DAILY EURO 4 REPAIR MANUAL MECHANICAL ELECTRIC/ELECTRONIC
This document provides data, data, characteristics, characteristics, instructions instructions and methodology methodology to perform perform repair interventions interventions on the vehicle and its components. components. Anyho Anyhow, w, this this docume document nt is addres addressed sed to qualif qualified ied and and special specialised ised personne personnel.l. Iveco Iveco commercia commerciall and assista assistance nce network personnel as well as all Iveco authorised points of assistance are specifically qualified and equipped to perform the repair interventions that are indicated in this document. Before performing any intervention, check to have available the document relating to the vehicle model on which the intervention is being performed and also make sure that all accident accident prevent prevention ion devices devices,, such as, as a rough rough guide, guide, goggles goggles,, helmet, helmet, gloves, gloves, shoes, shoes, as well as work tooling, tooling, lifting lifting and transport tooling, etc., are available and efficient, and further make make sure sure that that the the vehi vehicl cle e is put put such such a way way that hat an intervention can be made in safety conditions. Making interventions strictly observing the indications given here, here, as well as using using specific specific tooling indicate indicated, d, assures assures a correct repair intervention, execution timing observance and operators safety. Each repair intervention must be finalised to the recovery of functio functionali nality ty,, efficien efficiency cy and safety safety conditi conditions ons that that are provided provided by Iveco. Each Each interv interven entio tion, n, on the the vehicl vehicle, e, that that is final finalise ised d to a modification, alteration or else, which is not authorised by Iveco, involves the exclusion of any responsibility for Iveco, and, in particular particular,, where the vehicle is covered covered by a guarantee, guarantee, each such intervention involves an immediate lapse of the guarantee. Responsibility for Iveco in repair intervention execution is excluded. Iveco is available available to provide all clarifications clarifications necessary necessary to to make interventions, as well as to provide indications in cases and situations not included in this document. Data and information information contained contained in this this document could result not to be updated owing to modifications made by Iveco at any moment for technical or commercial reasons, or because of the need to adapt the vehicle to law requirements in different countries. In the case of a difference between what contained contained here and what what actually actually found found on the vehicle, vehicle, please please contact contact Iveco Iveco network before making any intervention. 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 requirements of local legislation. Copy, even partial, of text and drawings is forbidden.
Produced Produced by: Publication Publication Edited by: IVECO S.p.A. Customer Customer Service Lungo Stura Lazio, 15 10156 Torino (TO) - Italy Print 603.93.651 Print 603.93.651 - 1st Ed. 2006
B.U. TECHNICAL TECHNICAL PUBLISHING PUBLISHING Iveco Technical Publications Lungo Stura Lazio, 15 10156 Torino (TO) - Italy
PRELIMINARY REMARKS Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.). Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections disconnections disconnections of units to/from the vehicle, overhauls at the bench and relating troubleshooting. On the electric/electronic electric/electronic system section there are the descriptions descriptions of the electric network and vehicle electronic systems, electric schemes, components components electric characteristics, characteristics, components codes and troubleshooting troubleshooting relating relating to the central units specific of the electric system. The manual uses proper symbols in its descriptions; descriptions; the purpose of these symbols is to classify contained information. information. In particular, particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - WARNINGS Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons safety.
Danger of serious damage for the vehicle Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes guarantee lapse too.
!
General danger It includes the dangers of above described signals.
Environment protection It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
NOTE
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It indicates an additional explanation for a piece of information.
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SYMBOLS - ASSISTANCE OPERATIONS Removal Disconnection
Intake
Refitting Connection
Exhaust
Removal Disassembly
Operation
Fitting in place Assembly Tighten to torque
Compression ratio
Tolerance Weight difference
Tighten to torque + angle value
Rolling torque
Press or caulk
Rotation
Regulation Adjustment
Angle Angular value
Visual inspection inspection Fitting Fitting position check
Preload
Measurement Value to find Check
Number of revolutions revolutions
Equipment
Temperature
Surface for machining machining Machine finish
bar
Pressure
Interference Strained assembly
Oversized High Higher er than than . Maximum, peak
Thickness Clearance
Undersized Less Less than than . Minimum
Lubrication Damp Grease
Selection Classes Oversizing
Sealant Adhesive
Temperat Temperature ure < 0 C Cold Winter
Air bleeding bleeding
Temperat Temperature ure > 0 C Hot Summer
Replacement Original spare parts
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II
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PRODUCT CODE Each title or subtitle concerning operations being performed is preceded by a six-figure number named PRODUCT CODE. This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and TROUBLE CODE document. As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).
5
Product Code:
0
PRODUCT
7 UNI T
SUB-ASSEMBLY COMPONENT
6
PRODUCT
UNI T
SUB-ASSEMBLY COMPONENT
The first and second figures identify the PRODUCT within motor vehicle. Example : Produc t Product Product Product
50 52 53 76
= = = =
Ve Vehicle chassis ; Axles; Transmissi on on; El Elec tr tric ssy ssttem.
0 1
Unit Code: PRODUCT
UNI T
0 3 SUB-ASSEMBLY COMPONENT
PRODUCT
UNI T
SUB-ASSEMBLY COMPONENT
The third and fourth figures identify the UNIT within the PRODUCT. Example : Produc t Unit Unit Unit
50 01 02 03
= = = =
Ve Vehicle chassis ; Chassis; Bumpers; Alternator.
4
Sub-assembly Code: PRODUCT
UNI T
0
1
SUB-ASSEMBLY COMPONENT
PRODUCT
UNI T
3
SUB-ASSEMBLY COMPONENT
The fifth and sixth figures exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT. Example : Produc t Unit Sub-as Sub-assem sembly bly SubSub-as asse semb mbly ly
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50 01 40 13
= = = =
Ve Vehicle chassis ; Chassis; Chas Chassis sis cross cross memb members ers;; Roto Rotor. r.
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GENERAL WARNINGS
!
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both both specific specific and genera general-pu l-purpos rpose e tooling toolingss accordin accordingg to the prescrip prescriptio tions ns containe contained d in respect respective ive use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check. The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path. Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it. In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally accidentally striking workshop personnel. personnel. Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position. Keep personnel not authorised to operations clear of working area. Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair intervention intervention has been completed, completed, before starting up the vehicle, perform all checks indicated on paragraph Controls Controls care of user of Use and Maintenance handbook. In lack of visibility visibility in operating operating from the vehicle, vehicle, charge a person on the ground ground with assistance. assistance. Do not leave leave unmanned unmanned a vehicle in motion during repair interventions. Keep the vehicle stationary by proper chocks. In the the case of an interve interventio ntion n on a vehicle vehicle lifte lifted d from the the ground, ground, check check the vehicl vehicle e to be quite quite stead steadyy on special special support support stands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated. When it is necessary nec essary to perform an intervention on o n methane-fed vehicles, observe o bserve the indications contained c ontained inside the document, as well as all specific safety regulations provided. Only remove radiator radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out. Inflamm Inflammabl able e fuel fuel and all inflammab inflammable le fluids fluids and liquidsmust liquidsmust be handled handled withcare, accordin accordingg to what what containe contained d on harmful harmful materials materials 12 -point cards. Refuelling must be performed outdoors with the engine off, avoiding avoiding lit cigarettes, cigarettes, free flames or sparks sparks in order order to prevent prevent sudden sudden fires/bu fires/burst rsts. s. Adequat Adequately ely store store inflamma inflammable, ble, corrosiv corrosive e and polluti polluting ng fluids fluids and liquids liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids. Avoid to drill or bore pressurised pressurised containers, and throw cloths impregnated impregnated with inflammable substances substances into suitable containers. Worn out, damaged or consumable parts must be replaced by Iveco original spares. During During workshopactivi workshopactivity, ty, always always keepthe workplace clean; clean; timely timely clear clear or clean clean floors floors from from acciden accidental tal liquid liquid or oil spots. spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules. For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR - BAG systems, scrupulously observe indications indications specified in relating manual sections.
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GENERAL GENERAL WARNINGS Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, scarves, etc. Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside. Avoid to breathe fumes coming from heating heating or from paint welding because they they can cause damages to health; operate operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present. Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.
Clean Clean units units or assembl assemblies ies detache detached d from thevehicle and carefull carefullyy check check their their integr integrity ity before before overha overhaul. ul. Tidy up detached detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers. Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc. Self-locking nuts with an insert made of nylon must always be replaced. Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances. Before washing under pressure mechanical parts, protect electric connectors, and central units, if present. Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document. Before welding: Disconnect all electro electronic nic central central units, units, take take power power cable off off batter batteryy positiv positive e terminal terminal (connect (connect it to chassis chassis bonding) bonding) - Disconnect and detach connectors. connectors. solvents or paint removers removers and clean relevant surfices with soap and water. - Remove paint by using proper solvents about 15 minutes before welding. welding. - Await about
- Equip with suitable suitable fire resistant resistant protections protections to protect protect hoses or other components components where fluids or other materials materials flow which may catch fire easily on welding. Should the vehicle be subjected to temperatures exceeding 80 C (dryer ovens), disassemble drive electronic central units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
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GENERAL WARNINGS ON THE ELECTRIC SYSTEM
!
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated. Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery terminals. Do not cause sparks to be generated in checking if the circuit is energised. Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses. Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding braiding,, bonding, bonding, etc.) comply comply with IVECO system system and are careful carefully ly recover recovered ed after after repair repair or maintena maintenance nce interventions. Measurements Measurements in drive electronic central units, plugged connections connections and electric connections connections to components can only be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers, screwdrivers, clips clips and and the the like like in orderto orderto avoi avoid d the the dange dangerr of causi causinga nga shortcircu shortcircuit it,, as well well as of dama damagin gingg plug pluggedconne gedconnecti ction ons, s, which which would later cause contact problems.
To startup startup the the engin engine, e, do not not use use fast fast charg chargers ers.. Startup Startup must must only only be perfor performe med d with with eithersepa eitherseparat rate e batte batterie riess or spec special ial truck. A wrong polarisation of supply voltage voltage in drive electronic central central units (for instance, a wrong polarisation polarisation of batteries) batteries) can cause them to be destroyed. Disconnect the batteries from the system during their recharging with an external apparatus. On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque. Before disconnecting the junction connector from an electronic central unit, isolate the system. Do not directly supply electronic central units servo components at nominal vehicle voltage. Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure. Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according to original arrangement. Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key memorisation: 1 Pay attent attention ion that that jamming jamming sources sources are are not present present in the the cab or near the keys. keys. 2. Keys Keys not insered insered in the the panel panel must be at at least least 1 meter away. away.
NOTE
Connect Connectors ors present present mustbe seen fromcable side. side. Connect Connectors ors views views contai contained ned in the manual manual are represe representat ntative ive of cable cable side.
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Bonding and screening Negative Negative leads connected connected to a system bonded bonded point must be both both as short and possible possible and star-connected star-connected to to each other, trying trying then to have their centering tidily and properly made (Figure 1, re. M). Further, following warnings are to be compulsorily observed for electronic components: -
Electronic central central units units must be connected connected to system system bonding when when they are provided provided with with a metallic metallic shell.
-
Electronic Electronic central units negative negative cables cables must be connected connected both to a system system bonding point such as the dashboard dashboard opening bonding bonding (avoiding (avoiding serial or chain connections), connections), and to battery battery negative terminal. terminal.
-
Analog bonding bonding (sensors), (sensors), although although not connected connected to battery battery negative negative system/terminal system/terminal bonding, bonding, must have optimal optimal isolation. isolation. Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
-
Screened circuits circuits braiding braiding must only electrically electrically contact contact the end end towards the the central unit entered by the signal (Figure (Figure 2).
-
If junction connectors connectors are present, unscreened unscreened section section d , near them, must be as short as possible (Figure 2).
-
Cables must be arranged arranged such as to result to to be parallel to reference reference plane, plane, i.e. as close as possible possible to chassis/body chassis/body structure. structure.
Figure 1
1.
NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2.
SCREENING THROUGH METALLIC BRAIDING OF A CABLE CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR d. DISTANCE ! 0
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VII
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OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Accessor Accessories ies mounting mounting,, additio additions ns and modifica modificatio tions ns on the vehicl vehicle e are to be performe performed d complyin complyingg with IVECO mountin mountingg instructions (specific document Instructions for transformation and preparation is available at Assistance Network workshops). It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel. For any exception exception to mounting instructions, instructions, IVECOs authorisation is necessary. necessary. Lack of observance of above described prescriptions involves guarantee lapse.
It is absolutely absolutely forbidden to make modifications or connections to electric c entral units wiring harnesses; in particular, particular, the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power 1 kW = 1 kW = 1 met metric ric HP = 1 met metric ric HP = 1 HP = 1 HP =
1.36 metric HP 1.34 HP 0.73 0.736 6 kW 0.98 0.986 6 HP 0.746 kW 1.014 metric HP
Torque 1 Nm 1 kgm
0.1019 kgm 9.81 Nm
= =
OF
THE
Revolutions per time unit 1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602 Pressure 1 bar 1 kg/cm2 1 bar
= = =
1.02 kg/cm2 0.98 0.981 1 bar bar 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted converted into kgm according to ratio 10:1 1 kgm
=
10 Nm;
converted into kg/cm 2 according to ratio 1:1 - bar unit is for the sake of simplicity converted 1 kg/cm2
=
1 bar.
Temperature 0 C = 32 F 1 C = (1 x 1. 8 + 32) F
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INDEX OF SECTIONS
Section
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General information
1
Engine
2
Clutch
3
Gearbox
4
Propeller shafts
5
Rear axles
6
Front axle
7
Front and rear suspensions
8
Wheels and tyres
9
Steering system
10
Pneumatic system - Brakes
11
Bodywork and chassis frame
12
Maintenance
13
Electric/Electronic System
14
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DAILY E URO 4
GENERAL
1
Print 603.43.671
SECTION 1 General Page
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IDENTIFICATION DATA . . . . . . . . . . . . . . . . . .
3
- Vehicle Identification Plate . . . . . . . . . . . . . . . .
3
COMPOSITION OF MODELS . . . . . . . . . . . . . .
4
ALPHANUMERICAL CODING FOR BUS IDENTIFICATION . . . . . . . . . . . . . . . . .
6
REPLENISHING FLUIDS . . . . . . . . . . . . . . . . . . .
13
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DAILY E URO 4
3
GENERAL
IDENTIFICATION DATA Figure 1
Vehicle identification plate Plate legend 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13)
Approval Approval number Chassis Chassis numbe number r PTT - Total weight weight on groun ground d MTC - Total combin combined ed weight weight Max. weight permitted permitted on the the front axle axle Max. weight permitted permitted on the the rear axle Specific indication indication of type type Wheelbas Wheelbase e (mm) (mm) Type of engin engine e Engine Engine rating rating Permitted Permitted smoke smoke level Place of manufact manufacture ure Number Number of vehicle vehicle axles axles 108534
Figure 2
Manufacturer Manufacturer tag For vehicle identification identification according to the EC directive (on the front crosspiece)
Chassis Stamping (at the front on the chassis right-hand side-member)
Engine Stamping (on the right side on the engine base)
108533
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4
GENERAL
DAILY E URO 4
COMPOSITION OF MODELS MODELS ASSEMBLIES F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV
o
F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV
o o
o o
F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV
o
o
o
o o
o o
F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV
o
F1CE0481F*C F1CE0481F*C (DPF series) series) 146 CV o
F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV
o
F1CE0481H*C F1CE0481H*C (DPF series) series) 176 CV
Single disk
9 1/4
Single disk
10 1/2
Single disk
11
o o
o
o o
o
o
o
o
o
V V V V V V
ZF 5 S300
o
o o
o
o
V V V V
o
o
o
V V
ZF 6 S400A O.D.
V V V V V V V V V V V V V V V V V V
58 1 7
o
ZF 6 S400 O.D.
o
o
o
o
o
V V
o
5818 58 1 9
o
o
o
o
o
o
o
o
o
o
o
o
5823 NDA R.S.
o
o
o
o
o
o
o
NDA R.G.
o
o
o
o
o
45 0 51 1 450517/2 Rack-and-pinion Powered steering
FRONT MECHANICAL SUSPENSIONS: independent with transverse leaf spring (MK3) independent with torsion bars REAR Parabolic MECHANICAL - single leaf SUSPENSIONS:: - reinforced Semi-elliptical Semi-elliptic with leaf spring REAR AIR SUSPENSIONS
O.D. = Over Drive ( ) Optional Optional extra extra (with max load load of 1900 kg) o Standard with with ZF 6 S 400 A O.D. gearbox gearbox V Alternative Vehicles with front suspension with transverse leaf spring Vehicles with front suspension with torsion bars cabs only, as an alternative z Chassis cabs
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o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
( ) ( ) ( ) ( ) ( ) o
o
o
o
o
o
o
o o o o Z Z Z Z Z Z Z Z Z
o
o
o
o
o
o
o
o o
o
o
o
o
o s s s
s s s s s s
z z z z z z z z z V V V V V V V V V V V V V V V V
Standard on chassis chassis cabs, cabs, Alternati Alternatively vely on Vans Chassi Chassiss Cowls s Standard and Cut Aways Standard on Vans, Vans, Chassis Chassis Cowls Cowls and Cut Aways Aways Alterna Alternativel tively y Z Standard on Chassis Cabs S Singl Single e rear rear wheel wheelss L Light Light with with single single rear rear wheels wheels C Twin Twin rear rear wheel wheelss
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DAILY E URO 4
GENERAL
5
COMPOSITION OF MODELS MODELS ASSEMBLIES F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV F1CE0481F*C (DPF series) 146 CV
o
o
o
o
F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV F1CE0481H*C (DPF series) 176 CV
Single disk
9 1/4
Single disk
10 1/2
Single disk
11
o
o
o
o
o
o
o
o
o
o
o
o
ZF 5 S300 ZF 6 S400 O.D.
V V V V V V V V
ZF 6 S400A O.D.
V V V V V V V V
5817 5818 o
5819
o
o
o
5 8 23
o
o
o
o
o
o
o
o
NDA R.S. NDA R.G. o
450511
o
o
o
450517/2 Rack-and-pinion
Power steering
o
o
o
o
o
o
o
o
FRONT MECHANICAL MECHANICAL SUSPENSIONS: SUSPENSIONS: independent with transverse leaf spring (MK3) independent with torsion bars
o
o
o
o
o
o
o
o
Parabolic - single leaf - reinforced
Z Z Z Z Z Z Z Z
Semi-elliptical Semi-elliptic with leaf spring
s s
REAR AIR SUSPENSIONS SUSPENSIONS
O.D. = Over Drive ( ) Optional Optional extra extra (with max load load of 1900 kg) o Standard V Alternative Vehicles with front suspension with transverse leaf spring Vehicles with front suspension with torsion bars cabs only, as an alternative z Chassis cabs
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s
s s
s
s s
z z z z z z z z V V V V V V V V
Standard on chassis chassis cabs, cabs, Alternat Alternativel ivelyy on Vans Chassi Chassiss Cowls s Standard and Cut Aways Standard on Vans, Vans, Chassis Chassis Cowls Cowls and Cut Aways Aways Alterna Alternativel tively y Z Standard on Chassis Cabs S Singl Single e rear rear wheel wheelss L Light Light with with single single rear wheels wheels C Twin Twin rear rear wheel wheelss
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6
GENERAL
DAILY E URO 4
ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION CUSTOMIZED VEHICLE (V.P.) MARKET VEHICLE (V.M.)
STANDARD VEHICLE (V.C.B.)
1
2
3
4
5
6
7
8
9
12 13 14 10 11 12
3
4
5
6
7
8
9
12 13 14 10 11 12
8
9
12 13 14 10 11 12
RANGE
1
2
A
LIGHT ROAD VEHICLES
PROGRAMMING PROGRAMMING FAMILY
1
2
3
4
5
6
A
T 25C
29 L
B
T 30C
35 S
C
T 35C
35 C
7
CHASSIS CABS AND DERIVATIVES
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D
T 40C
40 C
E
T 50C
50 C 45 C
F
T 65C
60 C 65 C
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DAILY E URO 4
GENERAL
7
PROGRAMMING PROGRAMMING FAMILY
1
2
3
4
5
6
H
T 25V
29 L
K
T 30V
35 C
J
T 35V
35 C
L
T 40V
40 C
M
T 50V
50 C 45 C
N
T 65V
60 C 65 C
7
8
9
12 13 14 10 11 12
VANS AND DERIVATIVES
ENGINE
1
2
3
4
5
6
7
8
9
A
F1A E4 LD - 96 CV
B
F1A E4 LD - 116 CV
C
F1A E4 LD - 136 CV
D
F1C E4 HD - 146 CV
E
F1C E4 HD - 176 CV
12 13 14 10 11 12
E4 = Euro 4 LD = Light Light Duty Duty HD = Heav Heavy y Duty Duty
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8
GENERAL
DAILY E URO 4
SUSPENSION
1
2
3
4
5
6
7
8
9
12 13 14 10 11 12
A
Mechanical suspension: suspension: front front with transverse transverse leaf spring.
B
Mechanical suspension suspension:: front with torsion torsion bars. bars.
C
Mechanical Mechanical front suspension with transverse transverse leaf spring spring rear air suspension. suspension.
D
Mechanical Mechanical front suspension suspension with torsion torsion bars rear air suspension. suspension.
VERSION
1
2
3
4
5
6
7
8
CHASSIS CAB
CHASSIS 6+1
CHASSIS COWL
CHASSIS R SHORT
9
12 13 14 10 11 12
29 L10 ( L10 ( ) - 29 L12 ( L12 ( ) - 29 L14 ( ) 35 C10 ( C10 ( ) - 35 C12 ( C12 ( ) - 35 C15 ( C15 ( ) - 35 C18 ( C18 ( ) 45 C15 ( C15 ( ) - 50 C15 ( C15 ( ) - 50 C18 ( C18 ( ) 60 C15 ( C15 ( ) - 60 C18 ( C18 ( ) 65 C15 ( C15 ( ) - 65 C18 ( C18 ( )
29 L10 D ( D ( ) - 29 L12 D ( D ( ) - 29 L14 D ( D ( ) 35 S18 D ( D ( ) - 35 C10 D ( D ( ) - 35 C12 D ( D ( ) 40 C12 D ( D ( ) - 45 C15 D ( D ( ) - 45 C18 D ( D ( ) 50 C18 D ( D ( ) - 60 C15 D ( D ( ) - 60 C18 D ( D ( ) 65 C15 D ( D ( ) - 65 C18 D ( D ( )
35 S12 CC ( CC ( ) - 35 S 14 CC ( CC ( ) - 35 S18 CC ( CC ( ) 35 C12 CC ( CC ( ) - 35 C15 CC ( ) - 35 C18 CC ( CC ( ) 40 C12 CC - 40 C15 CC ( ) - 40 C18 CC ( CC ( ) 45 C15 CC - 45 C18 CC ( CC ( ) 50 C15 C15 CC - 50 C18 CC 60 C18 CC ( CC ( ) - 65 C18 CC ( )
35 S12 CCR ( CCR ( 35 C12 CCR ( CCR ( 40 C12 CCR ( CCR ( 45 C15 CCR ( CCR (
) - 35 S14 CCR ( CCR ( ) - 35 S18 CCR( CCR( ) ) - 35 C15 CCR ( ) - 35C18CCR( 35C18CCR( ) ) - 40 C15 CCR ( ) - 40C18CCR( 40C18CCR( ) ) - 45 C18 CCR ( ) 60 C18 CCR ( CCR ( ) - 65 C18 CCR ( )
( ) Also available in the A (automatic (automatic transmission) transmission) and /P (pneumatic (pneumatic rear suspensions) versions. versions.
Base - March 2006
Print 603. 93.651
DAILY E URO 4
GENERAL
9
VERSION
1
2
3
4
5
6
A
7
8
CUT-AWAY -
9
12 13 14 10 11 12
35 C10 CA ( ) - 35 C12 CA ( ) 40 C10 CA ( CA ( ) - 40 C12 CA ( ) 45 C18 CA ( CA ( ) - 50 C18 CA ( ) 60 C18 CA ( CA ( ) - 65 C18 CA ( CA ( )
29 L10 V ( V ( 35 S10 V ( V ( 35 S18 V ( V ( 35 C10 V ( V ( 35 C18 V ( V ( 40 C12 V ( V ( 45 C15 V ( V ( 5 0 C1 5 V 60 C15 V ( V ( 65 C15 V ( V (
SEMI-GLAZE D VA N
V
5
8
) - 29 L12 V ( V ( ) - 29 L14 V ( V ( ) ) - 35 S12 V ( V ( ) - 35 S14 V ( V ( ) ) ) - 35 C12 V ( V ( ) - 35 C15 V ( V ( ) ) ) - 40 C15 V ( ) - 40 C18 V ( ) ) - 45 C18 V ( V ( ) - 5 0 C1 8 V ) - 60 C18 V ( ) ) - 65 C18 V ( )
29 L10 SV ( SV ( ) - 29 L12 SV ( SV ( ) - 29 L14 SV ( ) 35 S10 SV ( SV ( ) - 35 S12 SV ( SV ( ) - 35 S14 SV ( ) 35 S18 SV ( SV ( ) 35 C10 SV ( SV ( ) - 35 C12 SV ( ) - 35 C15 SV ( SV ( ) 35 C18 SV ( SV ( ) 40 C10 SV ( ) - 40 C12 SV ( ) - 40 C15 SV ( SV ( ) 40 C18 SV ( SV ( ) 45 C15 C15 SV SV - 45 C18 SV 50 C15 SV ( SV ( ) - 50 C18 SV ( )
VEN DOR VERSION CITY VAN
35 S12 CV ( 35 C12 CV ( CV ( 45 C15 CV ( CV ( 50 C15 CV ( CV (
) - 35 S14 CV ( CV ( ) ) - 40 C12 CV ) - 45 C18 CV ( CV ( ) ) - 50 C18 CV ( )
CO MBI
29 L14 C ( ) -- 35 S14 C ( C ( )
CAMPER
35 S14 ( S14 ( ) - 35 S18 ( S18 ( ) 35 C14 ( C14 ( ) - 35 C18 ( C18 ( )
CHASSIS9
35 S14 CCRC ( CCRC ( ) - 35 S18 CCRC SHORT 35 C14 CCRC ( CCRC ( ) - 35 C18 CCRC VERSION FOR CAMPER VAN
( ) Also available in the A (automatic (automatic transmission) transmission) and /P (pneumatic (pneumatic rear suspensions) versions. versions. Print 603. 93.651
Base - March 2006
10
GENERAL
DAILY E URO 4
WHEELBASE WHEELBASE
1
Base - March 2006
2
3
4
5
6
7
8
9
12 13 14 10 11 12
1
3000 mm (T25C - T30C - T35C - T40C - T25V - T30V T35V - T40V - T50V)
2
3000 L mm (T25V (T25V - T30V - T35V - T40V - T50V)
3
3300 mm (T25V (T25V - T30V - T35V - T40V - T50V)
4
3450 mm (T25C (T25C - T30C - T35C - T40C - T50C - T65C)
5
3750 mm (T30C (T30C - T35C - T40C - T50C - T65C) T65C)
6
3950 L mm (T30V - T35V - T40V - T50V - T65V)
7
4100 mm (T35C - T40C)
8
4350 mm (T50C - T65C)
9
4750 mm (T50C - T65C)
Print 603. 93.651
DAILY E URO 4
GENERAL
11
GEARBOX
1
2
3
4
5
6
7
8
9
12 13 14 10 11 12
A
5 SPEED
(5 S 300)
B
6 SPEED EED
(6 S 400 400 O.D.) D.)
C
6 SPEED EED
(6 S 400 400 A O.D.) D.)
A Automated O.D. O.D. Over Over Drive Drive
Print 603. 93.651
Base - March 2006
12
GENERAL
DAILY E URO 4
DRIVE INTERNAL HEIGHT OF LOADING BAY
1
2
3
4
5
6
7
8
9
12 13 14 10 11 12
LEFT-HAND DRIVE (T25C - T30C - T35C - T40C - T50C)
1
LEFT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H1 = 1545 mm (T25V - T30V - T35V - T40V - T50V)
1
LEFT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H2 = 1900 mm (T25V - T30V - T35V - T40V - T50V)
2
LEFT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H3 = 2100 mm (T30V - T35V - T40V - T50V)
3
RIGHT-HAND DRIVE (T25C - T30C - T35C - T40C - T50C)
A
RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H1 = 1545 mm (T25V - T30V - T35V - T40V - T50V)
A
RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H2 = 1900 mm (T25V - T30V - T35V - T40V - T50V)
B
RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H3 = 2100 mm (T30V - T35V - T40V - T50V - T65V)
C
MANDATORY MARKET OPTIONAL EXTRAS
1
2
3
4
5
6
7
8
9
12 13 14 10 11 12
OPTIONAL EXTRAS REQUIRED BY THE CUSTOMER
1 Base - March 2006
2
3
4
5
6
7
8
9
12 13 14 10 11 12 Print 603. 93.651
DAILY E URO 4
GENERAL
13
REPLENISHING REPLENISHING FLUIDS
IVECO RECOMMENDED LUBRICANTS
PARTS TO BE REPLENISHED
Quantity kg
Litres
Urania Daily Urania LD 5
Quantity of oil in circulation in the car tridge filter and heat exchanger
1.4
Total dry engine capacity
5.7
5 . 02
Sump capacity: capacity: - max level - min level
4.3 3
3.78 2.65
Quantity of oil in circulation in the car tridge filter and heat exchanger Total dry engine capacity Sump capacity: capacity: - max level - min level
!
1 7.6
1.23
0.88
6.79
6.6 4.29
5.81 3.78
2
1.8
ZF 6S 400 O.D.
2.2
1.98
ZF 6S 400 A O.D.
2.7
2.43
-
-
Max. gradient negotiable by vehicle uphill/downhill with oil at minimum level 30% Gearbox ZF 5S 300 Tutela TRUCK GEARLITE
Front axle: 5817 5818 5819 5823
Rear axles: Tutela W140/M-DA (SAE 80W90)
NDA R.S.
1 .35
1. 21
Tutela W90/M-DA (SAE 80W90)
NDA R.G.
1 .35
1. 21
Tutela W 14 140/M-DA (SAE 85W140)
450511
1.9
1.65
Tutela W140/M-DA (SAE 85W140)
450517/2
3
2. 7
Tutela GI/A
Power steering
1.4
1.3
Tutela TRUCK DOT SPECIAL
Brake circuit
1 .11
1
Arexons DP1
Windscreen washer
5
4.5
Paraflu 11 *
Cooling system
9
-
* = Protective anti-freeze (concentration 50%, freezing point 35 C)
Print 603. 93.651
Base - March 2006
14
GENERAL
DAILY E URO 4
International lubricant description
FL Group products
Engine oil meets specifications: specifications: ACEA B5 with synthetic base SAE 5W30 ACEA E3/E5 with mineral base SAE 15W40
Urania Daily Urania LD5
Differential and wheel hub oil meets specifications: API GL-5 with mineral base SAE 85W140 API GL-5 with mineral base SAE 80W90
Tutela W 140/M - DA (1) Tutel Tutelaa W 90/M 90/M - DA DA (2)
Mechanical gearbox oil containing non-EP anti-wear additives Meets specification API GL 4 SAE 75W80
Tutela Truck Gearlite
Hydrostatic Hydrostatic transmission transmission and power steering steering oil Meets specifications: ATF-DEXRON II D
Tutela GI/A
General-purpose grease lithium soap based grease N.L.G.I. fluidity no. 2
Tutela MR 2
Specific grease for wheel hubs and bearings lithium soap based grease N.L.G.I. fluidity no. 3
Tutela MR 3
Hydraulic Hydraulic brake and clutch control control fluid In conformity with N.H.T.S.A. standards No. 116, ISO 4925 Standard SAE J 1703, IVECO STANDARD 18-1820
Tutela TRUCK DOT SPECIAL SPECIAL
Windscreen washer liquid Mixture of spirits, water and surfactants CUNA NC 956-11
Tutela Professional SC 35
Concentrated protective radiator fluid ethylene glycol based containing corrosion inhibitors, in conformity with Iveco Standard 18-1830 (1) Hot or temperate temperate climate (2) Specific for for cold climes. (3) 100% Paraflu to be be diluted with with water to 50%
Paraflu11(3)
Figure
Base - March 2006
95
35
50
10 SAE 40
32
0
14
-1 0
5
-15
-13 oF
-25 oC
SAE 30 SAE 20W
SAE 15W/40 SAE 10W
SAE 5W 30 108535
Print 603. 93.651
F1A ENGINE
DAILY E URO 4
1
SECTION 2 5401
Engine Page
Print 603.93.651
F1A ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
F1C ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
157
Base - March 2006
F1A ENGINE
DAILY E URO 4
3
F1A Engine Engine Page MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . -
7
Service procedures procedures to be performed performed after replacing replacing high-pressure feeding system and/or exhaust gas post treatment system components . . . . . . . . . . . . 8
POWER UNIT REMOVAL/REFITTING . . . . . . . .
9
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
-
Checks and tests . . . . . . . . . . . . . . . . . . . . . . .
13
-
Power steering system air bleed . . . . . . . . . . .
13
REPLACING BELTS . . . . . . . . . . . . . . . . . . . . . . .
14
-
Power Power steerin steeringg pump-al pump-alter ternat nator or belt replacem replacement ent
14
-
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
-
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
-
Replacin Replacingg air-cond air-conditio itioning ning compress compressor or drive drive belt
14
-
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
-
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
-
Replacing timing drive belt . . . . . . . . . . . . . . . .
15
-
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
-
Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
REPLACING THE ELECTRIC INJECTORS . . . . .
17
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
CYLI CYLIND NDER ER HEAD HEAD REMO REMOVA VAL L AND REF REFITTI TTING
19
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
REP LA LACING HIGH -P -PRE SS SSURE PUM P CPH1 . . .
22
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
REPLACING WATER PUMP . . . . . . . . . . . . . . .
22
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
PREHE REHEA ATIN TING PLUG LUG REMO EMOVAL/ VAL/R REFI EFITTIN TING . . .
23
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
THROTTLE VALVE ASSEMBLY ASSEMBLY REMOVAL-REFITT REMOVAL-REFITTING ING 23
Print 603.93.651
Base - March 2006
4
F1A ENGINE
DAILY E URO 4
Page
Page
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
- Me Measuring main jou rn rnals and c ra ran k pins . . . . . .
79
E.G.R. VALVE REMOVAL/REFITTING . . . . . . . . .
24
-
Checking crankshaft . . . . . . . . . . . . . . . . . . . . .
80
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
-
Replacing timing control gear . . . . . . . . . . . . . .
82
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
82
HEAT EAT EXC XCHA HAN NGER REMO REMOVA VAL/ L/RE REFFITTI TTING . . .
24
-
Assembling main bearings . . . . . . . . . . . . . . . . .
82
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
- Meas Measur urin ingg main main jour journa nall asse assemb mbly ly clea cleara ranc nce e ...
82
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
-
Checking crankshaft end float . . . . . . . . . . . . . .
83
BURNT GAS EXHAUST SYSTEM . . . . . . . . . . . .
25
-
Assembling rear seal . . . . . . . . . . . . . . . . . . . . .
84
-
25
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . .
85
OXICAT - OXYDIZER CATALYST . . . . . . . . . .
25
-
85
-
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
CONNE CT CTING RO D PISTON ASSEM BL BLY . . .
86
EXHAU EXHAUST ST PIPE PIPE ASSEM ASSEMBLY BLY REMOV REMOVAL/ AL/REF REFIT ITTI TING NG
27
-
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
-
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
-
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
-
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
-
Measuring piston diameter . . . . . . . . . . . . . . . .
87
REMOVAL/REFITTI REMOVAL/REFITTING NG OF EXHAUST PIPE ASSEMBLY COMPONENTS (SYSTEMS EQUIPPED WITH D.P.F. CATALYST) . . . . . . . . . . . . . . . . . . . . . . . . . . 28
-
Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
Condit nditio ion ns for for corr correc ectt pinpin-pi pist sto on coup couplilin ng . . . . - Co
87
-
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
-
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . .
88
-
Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
-
Checking connecting rod . . . . . . . . . . . . . . . . .
89
-
Checking bending . . . . . . . . . . . . . . . . . . . . . . .
89
-
Asse Assembl mblin ingg conn connec ecti ting ng rodrod-pi pist ston on asse assemb mbly ly . . .
89
-
Check Checking ing for conne connecti cting ng rod pisto piston n dist distort ortion ion
90
-
Fitting piston rings . . . . . . . . . . . . . . . . . . . . . . .
90
-
Assembling Assembling connecting connecting rod piston assemblies assemblies in cylinder barrels . . . . . . . . . . . . . . . . . . . . . . .
90
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
Ex haust silencer removal . . . . . . . . . . . . . . . . .
28
-
Replacing D.P.F. catalyst . . . . . . . . . . . . . . . . . .
29
-
Refittingl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
-
D.P.F. catalyst removal . . . . . . . . . . . . . . . . . . .
28
-
Replacing dif fe ferential sensor (delta-p) . . . . . . . .
29
Replacin Replacingg bearing bearing suppor supporting ting gearbo gearbox x input input shaft shaft
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . .
30
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
ENGINE IDENTIFICATION CODE . . . . . . . . . . .
34
CHARACTERISTICS CURVES . . . . . . . . . . . . . . .
35
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
39
-
M ea easuring c ra ran kp kpin assembly clearance . . . . . .
91
ASSEMBLY DATA CLEARANCES . . . . . . . . . .
40
-
Checking piston protrusion . . . . . . . . . . . . . . .
91
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . .
92
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . .
52
-
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . .
63
-
Removing valves . . . . . . . . . . . . . . . . . . . . . . . .
92
OVERHAULING ENGINE . . . . . . . . . . . . . . . . . .
68
-
Checking cylinder head seal . . . . . . . . . . . . . . .
93
DISA DISASS SSEM EMBL BLIN ING G TH THE E ENGI ENGINE NE AT TH THE E BENC BENCH H
68
-
Ch e eccking c yl ylinder head mating su rf rface . . . . . . .
93
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . .
78
-
Removing Removing deposi deposits, ts, refacing refacing and checking checking valves valves
93
-
Checks and measurements . . . . . . . . . . . . . . . .
78
-
-
Check Checking ing head head matin matingg surfa surfae e on cylind cylinder er block block
78
Checking clearance clearance between between valve stem and and valve guide and centring valves . . . . . . . . . . . . . . . . .
94
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .
Base - March 2006
79
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
-
94
Replacing valve guide . . . . . . . . . . . . . . . . . . . .
Print 603. 93.651
F1A ENGINE
DAILY E URO 4
Page -
Boring valve guides . . . . . . . . . . . . . . . . . . . . . .
5
Page
94
-
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
126
-
95
-
Pressure relief valve . . . . . . . . . . . . . . . . . . . . .
1 26
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .
96
-
Checking pressure relief valve . . . . . . . . . . . . . .
1 26
ROCKER ARMS TAPPETS . . . . . . . . . . . . . . . .
96
-
-
97
GARRET GT 17 variable variable geometry geometry turbosupercharger . . . . . . . . . . . . . . . . . . . . . .
127
-
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127
-
Operation at low engine rpm . . . . . . . . . . . . . .
127
-
Operation at high engine rpm . . . . . . . . . . . . .
1 27
-
Proportional solenoid valve controlling turbocharger actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
-
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recutting and replacing valve seats . . . . . . . . . .
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING CYLINDER HEADS . . . . . . . . . . .
97
-
Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98
-
Overhead removal . . . . . . . . . . . . . . . . . . . . . .
98
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
99
-
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
-
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100
-
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 00
-
Checking cam lift and pin alignment . . . . . . . . .
100
-
Assembling overhead . . . . . . . . . . . . . . . . . . . .
-
Turbo Turbocha charg rger er (KKK (KKK K03-207 K03-2074-C 4-CCB CB 5.88 type) type)
125
128
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
-
Checking and adjusting the actuator . . . . . . . . .
1 29
10 2
EXHAUST GAS RECIRCULATION (EGR) SYSTEM (EXHAUST GAS RECIRCULATION) . . . . . . .
1 30
Assembling front seal ring . . . . . . . . . . . . . . . . .
103
-
EGR system operation . . . . . . . . . . . . . . . . . . .
130
-
Refitting cylinder head . . . . . . . . . . . . . . . . . . .
106
-
Main system components . . . . . . . . . . . . . . . . .
131
-
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . .
10 7
-
E.G.R. valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .
131
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
11 5
-
Modulator solenoid valve . . . . . . . . . . . . . . . . .
131
-
115
-
Air flow rate meter (flow meter) . . . . . . . . . . .
131
OIL VACUUM PUMP AS SE SEMBLY (GPOD ) . . . . .
117
-
Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .
132
-
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 17
-
Throttle valve assembly . . . . . . . . . . . . . . . . . .
132
-
Characteristic data . . . . . . . . . . . . . . . . . . . . . .
1 17
EXHAUST POLLUTANT REDUCTION SYSTEM WITH DPF CATALYST (ON REQUEST) . . . . . . . . . 133
-
Vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . .
117
-
Oil pressure control valve . . . . . . . . . . . . . . . .
1 18
-
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 18
-
Modine heat exchanger . . . . . . . . . . . . . . . . . .
118
-
Oil vapour recirculation system . . . . . . . . . . . .
119
-
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 19
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 1
-
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 21
-
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121
-
Electromagnetic pulley . . . . . . . . . . . . . . . . . . .
-
-
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133
D.P.F. D.P.F. (DIESE (DIESEL L PARTICU PARTICULATE LATE FILTER FILTER)) CATALY CATALYST ST
134
-
134
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTIC PARTICULA ULATE TE FILT FILTER ER REGEN REGENERA ERATIO TION N SYSTEM SYSTEM
135
-
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 5
-
Forced regeneration . . . . . . . . . . . . . . . . . . . . .
1 36
-
Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . .
13 6
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
1 23
HIGH-PRESSURE HIGH-PRESSURE ELECTRONIC ELECTRONIC INJECTION SYSTEM (MS 6. 3 - EDC 16 ) . . . .
13 7
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . .
12 3
-
137
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .
123
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . .
139
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . .
124
-
139
-
1 24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print 603.93.651
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis BLINK CODE . . . . . . . . . . . . .
Base - March 2006
6
F1A ENGINE
DAILY E URO 4
Page
Page
-
Immobilizer recognition . . . . . . . . . . . . . . . . . .
1 39
-
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 6
-
Checking fuel temperature . . . . . . . . . . . . . . . .
13 9
-
Fuel filter UFIfilters . . . . . . . . . . . . . . . . . . . .
147
-
Checki ng ng engine c oo oolan t temperature . . . . . . .
13 9
-
Fuel filter Filtrauto . . . . . . . . . . . . . . . . . . . . .
148
-
Checking quantity of fuel injected . . . . . . . . . . .
13 9
-
-
Checking idling adjustment . . . . . . . . . . . . . . . .
139
Fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 8
-
Fuel cut-off in release phase . . . . . . . . . . . . . . .
13 9
-
High-pressure pump CPH1 . . . . . . . . . . . . . . .
149
-
Che cckki ng ng c yl ylinder balancing on idling . . . . . . . .
13 9
-
Pressure control valve . . . . . . . . . . . . . . . . . . .
150
- Checking Checking regular regular engine engine rotati rotation on (anti-sa (anti-sawing wing)) .
139
-
Replacing pressure regulator . . . . . . . . . . . . . . .
150
-
139
-
Hydraulic accumulator (rail) . . . . . . . . . . . . . . .
151
Checkin Checkingg smokine smokiness ss at exhaust exhaust on accelera acceleratio tion n
Checki king ng exha exhaus ustt gas gas reci recirc rcul ulat atio ion n (E.G (E.G.R .R.) .) . . . - Chec
139
-
Checking top speed limit . . . . . . . . . . . . . . . . .
139
-
Chec Checki king ng regu regula larr rot rotatio ation n on acce accele lera rati tion on . . . .
139
-
Checking glow plug control unit . . . . . . . . . . . .
-
ELECTRO-INJECTORS . . . . . . . . . . . . . . . . . . . .
152
-
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
152
13 9
-
Replacing an electrical injector . . . . . . . . . . . . .
152
Check Checkin ingg activ activat ation ion of air-c air-con ondit dition ioning ing system system .
139
ELECTRIC/ELECTRONIC COM PO PO NE NENTS . . . . .
153
-
Checking fuel pump . . . . . . . . . . . . . . . . . . . . .
139
-
Electronic control unit EDC 16 . . . . . . . . . . . .
153
-
Checking diesel warming . . . . . . . . . . . . . . . . .
140
-
Checking cylinder position . . . . . . . . . . . . . . . .
140
-
Glow plug electronic control unit . . . . . . . . . . .
154
Check ecking ing pilo pilott and main main inje inject ctio ion n timin imingg . . . . . - Ch
140 140
-
Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
154
-
Chec Checki kin ng inj inject ection ion pres presssure ure clo closed sed cycl cycle e .....
140 140
SENSORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
154
-
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
-
Engine speed sensor . . . . . . . . . . . . . . . . . . . . .
154
-
Correcting Correcting flow rate according according to water water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
-
Camshaft timing sensor . . . . . . . . . . . . . . . . . .
154
Correcting Correcting flow rate to avoid avoid noise, smoke smoke or overloading . . . . . . . . . . . . . . . . . . . . . . . . .
140
-
Air te mp mperature and pressure sensor . . . . . . . .
155
-
De-rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
-
Fuel temperature sensor . . . . . . . . . . . . . . . . .
155
-
Injection timing electronic test . . . . . . . . . . . . .
140
-
Fuel pressure sensor . . . . . . . . . . . . . . . . . . . . .
155
-
Speed governor . . . . . . . . . . . . . . . . . . . . . . . .
140
-
Atmospheric pressure sensor . . . . . . . . . . . . . .
155
-
Engine starting . . . . . . . . . . . . . . . . . . . . . . . . .
140
-
Engine coolant temperature sensor . . . . . . . . .
155
-
Cold starting . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
-
Warm starting . . . . . . . . . . . . . . . . . . . . . . . . .
141
-
Throttle pedal position sensor . . . . . . . . . . . . .
155
-
Run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
-
Clutch pedal position sensor . . . . . . . . . . . . . .
155
-
After run . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
-
Brake pedal position sensor . . . . . . . . . . . . . . .
155
-
Cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
-
Vehicle speed sensor . . . . . . . . . . . . . . . . . . . .
155
-
Cylider balancin . . . . . . . . . . . . . . . . . . . . . . . .
141
-
Differential Differential pressure pressure sensor - deltap deltap ( p
....
15 5
-
Synchronisation search . . . . . . . . . . . . . . . . . . .
141 -
Exhaust gas temperature sensor . . . . . . . . . . . .
155
-
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . .
1 46
Base - March 2006
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . .
156
- PWM PWM (Pul (Pulse se Widt Width h Modu Modula lati tio on) cont contro rols ls . . . .
156 156
Print 603. 93.651
DAILY E URO 4
F1A ENGINE
7
MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE
Keep Keep to the follo followi wing ng instr instruc uctio tions ns befo before re doing doing any any work work on the the engi engine ne invol involvi ving ng comp compon onen ents ts of thefuel suppl supplyy syste system. m. - Before Before doing any work on the engine, engine, perform the engine/vehicle engine/vehicle fault diagnosis with specific IVECO diagnosis equipment equipment and print out the results. results.
Desk. Replacing operation - Replacement Replacement of the MS6.3 or EDC 16control unit must be authorized authorized by the Help the Help Desk. Replacing requires reprogramming as described in specific section. - Followi Following ng compon component entss in feed feed system system cannot cannot be overha overhaule uled d but have have to be replace replaced:press d:pressure ure reliefvalve,if reliefvalve,if prese present, nt, fuel pressure sensor, hydraulic accumulator, complete CP1H high pressure feed pump, pressure control valve, electric injectors. - All the parts of the Common Rail system are packaged packaged by the supplier supplier in sheets of oiled paper paper and are stored in cardboard boxes. They must therefore be protected against moisture and unpacked just prior to assembly. - The greatest care must be taken over the cleanliness of parts, making sure that when handling or assembling (starting with straightforward filter and pre-filter replacement) no dirt of foreign bodies can get inside. For this reason, reason, the plugs plugs protec protecting ting the hydrau hydraulic lic parts parts and sensors sensors must must be removed removed just prior prior to positio positioningin ningin their their seats. seats. - Take care over the direction direction of assembly for all electrical electrical connections. connections. - All threaded connections connections must be tightened tightened to the prescribed prescribed torque. - All the quickquick-coup coupling ling connect connectors ors (on the engine engine they they are found found on the high-p high-pres ressur sure e pump pump and on the diesel diesel drain drain manifold) must be fully inserted. To drive them out, press on the tabs at the base of the connectors.
Electro-injector None of the couplings/unions/nuts on the injector body may be handled. It is neither necessary nor permitted to dismantle the nozzle body or the electromagnet. If working on the high-pressure pipe, the hexagon on the injector side must be kept stationary with a wrench. Before working on pipes, make sure the injector is stationary in its seat on the cylinder head. When assembling/disassembling the injector drain, the retaining spring must not be removed from its seat in the injector: pushing the spring towards the engine and applying a vertical force on the connector frees the recirculation. When assembling, rest the recirculation connector in its seat and apply a vertical force while keeping the retaining spring pressed in the direction of the engine. Fitting in has to be easy. Replacing Replacing one or more electrical electrical injectors injectors requires requires central unit programmin programmingg as described in specific specific section. section. CP1H High-pressure pump If working on the high-pressure pipe, the hexagon on the pump side must be kept stationary with a wrench. Before working on the high-pressure pipe, make sure the pump is secured in its seat. High-pressure pipes Each high-pressure pipe must be replaced after disassembly operations. The couplings must be tightened or loosened with the injectors, hydraulic accumulator (rail) and high-pressure pump well secured and taking care to keep the hexagon on the component side stationary, space permitting. Hydraulic accumulator (rail) and accessories The pressure sensor can be assembled five consecutive times; after that, it must be replaced. They must be lubricated with a thin layer of oil before being mounted.. Replacing Replacing the sensor requires requires central unit programming programming as described described in specific specific section.
Print 603.93.651
Base - March 2006
8
F1A ENGINE
DAILY E URO 4
Serv Servic ice e proc proced edur ures es to be perf perfor orme med d afte after r replacing replacing high-pressur high-pressure e feeding feeding system system and/or and/or exhaust exhaust gas post-treatm post-treatment ent systemcompo system components nents To ensure correct operation of the engine, the CP1 control unit 16 stores stores,, in the memory memory non-lab non-labile ile area, area, the inform informatio ation n relative to the engine parameters originally set or acquired during engine operation. As a result, after any of the operations below is carried out: - replacing one or several injectors, - replacing replacing all the injectors, - replacing replacing the air flow meter, - replacing replacing the hydraulic hydraulic accumulator accumulator pressure sensor (common rail), - replacing replacing the EDC control control unit 16; - changing changing the engine oil, - replacing the D.P.F. D.P.F. catalyst, - replacing the filter differential pressure (Dp) sensor, - replacing any significant component as as regards emission levels, - performing forced regeneration,
the control cont rol unit shall be programmed again by means of the IVECO IVECO MODUS MODUS - E.A.SY E.A.SY.. - IT 2000 diagno diagnosis sis instrum instrument ent,, and the replacement procedure for the concerned component shall be performed, in accordance with the indications of the diagnosis instruments used.
Base - March 2006
Print 603.93.651
F1A ENGINE
DAILY E URO 4
Refitting To refit refit the engine engine assemb assembly, ly, carry carry out the operatio operations ns describ described ed for remova removall in revers reverse e order order,, follow following ing these these instructions: - Before Before refitting refitting the gearbox gearbox to the engine, engine, it is necessary necessary to remove the pressure plate bearing from the diaphragm diaphragm spring by opening out the retaining circlip. Fit the pressure plate bearing on the sleeve of the drive input shaft cover, connecting it to the clutch release lever. lever. Spread Spread the gearbo gearbox x input input shaft shaft with with Moliko Molikote te molybdenum disulphide grease. As regards the 5 S 300 - 6 S 400 O.D. gearbox units, proceed as follows. Engage a gear to let the main shaft turn, rotating the propeller shaft connecting flange. Push the gearbox fully in so that the pressure plate bearing couples with the diaphragm spring correctly. As regards the 6 S 400 O.D. gearbox units, follow the procedures described in the specific chapter. - Pay special attention to the operations needed to install the engine assembly in the engine bay.
Checkk the cond conditi ition onss of the the coola coolant nt pipe pipess or sleev sleeves es and and - Chec of the air ducts. Replace them if they show any sign of deterioration. mountings of the assemblies: assemblies: engine engine - Check the flexible mountings and gearbox. Replace them if they show any sign of deterioration. - Chec Checkk that that the the exha exhaus ustt pipe pipe memb member erss have have not not deteriorated and are not about to deteriorate. If this is so,replace so,replace them them along along with with the flexib flexible le parts parts for securi securing ng them. - Tighten Tighten the screws or nuts to the required required torque. torque. - Meticulously Meticulously check the state state of the vacuum pipe. pipe. It must show no sign of cracking, cutting, scoring or of being crushed. Replace it if there is any doubt at all about its soundness. When mounting it, make sure the pipe does not come come into contact contact with sharp sharp metal metal parts parts or corner cornerss or with with any particu particular larly ly hot parts. parts. In additio addition, n, after after assembly, the pipe must have no bends or constrictions, its radius of curvature should be broad and it must be secure secured d to the vacuum pump fitting with a suitabl suitable e clamp. - make sure that fuel pipes rapid engageme engagement nt fittings are accurately clean, and result to have been fully inserted and not going going to be disconn disconnecte ected d after after their their being being connected to relating engagement unions. - Fill the cooling cooling system with coolant. coolant. - Fill the hydraulic power steering circuit and bleed the air as described under the relevant heading. - Check the level level of oil in the engine and gearbox. gearbox. - recharg recharge e climate climate control control system system (if presen present) t) as descri described bed in chapter relating to section Body and chassis;
13
NOTE When positioning the engine in the engine bay, take special care not to damage the top pipe of the power power steeri steering ng and the soundp soundproo roof-h f-heat eatpr proof oof cladding of the engine bay. Once positioned, positioned, meticulously check that the top pipe of the power steering is sound. Befor Before e using using it again, again, check check that the power power steeri steering ng oil and coolant contain no impurities. If they do, filter with suitable mesh filters. For any topping up, refer to the REPLENISHING FLUIDS table in the GENERAL section.
Checks and tests Start up engine, leave running at a speed slightly in excess of idle speed and wait for coolant to heat sufficiently to open thermostat. Then check the following:
- no coolant leaks from coolant hose and cab interior heating hose connection sleeves. Tighten hose clips, if necessary; - no oil leaks from between cover and cylinder cylinder head, oil sump sump and and cran crankc kcas ase, e, oil oil filt filter er and and hous housin ing, g, heat heat exchan exchanger ger andcrankcase andcrankcase or from from lubrica lubrication tion circuit circuit lines; lines; - no fuel leaks from injection pump and injector lines. Tighten Tighten fittings if necessary; necessary; - check that injection pump control linkage linkage allows the flow regulat regulation ion to perfor perform m its full travel travel in both both directi directions. ons. Otherwise adjust the travel by acting on nuts (1-2, Fig. 6); - check that the engine shut-off device is working properly; properly; - check that the indicator lights on the instrument panel and relating relating to the devices devices disconnec disconnected ted when the engine was removed are working properly.
5014 501430 30
Powe Powerr stee steeri ring ng syst system em air air bleed
Check the level of oil in the tank and top it up if necessary. Lift the vehicle at the front, start up the engine and let it idle for some time. Check there is no oil leakage from the hydraulic circuit and check the level in the tank. Slowly turn the steering wheel in both directions of steering so that the air in the hydraulic system comes out. Chec Checkk thelevel thelevel of oil oil in thetank agai again n and and topup if nece necess ssar ary. y.
- check the inclination of light from headlights, headlights, if needed.
Print 603.93.651
Base - March 2006
14
F1A ENGINE
DAILY E URO 4
REPLACING BELTS 5439 543910 10 Replacin Replacing g air-condi air-conditioni tioning ng compressor drive belt Disassembly Figure 5
90155
Cut elastic belt (3), as it cannot be reused.
Assembly Fit the flexible flexible belt belt (3) equipp equipped ed with tool 99360191 99360191 (2) on the pulley (4) and apply the tool on the pulley (1). Fit the drive ring (5) on the flexible belt (3) and fasten the ring on the compressor support. su pport. Turn Turn the the driv drive e shaft shaft clockw clockwis ise e until until the belt belt fits fits perfectly on the pulley (1).
543910
Powe Powerr steer steerin ing g pumppump-al alte tern rnat ator or belt replacement replacement Disassembly Figure 6
75248
Disassemble the compressor drive belt, if there is one, as described under the relevant heading. Slacken off the tension of the belt (1) using a specific wrench on the automatic tightener (2) and remove the belt.
Assembly Mount the drive belt (1) taking care to position its ribs correctly in the respective races of the pulleys. Rele Releas ase e the auto automa matic tic tighte tightene nerr (2). (2). Turn Turn the crankshaft by one turn to settle the belt. Mount the compressor drive belt, if there is one, and adjust the tension as described under the relevant heading. Fit the middle soundproofing guard back on.
Base - March 2006
Print 603.93.651
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