRALIS AT/AD

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 99

5432 COOLING
Figure 201
Description
The engine cooling system works with forced circulation
inside closed circuit and can be connected to an additional
heater (if any) and to the intarder intercooler.
It consists mainly of the following components:
- an expansion reservoir whose plug (1) incorporates two
valves — discharge and charge — controlling the system
pressure.
- a coolant level sensor placed at the bottom of the expan-
sion reservoir with two coupling points:
D coupling point for sensor S1 6 litres
D coupling point for sensor S2 3.7 litres
- an engine cooling unit to dissipate the heat taken by the
coolant from the engine through the intercooler.
- a heat exchanger to cool down lubrication oil;
- a water pump with centrifugal system incorporated in
the cylinder block;
- an electric fan consisting of a 2-speed electro-magnetic
joint equipped with a neutral wheel shaft hub fitted with
a metal plate moving along the axis and where the fan
is installed. It is controlled electronically by the vehicle
Multiplex system.
- a 3-way thermostat controlling the coolant circulation.
Operation
The water pump is actuated by the crankshaft through a
poli-V belt and sends coolant to the cylinder block, especially
to the cylinder head (bigger quantity). When the coolant
temperature reaches and overcomes the operating
temperature, the thermostat is opened and from here the
coolant flows into the radiator and is cooled down by the fan.
The pressure inside the system depending on the
temperature variation is controlled by the discharge and
charge valves incorporated in the expansion reservoir filling
plug (1).
The discharge valve has a double function:
- keep the system under light pressure in order to raise the
coolant boiling point;
- discharge the pressure surplus in the atmosphere as a re-
sult of the coolant high temperature. Water leaving the thermostat
The charge valve makes it possible to transfer the coolant
Water circulating in the engine
from the expansion reservoir to the radiator when a
depression is generated inside the system as a result of the Water entering the pump
coolant volume reduction depending on the fall in the
coolant temperature.
Discharge valve opening:
+ 0.2
D 1st breather 0.9 - 0.1 bar
+ 0.2
D 2nd breather 1.2 - 0.1 bar
+0
Charge valve opening -0.03 - 0.02 bar

79551

Print 603.93.141 Base - January 2003

 100 ENGINE F2B STRALIS AT/AD

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 101

543210 Water pump 543210 Electromagnetic coupling

Figure 202 Figure 205

44915

WATER PUMP SECTION

The water pump consists of: rotor, seal bearing and control
pulley.

Make sure that the pump casing has no cracking or

! water leakage; otherwise, replace the entire pump.

543250 Thermostat
THERMOSTAT OPERATION VIEW
Figure 203

TO THE HEATER

78842
ELECTROMAGNETIC COUPLING SECTION
The electro-magnetic joint action depends on:
- the coolant temperature;
- the climate control system fluid pressure (if any);
45357 - the slowing down action of the intarder on (if any).
TO BY-PASS FROM THE HEAD
Coolant temperature for:
Water circulating in the engine - engagement 93°C
- disengagement 88°C
Figure 204 With climate control system
Climate control system fluid pressure:
TO THE HEATER
- 2nd speed engagement 22 bar
With intarder
With braking power below 41% of maximum power.
TO RADIATOR Coolant temperature for:
- 2nd speed engagement 93°C
- disengagement 88°C
With braking power over 41% of maximum power:
TO EXPANSION TANK Coolant temperature for:
- 2nd speed engagement 85°C
FROM THE HEAD 45358 - disengagement 80°C
Water issuing from thermostat

Check the thermostat works properly; replace it if in doubt. Using a feeler gauge, check the gap between the anchor
assembly (2) and the pulley (1), it must be no greater than 2.5
Temperature of start of travel 84°C ±2°C. mm.
Minimum travel 15 mm at 94°C ±2°C. As to the description of the electro-magnetic joint operation
and servicing, see the “Manual for electric/electronic system
repairing” St. 603.93.191.

Print 603.93.141 Base - January 2003

 102 ENGINE F2B STRALIS AT/AD

5424 TURBOCHARGING
The turbocharging system consists of:
- air filter;
- variable geometry turbocharger;
- “intercooler” radiator.

Figure 206

Engine exhaust gas

Intake air
Compressed air (hot)
Compressed air (cooled)

44916

TURBOCHARGING DIAGRAM
TURBOCHARGER The movement of the device, choking the exhaust gas
Operating principle flowing section, is carried out by a mechanism, activated by
a pneumatic actuator.
The variable geometry turbocharger (VGT) consists of a
centrifugal compressor and a turbine, equipped with a This actuator is directly controlled by the electronic control
mobile device which adjusts the speed by changing the area unit by a proportional solenoid valve.
of the passing section of exhaust gases to the turbine. The device is in maximum closing condition at idle speed.
Thanks to this solution, gas velocity and turbine speed can At high engine operating speed, the electronic control
be high even when the engine is idling. system is activated and increases the passing section, in
If the gas is made to go through a narrow passage, in fact, order to allow the in-coming gases to flow without
it flows faster, so that the turbine rotates more quickly. increasing their speed.
A toroidal chamber is obtained during the casting process
in the central body for the passage of the coolant.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 103

Figure 207

3
1 2

5 4

CONTROL AIR SYSTEM DIAGRAM

1) Service tank 4) VGT control solenoid valve

2) Shut-off solenoid valve 5) Actuator pressure sensor
3) Air filter 6) Turbine actuator

Print 603.93.141 Base - January 2003

 104 ENGINE F2B STRALIS AT/AD

TURBO COMPRESSOR HOLSET HX 40V

Figure 208

71759

1. Air delivery to the intake manifold - 2. Compressor - 3. Air inlet - 4. Actuator -

5. Exhaust gas speed governor - 6. Exhaust gas inlet - 7. Exhaust gas outlet - 8. Turbine

CROSS-SECTION OF MINIMUM CROSS-SECTION OF MAXIMUM FLOW

FLOW
71733 71734

CROSS-SECTION OF TURBOCHARGER
1. Air delivery to the intake manifold - 2. Compressor - 3. Air inlet - 4. Actuator - 5. Exhaust gas flow-rate adjustment ring -
6. Exhaust gas inlet - 7. Exhaust gas outlet - 8. Turbine - 9. Exhaust gas flow-rate control fork

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 105

Figure 209

60753

Figure 210

60754

1. Slide guide - 2. Compressor - 3. Slide rods - 4. Compressor fan - 5. Lubrication bushings -

6. Exhaust gas flow-rate adjustment ring - 7. Exhaust gas fan - 8. Gas exhaust body -
9. Locking rings - 10. Oil delivery - 11. Oil outlet - 12. Actuator drive shaft

Print 603.93.141 Base - January 2003

 106 ENGINE F2B STRALIS AT/AD

Figure 211

71762

Figure 212

71763
1. Slide guide - 3. Slide rod - 11. Oil outlet - 12. Actuator drive shaft -
13. Actuator - 14. Exhaust gas flow-rate control fork

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 107

Actuator
Figure 213

[bar]

Stroke [mm]
72421

a Gradient characterized by the effect of the external

spring (4).
b Gradient characterized by the effect of the external
(4) and internal (6) springs.

71834

1. Air inlet - 2. Gasket - 3. Piston - 4. External spring - 5. Internal spring control disc - 6. Internal spring -
7. O-ring - 8. Spring holder - 9. Limit stop - 10. Dust seal - 11. Control rod

Working principle Solenoid valve for VGT control

The actuator piston, connected to the drive rod, is controlled This N.C. proportional solenoid valve is located on the
with the compressed air introduced through the air inlet (1) left-hand side of the crankcase under the turbine.
on the top of the actuator.
The electronic control unit, via a PWM signal, controls the
Modulating the air pressure varies the movement of the pis- solenoid valve, governing the supply pressure of the turbine
ton and turbine control rod. As the piston moves, it progress- actuator, which, on changing its position, modifies the
ively compresses the external spring (4) until the base of the cross-section of the flow of exhaust gases onto the blades of
piston reaches the disc (5) controlling the internal spring (6). the impeller and therefore its speed.
On further increasing the pressure, the piston, via the disc (5), The VGT solenoid valve is connected to the electronic
interferes with the bottom limit stop (10). control unit between pins A18/A31.
Using two springs makes it possible to vary the ratio between The resistance of the coil is approx. 20-30 Ohms.
the piston stroke and the pressure. Approximately 85% of the
stroke of the rod is opposed by the external spring and 15%
by the internal one.

Print 603.93.141 Base - January 2003

 108 ENGINE F2B STRALIS AT/AD

FUEL FEED
Fuel feed is obtained by means of a pump, fuel filter and
pre-filter, 6 pump-injectors controlled by the camshaft by
means of rockers and by the electronic control unit.

Figure 214

Return circuit
Delivery circuit

52877

1. Valve for return circuit, starts opening 0.2 bar - 2. Valve for return circuit, starts opening 3.5 bar

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 109

Fuel pump Pumping element

Figure 215 The pumping element is operated by a rocker arm governed
directly by the cam of the camshaft.
The pumping element is able to ensure a high delivery pres-
sure. The return stroke is made by means of a return spring.
Nozzle
Garages are authorized to perform fault diagnosis solely on
the entire injection system and may not work inside the injec-
tor-pump, which must only be replaced.
A specific fault-diagnosis program, included in the control
unit, is able to check the operation of each injector (it deacti-
vates one at a time and checks the delivery of the other five).
Fault diagnosis makes it possible to distinguish errors of an
electrical origin from ones of a mechanical/hydraulic origin.
It indicates broken pump-injectors.
73547 It is therefore necessary to interpret all the control unit error
messages correctly.
A. Fuel inlet — B. Fuel delivery — C. By-pass nut — Any defects in the injectors are to be resolved by replacing
D. Fuel return from the pump-injectors — them.
E. Pressure relief valve — Opening pressure: 5-8 bars
Solenoid valve
Figure 216 The solenoid, which is energized at each active phase of the
cycle, via a signal from the control unit, controls a slide valve
that shuts off the pumping element delivery pipe.
When the solenoid is not energized, the valve is open, the
fuel is pumped but it flows back into the return pipe with the
normal transfer pressure of approximately 5 bars.
When the solenoid is energized, the valve shuts and the fuel,
not being able to flow back into the return pipe, is pumped
into the nozzle at high pressure, causing the needle to lift.
The amount of fuel injected depends on the length of time
the slide valve is closed and therefore on the time for which
the solenoid is energized.
The solenoid valve is joined to the injector body and cannot
be removed.
On the top there are two screws securing the electrical wir-
ing from the control unit.
73548 To ensure signal transmission, tighten the screws with a torque
CROSS-SECTION OF THE FUEL PUMP wrench to a torque of 1.36 — 1.92 Nm (0.136 — 0.192 kgm).
1. Oil and fuel leakage indicator
Injector-pump 775010 Replacing injectors-pump
Injectors have to be replaced with great care (for their re-
Figure 217 moval see the description on pages 44 and 45, for fitting them
see the description on pages 85 and 86).

44908 If this job is done with the engine on the vehicle, be-
1. Fuel/oil seal — 2. Fuel/diesel seal — 3. Fuel/exhaust gas seal ! fore removing the injectors-pump drain off the fuel
contained in the pipes in the cylinder head by un-
The injector-pump is composed of: pumping element, nozzle, screwing the delivery and return fittings on the cylin-
solenoid valve. der head.

Print 603.93.141 Base - January 2003

 110 ENGINE F2B STRALIS AT/AD

Figure 218 Injector Phases

Figure 219

0 411 700 002

XXXXXX XXXX X
868 USA /

For each injector replaced, hook up to the MODUS station

and, when asked by the program, enter the code punched on
the injector (→) to reprogram the control unit.

When checking the clearance of the rocker arms, it

! is important to check the injector-pump pre-load.

60669

1. Fuel valve - 2. Pumping element - 3. Fuel outlet -

4. Filling and backflow passage

Filling phase
During the filling phase the pumping element (2) runs up to
the top position.
After passing the highest point of the cam, the rocker arm
roller comes near the base ring of the cam.
The fuel valve (1) is open and fuel can flow into the injector
via the bottom passage (4) of the cylinder head.
Filling continues until the pumping element reaches its top
limit.

Base - January 2003 Print 603.93.141

STRALIS AT/AD ENGINE F2B 111

Figure 220 Figure 221

60670 60671

1. Fuel valve - 2. Pumping element - 3. Fuel outlet - 1. Fuel valve - 2. Pumping element - 3. Fuel outlet -
4. Filling and backflow passage 4. Filling and backflow passage

Injection phase Pressure Reduction phase

The injection phase begins when, at a certain point in the Injection ceases when the fuel valve (1) opens, at a certain
down phase of the pumping element, the solenoid valve gets point in the down stroke of the pumping element, after the
energized and the fuel valve (1) shuts. solenoid valve gets de-energized.
The moment delivery begins, appropriately calculated by the The fuel flows back through the open valve (1), the injector
electronic control unit, depends on the working conditions holes and the passage (4) into the cylinder head.
of the engine.
The time for which the solenoid valve stays energized, ap-
The cam continues with the rocker arm to push the pumping propriately calculated by the electronic control unit, is the
element (2) and the injection phase continues as long as the duration of injection (delivery) and it depends on the working
fuel valve (1) stays shut. conditions of the engine.

Print 603.93.141 Base - January 2003

 112 ENGINE F2B STRALIS AT/AD

Base - January 2003 Print 603.93.141

STRALIS AT/AD F3A ENGINE 113

Print 603.43.671

F3A Engine

Page

VIEWS OF THE ENGINE . . . . . . . . . . . . . . . . . . 115

TECHNICAL DESIGNATION . . . . . . . . . . . . . . . 119

CHARACTERISTIC CURVES . . . . . . . . . . . . . . . 120

GENERAL CHARACTERISTICS . . . . . . . . . . . . . 122

ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . 125

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 131

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

DISMANTLING THE ENGINE ON THE BENCH 149

REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 156

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 156

- Checks and measurements . . . . . . . . . . . . . . . 156

CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . 157

- Replacing cylinder liners . . . . . . . . . . . . . . . . . . 158

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 159

- Measuring the main journals and crankpins . . . 160

- Preliminary measurement of main and big end

bearing shell selection data . . . . . . . . . . . . . . . 161

- Selecting the main and big end bearing shells . . 162

- Replacing the timing gear

and oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 168

- Checking main journal assembly clearance . . . . 168

- Checking crankshaft end float . . . . . . . . . . . . . 169

PISTON CONNECTING ROD ASSEMBLY . . . . 170

- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

CONNECTING RODS . . . . . . . . . . . . . . . . . . . . 173

- Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

- Checking connecting rods . . . . . . . . . . . . . . . . 174

- Mounting the connecting rod — piston assembly 175

Print 603.93.141 Base - January 2003

114 F3A ENGINE STRALIS AT/AD

Page Page
- Fitting engine flywheel . . . . . . . . . . . . . . . . . . . 194
- Mounting the piston rings . . . . . . . . . . . . . . . . . 175 - Fitting camshaft . . . . . . . . . . . . . . . . . . . . . . . . . 195
- Fitting the big end bearing shells . . . . . . . . . . . . 175 - Fitting pump-injectors . . . . . . . . . . . . . . . . . . . . 196

- Fitting connecting rod - piston assemblies - Fitting rocker-arm shaft assembly . . . . . . . . . . . 196
in the cylinder liners . . . . . . . . . . . . . . . . . . . . . 176
- Camshaft timing . . . . . . . . . . . . . . . . . . . . . . . . 197
- Checking piston protrusion . . . . . . . . . . . . . . . 176
- Phonic wheel timing . . . . . . . . . . . . . . . . . . . . . 199
- Checking crankpin assembly clearance . . . . . . . 177
- Intake and exhaust rocker play adjustment and
pre-loading of rockers controlling pump injectors 200
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 177
- Completing Engine Assembly . . . . . . . . . . . . . . 201
- Removing valves . . . . . . . . . . . . . . . . . . . . . . . . 177
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 203
- Checking the planarity of the head on the
cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . 177 - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

- Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 - Overpressure valve . . . . . . . . . . . . . . . . . . . . . 205

- Oil pressure control valve . . . . . . . . . . . . . . . . 206

- Removing deposits and checking the valves . . . 177
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 206
- Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
- By-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . . 207
- Checking clearance between valve-stem and
associated valve guide . . . . . . . . . . . . . . . . . . . . 179 - Thermostatic valve . . . . . . . . . . . . . . . . . . . . . . 207

- Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 - Engine oil filters . . . . . . . . . . . . . . . . . . . . . . . . 207

- Replacing injector cases . . . . . . . . . . . . . . . . . . 179 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
- Checking injector protrusion . . . . . . . . . . . . . . 181
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 182
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 211
- Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
- Electromagnetic coupling . . . . . . . . . . . . . . . . . 211
- Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . 212
- Fitting valves and oil seal . . . . . . . . . . . . . . . . . . 186 - Turbocharger HOLSET HY55V . . . . . . . . . . . . 212

ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 186 - Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

- Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 - Solenoid valve for VGT control . . . . . . . . . . . . 216

- Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

- Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

ENGINE ASSEMBLY ON BENCH . . . . . . . . . . . . 188
- Injector-pump . . . . . . . . . . . . . . . . . . . . . . . . . . 219
- Fitting connecting rod - piston assemblies
in cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . 191 - Replacing injectors-pump . . . . . . . . . . . . . . . . . 219

ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . 194 - Injector Phases . . . . . . . . . . . . . . . . . . . . . . . . . 220

Base - January 2003 Print 603.93.141

STRALIS AT/AD F3A ENGINE 115

VIEWS OF THE ENGINE

Figure 1

73835

F3A ENGINE

Print 603.93.141 Base - January 2003

 116 F3A ENGINE STRALIS AT/AD

Figure 2

73526

RIGHT-HAND SIDE VIEW OF THE ENGINE

Figure 3

73527

REAR VIEW OF THE ENGINE

Base - January 2003 Print 603.93.141

STRALIS AT/AD F3A ENGINE 117

Figure 4

73528

RIGHT-HAND SIDE VIEW OF THE ENGINE

Figure 5

73529

LEFT-HAND SIDE VIEW OF THE ENGINE

Print 603.93.141 Base - January 2003

 118 F3A ENGINE STRALIS AT/AD

Figure 6

73834

VIEW OF THE ENGINE FROM ABOVE

Base - January 2003 Print 603.93.141

STRALIS AT/AD F3A ENGINE 119

TECHNICAL DESIGNATION

ENGINE

TYPE PART NUM-

BER
F 3 A E 0 6 8 1 B * A 0 0 1 -

Progressive production number

Version number within the B.o.M.

Only for exhaust gas level with the same torque

and power curves
Engine power output or torque level

Use (eg I = truck)

Fuel feed + injection (TCA, direct injection diesel engine)

Number of cylinders

Number of strokes and cylinders’ position (eg 0 = 4 strokes, vertical) B 400 HP 1900 Nm
D 430 HP 1900 Nm
Engine (invariable)

Engine family evolution (also irrespective of the displacement)

Indicates the engine family

Print 603.93.141 Base - January 2003

 120 F3A ENGINE STRALIS AT/AD

CHARACTERISTIC CURVES
Figure 7

kgm

rpm

73531

CHARACTERISTIC CURVES OF ENGINE F3AE 0681B

Max OUTPUT 294 kW 400 HP at 2100 rpm

Max TORQUE 1900 Nm 194 kgm at 1050 ÷ 1480 rpm

Base - January 2003 Print 603.93.141

 STRALIS AT/AD F3A ENGINE 121

17
Print 603.43.671

Figure 8

kgm

rpm
73532

CHARACTERISTIC CURVES OF ENGINE F3A0681D

Max OUTPUT 316 kW 430 HP at 2100 rpm

Max TORQUE 1900 Nm 194 kgm at 1050 ÷ 1590 rpm

Print 603.93.141 Base - January 2003

 122 F3A ENGINE STRALIS AT/AD

GENERAL CHARACTERISTICS

Type F3AE0681B F3AE0681D

Cycle 4-stroke Diesel engine

Fuel feed Turbocharged with aftercooler

Injection Direct

No. of cylinders 6 in line

∅
Bore mm 125

Stroke mm 140

+ + +.. = Total displacement cm3 10300

ρ Compression ratio 17  0.8

Max output KW 294 316

(HP) (400) (430)

rpm 2100 2100

Max. torque Nm 1900 1900

(kgm) (194) (194)

rpm 1050 ÷ 1480 1050 ÷ 1590

Engine idling speed,

no load rpm 550 ±25
Maximum engine speed,
no load rpm 2550 ±20

Base - January 2003 Print 603.93.141

STRALIS AT/AD F3A ENGINE 123

Type F3A

A
VALVE TIMING

opens before T.D.C. A

16°
closes after B.D.C. B
B 32°
C

opens before B.D.C. D

50°
closes after T.D.C. C
9°
D

For timing check

mm
X -
X mm
-
Running

mm 0.35 to 0.45
X
mm 0.45 to 0.55

FEED Through fuel pump - filters

Injection With electronically regulated injectors PDE 31
type: Bosch pump injectors controlled by overhead camshaft

Nozzle type _

Injection order 1-4-2-6-3-5

bar Injection pressure bar 1500

Injector calibration bar 290

Print 603.93.141 Base - January 2003

 124 F3A ENGINE STRALIS AT/AD

Type F3A

SUPERCHARGING

Turbocharger type Variable geometry Holset HY 55 V

LUBRICATION Forced by gear pump, pressure control valve, oil filter
Oil pressure with hot engine
bar
(I00ºC ±5ºC):
at idling speed bar 1.5
at maximum rpm bar 5
By centrifugal pump, regulating thermostat, viscostatic fan,
COOLING
radiator and heat exchanger
Water pump control By belt
Thermostat N. 1
initial opening ~84ºC ±2ºC
maximum opening 94ºC ±2ºC
OIL FILLING
Total capacity
at 1st filling
litres 30
kg 29.8
Capacities
- engine sump min level
litres 17
Fiat Lubrificanti kg 15.3
Urania Turbo LD - engine sump max level
(according
( g to litres 25
E3 96 standard)
E3-96 d d) kg 22.5
Urania Turbo
(according to - quantity in circulation
that does not flow back
E2-96 standard)
to the engine sump
litres 7
kg 6.3
- quantity contained in
the cartridge filter (which
has to be added to the
cartridge filter refill)
litres 2.5
kg 2.3

Base - January 2003 Print 603.93.141

STRALIS AT/AD F3A ENGINE 125

ASSEMBLY CLEARANCE DATA

Type F3A

CYLINDER BLOCK AND

mm
CRANKMECHANISM COMPONENTS
∅1
Bores for cylinder liners:
upper 142.000 to 142.025
∅1
lower 140.000 to 140.025

Cylinder liners:
external diameter:
L upper 141.961 to 141.986
∅2
lower 139.890 to 139.915
∅2 length L -
Cylinder liners -
crankcase bores
upper 0.014 to 0.064
lower 0.085 to 0.135

External diameter ∅2 -

Cylinder sleeve
∅3
inside diameter ∅3A* 125.000 to 125.013
X
inside diameter ∅3B* 125.011 to 125.024

Protrusion X 0.045 to 0.075

* Selection class
Pistons: NUERAL MAHLE - MONDIAL
∅1 measuring dimension X 18 18
X external diameter ∅1A F 124.884 to 124.896 124.881 to 124.893
external diameter ∅1Bf 124.895 to 124.907 124.892 to 124.904
∅2 pin bore ∅2 50.010 to 50.018
Piston - cylinder sleeve
A* 0.104 to 0.129 0.107 to 0.132
B* 0.093 to 0.118 0.096 to 0.131
* Selection class

Piston diameter ∅1 -

X
Pistons protrusion X 0.23 to 0.53

∅3 Gudgeon pin ∅3 49.994 to 50.000

Gudgeon pin - pin housing 0.010 to 0.024

F Class A pistons supplied as spares.
f Class B pistons are fitted in production only and are not supplied as spares.

Print 603.93.141 Base - January 2003