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User Manuals: Iveco daily euro 4 Diesel Engine
Manuals and User Guides for Iveco daily euro 4 Diesel Engine. We have
1
Iveco daily euro 4 Diesel Engine manual available for free PDF download: Repair Manual
Iveco daily euro 4 Repair Manual (1133 pages)
mechanical electric/electronic
Brand:
Iveco
| Category:
Engine
| Size: 91.19 MB
Table of Contents
Preliminary Remarks
3
Symbols - Warnings
3
Symbols - Assistance Operations
4
Product Code
5
General Warnings
6
General Warnings on the Electric System
8
Bonding and Screening
9
Optional Electrical and Mechanical Parts Installations
10
Conversions between the Main Units of Measurement of the International System and most Used Derived Quantities
10
Index of Sections
13
Table of Contents
13
General
15
Identification Data
17
Vehicle Identification Plate
17
Composition of Models
18
Alphanumerical Cosing for Vehicle Identification
20
Replenishing Fluids
27
Engine
29
F1A Engine
31
Main Operations on Engine Mounted on Vehicle
35
Service Procedures to be Performed after Replacing High-Pressure Feeding System And/Or Exhaust Gas Post-Treatment System Components
36
Power Unit Removal/Refitting
37
Refitting
41
Checks and Tests
41
Power Steering System Air Bleed
41
Replacing Belts
42
Power Steering Pump-Alternator Belt Replacement
42
Replacing Air-Conditioning Compressor Drive Belt
42
Disassembly
42
Assembly
42
Replacing Timing Drive Belt
43
Disassembly
43
Assembling
44
Replacing the Electric Injectors
45
Removal
46
Refitting
46
Cylinder Head Removal and Refitting
47
Refitting
49
Replacing High-Pressure Pump CPH1
50
Replacing Water Pump
50
Removal
50
Refitting
50
Throttle Valve Assembly Removal-Refitting
51
Preheating Plug Removal/Refitting
51
E.G.R. Valve Removal/Refitting
52
Heat Exchanger Removal/Refitting
52
Burnt Gas Exhaust System
53
Oxicat - Oxydizer Catalyst
53
Description
53
Exhaust Pipe Assembly Removal/Refitting
55
Removal/Refitting of Exhaust Pipe Assembly Components (Systems Equippedwith D.P.F. Catalyst)
56
Exhaust Silencer Removal
56
D.P.F. Catalyst Removal
56
Refittingl
56
Replacing D.P.F. Catalyst
57
Replacing Differential Sensor (Delta-P)
57
Engine View
58
Left-Hand Side View
59
Front View
59
Rear View
59
Right-Hand Side View
60
Top View
60
Emissions
61
Gas Emissions
61
Smokiness
61
Noise Emissions
61
Engine Identification Code
62
Characteristic Curves
63
Characteristic Curves of Engine F1AE0481F
63
Characteristic Curves of Engine F1AE0481G
64
Characteristic Curves of Engine F1AE0481H
65
Self-Adhesive Label
66
Crankcase Marking
66
General Specifications
67
Assembly Data - Clearances
70
Tools
75
Experimental Tools
80
Tightening Torque
91
Longitudinal Cross-Section of Engine
94
Transverse Cross-Section of Engine
95
Overhauling Engine
96
Disassembling the Engine at the Bench
96
Repairs
106
Cylinder Block
106
Checks and Measurements
106
Crankshaft
107
Checking Head Mating Surface on Cylinder Block
107
Measuring Main Journals and Crank Pins
107
Checking Crankshaft
108
Journal on Timing System Side
109
Journal on Flywheel Side
109
Crankpins
109
Main Data of Main Journals and Crankpins
109
Engine Assembly
110
Replacing Timing Control Gear
110
Assembling Main Bearings
110
Measuring Main Journal Assembly Clearance
110
Checking Crankshaft End Float
111
Assembling Rear Seal
112
Engine Flywheel
113
Replacing Bearing Supporting Gearbox Input Shaft
113
Connecting Rod - Piston Assembly
114
Disassembly
114
Measuring Piston Diameter
115
Conditions for Correct Pin-Piston Coupling
115
Piston Pins
115
Piston Rings
115
Connecting Rods
116
Bushes
117
Checking Connecting Rod
117
Checking Bending
117
Assembling Connecting Rod-Piston Assembly
117
Checking for Connecting Rod - Piston Distortion
118
Fitting Piston Rings
118
Assembling Connecting Rod - Piston Assemblies in Cylinder Barrels
118
Measuring Crankpin Assembly Clearance
119
Checking Piston Protrusion
119
Cylinder Heads
120
Removing Valves
120
Disassembly
120
Checking Cylinder Head Mating Surface
121
Removing Deposits, Refacing and Checking Valves
121
Checking Clearance between Valve Stem and Valve Guide and Centring Valves
122
Valve Guide
122
Replacing Valve Guide
122
Boring Valve Guides
122
Valve Seats
123
Recutting and Replacing Valve Seats
123
Valve Springs
124
Rocker Arms - Tappets
124
Assembling Cylinder Heads
125
Overhead Removal
126
Timing System
127
Camshaft
128
Checking Cam Lift and Pin Alignment
128
Assembling Overhead
130
Assembling Front Seal Ring
131
Refitting Cylinder Head
134
Lubrication
143
Oil Vacuum Pump Assembly (GPOD)
145
Characteristic Data
145
Vacuum Pump
145
Oil Pump
145
Oil Pressure Control Valve
146
Oil Filter
146
Modine Heat Exchanger
146
Oil Vapour Recirculation System
147
Cooling
149
Electromagnetic Pulley
151
Thermostat
151
Water Pump
151
Turbocharging
152
Turbocharger (KKK K03-2074-CCB 5.88 Type)
153
Repairs
154
Pressure Relief Valve
154
Checking Pressure Relief Valve
154
GARRET GT 17 Variable Geometry Turbosupercharger (Engine F1A E0481 H - 136 HP)
155
Operation at Low Engine Rpm
155
Operation at High Engine Rpm
155
Proportional Solenoid Valve Controlling Turbocharger Actuator
156
Actuator
156
Turbocharging Functional Diagram
156
Checking and Adjusting the Actuator
157
Exhaust Gas Recirculation (EGR) System
158
EGR System Operation
158
Main System Components
159
E.G.R. Valve
159
Air Flow Rate Meter (Flow Meter)
159
Modulator Solenoid Valve
159
Throttle Valve Assembly
160
Heat Exchanger
160
Exhaust Pollutant Reduction System with DPF Catalyst (on Request)
161
D.P.F. (Diesel Particulate Filter) Catalyst
162
Particulate Filter Regeneration System
163
Forced Regeneration
164
Refilling Engine Oil
164
Fuel Supply
165
High Pressure Electronic Injection System (MS 6.3 - EDC 16)
165
System Operation
167
Operation
171
Functional Diagram of Hydraulic System
173
Hydraulic System
174
Fuel Pump
174
Fuel Filter “UFI Filters”
175
Fuel Filter “Filtrauto”
176
Fuel Pipes
176
High-Pressure Pump CPH1
177
Pressure Control Valve
178
Replacing Pressure Regulator
178
Hydraulic Accumulator (Rail)
179
Electro-Injectors
180
Replacing an Electrical Injector
180
Electronic Control Unit EDC 16
181
Sensors
182
Glow Plug Electronic Control Unit
182
Engine Speed Sensor
182
Camshaft Timing Sensor
182
Actuators
184
PWM (Pulse Width Modulation) Controls
184
F1C Engine
185
Main Operations on Engine Mounted on Vehicle
189
Service Procedures to be Performed after Replacing High-Pressure Feeding System And/Or Exhaust Gas Post-Treatment System Components
190
Power Unit Removal/Refitting
191
Power Steering System Air Bleed
195
Refitting
195
Checks and Tests
195
Replacing Air-Conditioning Compressor Drive Belt
196
Replacing the Water Pump
196
Power Steering Pump-Alternator Belt Replacement
196
Disassembly
196
Assembly
196
Removal
196
Refitting
196
Replacing the High-Pressure Pump
197
Removal
197
Refitting
197
Replacing the Power Steering Pump
198
Replacing the Drive Shaft Seal Ring and the Front Cover Gasket
198
Removal
198
Refitting
198
Refitting
199
Replacing the Vacuum Pump Oil Pump Assembly (GPOD)
200
Removal
200
Refitting
200
Replacing the Drive Shaft Rear Seal Ring
201
Removal
201
Refitting
201
Replacing Electro-Injectors
202
Removal
202
Refitting
202
Removal/Refitting the Cylinder Head
203
Refitting
205
Egr Heat Exchanger Removal - Refitting
207
Refitting
208
Checks and Tests
208
Egr Heat Exchanger Removal - Refitting
208
Removal
208
Refitting
209
Checks and Tests
209
Burnt Gas Exhaust System
210
Removal/Refitting of Exhaust Pipe Assembly Components (Systems Equipped with D.P.F. Catalyst)
211
Exhaust Silencer Removal
211
Replacing D.P.F. Catalyst
212
Replacing Differential Sensor (Delta-P)
212
Engine Views
213
Engines for LD (Light Duty) Vehicles
216
Emissions
216
Engine Identification Code
217
Self-Adhesive Label
218
F1C Engine Cylinder Axis Cross Section (146 HP)
220
F1C Engine Cross Section (176 HP)
222
Characteristic Curves
223
General Specifications
225
Assembly Data - Clearances
228
Tools
233
Experimental Tools
239
Schematic Diagram
240
Tightening Torque
246
Overhauling Engine F1C
249
Disassembling the Engine at the Bench
249
Cylinder Block
260
Checks and Measurements
260
Repairs
260
Checking Head Mating Surface on Cylinder Block
261
Crankshaft
261
Measuring Main Journals and Crank Pins
261
Checking Crankshaft
262
Replacing Timing Control Gear
264
Engine Assembly
264
Assembling Main Bearings
264
Checking Crankshaft End Float
265
Assembling Rear Seal
266
Engine Flywheel
267
Replacing Bearing Supporting Gearbox Input Shaft
267
Connecting Rod - Piston Assembly
267
Piston
268
Measuring Piston Diameter
268
Piston Pin
269
Conditions for Correct Pin-Piston Coupling
269
Bushing
270
Checking Connecting Rods
270
Checking Torsion
271
Checking Bending
271
Assembling Connecting Rod-Piston Assembly
271
Assembly Piston Rings
272
Assembly Connection Rod-Piston Assembly in the Cylinder Liner
272
Checking for Connecting Rod - Piston Distortion
272
Measuring Crankpin Assembly Clearance
272
Checking Piston Protrusion
273
Disassembly the Camshaft
274
Cylinder Heads
274
Checking Cylinder Head Seal
275
Checking Cylinder Head Mating Surface
275
Valves
275
Removing Deposits, Refacing and Checking Valves
275
Checking Clearance between Valve Stem and Valve Guide and Centring Valves
276
Valve Guide
276
Replacing Valve Guide
276
Boring Valve Guides
276
Valve Seats
277
Recutting and Replacing Valve Seats
277
Valve Springs
278
Rocker Arms - Tappets
278
Checks
279
Assembling Cylinder Heads
279
Overhead
280
Overhead Removal
280
Timing System
281
Description
281
Camshaft
282
Checks
282
Checking Cam Lift and Pin Alignment
282
Assembling Overhead
284
Auxiliary Organ Controls
284
Cynder Head Refitting
286
Timing System Control
287
Replacement of Alternator Free Wheel
292
Lubrication
299
General
299
Oil Pump/Depressor Unit
301
Characteristic Data
301
Oil Pressure Adjusting Valve
302
Vacuum Pump
302
Disassembly
302
Assembly
303
Oil Filter
303
Heat Exchanger
303
Disassembly
303
Oil Vapour Recirculation (Blow-By)
305
Operation
305
Cooling
306
Description
306
Operation
306
Electromagnetic Pulley
307
Water Pump
307
Thermostat
307
Turbocharging
308
Description
308
Turbocharger Type MITSUBISHI
309
Repairs
310
Pressure-Relief Valve Check
310
GARRET GT 2260 V Variable Geometry Turbosupercharger
311
General
311
Operation at Low Engine Rpm
311
Operation at High Engine Rpm
311
Proportional Solenoid Valve Controlling Turbocharger Actuator
312
Actuator
312
Repairs
313
Checking and Adjusting the Actuator
313
Exhaust Gas Recirculation (Egr) System
314
Operating
314
Main System Components
315
Modulator Solenoid Valve
315
Air Flow Rate Meter (Flow Meter)
315
Throttle Valve Assembly
316
Heat Exchanger
316
Exhaust System Removal-Refitting
317
General
317
D.P.F. (Diesel Particulate Filter) CATALYST
318
Description
318
System to Reduce Pollutants at Exhaust
319
Operation
319
”Filtrauto” Fuel Filter
330
”Ufifilters” Fuel Filter
331
CP3.2 High-Pressure Pump
332
Pressure Regulator
333
Glow Plugs
337
Clutch
341
Diagnostics
344
Characteristics and Data
347
Tightening Torques
353
Clutch Removal and Refitting
354
Thrust Bearing Removal and Refitting
355
Hydraulic Clutch Drive
356
Hydraulic Clutch Drive Removal - Refitting
358
Pedal Board Removal - Refitting
360
Pedal Boards
361
Clutch with Automatic Wear Recovery - Combined with 6 AS’300 VD Gearbox
362
Clutch Disc Automatic Wear Recovery Diagram
363
Removal and Refitting of Clutch with Device Recovery Combined
364
Transmission
367
Diagnistics
369
Transmission Removal - Refitting
373
Gear Control Check and Adjustment
374
Gear Control
376
Flexible Cable Replacement
376
Gear Shift Lever Support
377
5 S 300 Transmissions
379
Gear Selection and Engagement Control
382
Safety Devices
383
Reverse Gear Anti-Engagement Device
383
Specifications and Data
384
Gearbox Unit
386
Gearbox Control
387
Section on Gear Engagement Rod Positioning Pawls
393
Transverse Section on Internal Control Box
393
Overhauling the Transmission
394
Selection and Adjustment Tie-Rod Assembling
396
Disassembling the Transmission
397
Disassembling the Rear Cover Bearings
399
Disassembling the Transmission Bearings
399
Disassembling the Main Shaft
400
Disassembling the Transmission Shaft
402
Input Shaft Assembly Drawing
403
Main Shaft Assembly Drawing
403
Transmission Shaft Assembly Drawing
403
1St - 2Nd Gear Dual Cone Synchronizer Assembly
404
3Rd - 4Th - 5Th Gear Single Cone Synchronizer Assembly
404
Hubs - Sliding Sleeves - Forks
405
Bearings
405
Shafts - Gears
405
Synchronizing Devices
405
Mounting the Transmission Shaft
406
Mounting the Main Shaft
406
Rods - Forks - Selector - Driver
409
Mounting the Transmission
409
Adjusting the Transmission Shaft Bearing End Float
409
6 S 400 O.D. Transmission
415
Gear Selection and Engagement
418
Neutral Arrangement And/Or 3/4 Gear Selection and Engagement Arrangement
418
1, 3 Gear Selection Election and Engagement Arrangement
418
5/6 Gear Selection and Engagement Arrangement
419
Reverse Gear Selection and Engagement Arrangement
419
Gear Control Box Disassembly
432
Primary Shaft and Input Shaft Assembly
443
6 S 400 a O.D. Transmission
457
Main Components Location
460
Main System Functions
461
Startup/Start Procedure
461
Check Procedures
461
Limp Home
462
Buzzer
462
Start up with Tow
462
Hill Holder (Function Only Available to Vehicles with ESP8 Braking System)
463
Functional Features
463
System Structure
464
System Central Unit
464
Central Unit Location
464
Gears Actuator
465
Clutch Actuator
465
Accelerator Pedal
466
Display Unit
466
Gear Selector
467
Diagnosis Instruments
474
Modus - IT 2000 - E.A.SY. Connection
475
Gearbox Unit Overhauling
483
Control Unit
483
Gearbox Actuator
486
Chassis Wiring Gearbox
487
Gearbox Wiring - Gearbox
488
Calibration
490
Calibration in Case of Replacement of the Gearbox Kit + Control Unit
490
Calibration in Case of Replacement of the Control Unit
490
Calibration in Case of Replacement of the Clutch Actuator
491
Calibration in Case of Replacement of the Gearbox Actuator or an Electric Motor of the Gearbox Actuator
491
Calibration in Case of Replacement of the Clutch Engaging/Release Fork
491
Power Take off
493
Power Take off Components
497
Power Take off Electric Actuator
498
Power Takeoff Connection
498
Power Takeoff Disconnection
499
Propeller Shafts
501
GKN-Type Articulated Propeller Shaft
503
Dana-Type Articulated Propeller Shaft
503
GKN-Type Connecting Shaft
504
Dana-Type Connecting Shaft
504
Propeller Shaft Removal and Refitting
511
Checking Propeller Shafts on Vehicle
511
Rear Axles
513
Rear Axle NDA RS
517
NDA RS Rear Axle Differential Section
522
NDA RS Rear Axle Wheel Hub Section
524
Rear Axle NDA - RS Removal - Refitting
529
Overhauling the Rear Axle Assembly
531
Wheel Hub Overhaul
531
Air Breather Disassembly - Assembly
531
Repairing the Differential
534
Disassembling the Differential Unit
534
Gear Housing Removal
535
Dismounting Bevel Pinion
536
Checking the Parts Comprising the Differential
537
Differential Unit Components
537
Assembly of Gear Housing
538
Assembling the Bevel Pinion Assembly
539
Assembly of Differential Unit
542
Rear Axles NDA RG
547
NDA RG Rear Axle Differential Section
553
NDA RG Rear Axle Wheel Hub Section
554
Overhauling the Rear Axle Assembly Overhauling Therear Axle Assembly
560
Rear Axles 450511
565
Rear Axle Differential Section with Differential Locking
570
450511 Rear Axle Differential Section
571
Rear Axle Removal - Refitting
577
Replacing the Wheel Hub Bearing
580
Disassembly of Differential Locking
583
Assembling the Differential Locking Device
583
Differential Locking Refitting
583
Differential Locking Removal
583
Adjusting the Differential Locking Device
584
Disassembly of Gear Housing
585
Parts Comprising the Differential Unit
586
Assembling Bevel Pinion Unit
587
Differential Unit Refitting
591
Rear Axle 450517/2
595
450517/2 (R0537) Rear Axle Differential Section
600
ABS Version
601
Overhaul of Rear Axle
609
Overhaul of Wheel Hubs
609
Stud Replacement
611
Differential Locking
614
Differential Unit Removal
615
Gearing Case Removal
615
Gearing Case Refitting
617
Differential Components Check
617
Rear Axle Casing Check
617
Axles
625
Axle 5817
631
Removing and Refitting Axle 5617
637
Overhauling Axle 5817
639
Wheel Hub Removal and Refitting
639
Replacing Phonic Wheel
640
Stub Axle Removal-Refitting
641
Axle 5818
645
Axle 5819
653
Axle 5819 Overhaul
659
Stub Axle Removal and Refitting
659
Axle 5823
661
Removing and Refitting Axle 5823
667
Axle 5823 Overhaul
669
Wheel Geometry
673
Camber Angle
675
Wheel Camber Angle
675
Caster Angle
675
Wheel Geometry Specifications and Data
677
Checking Characteristic Angels
679
Positioning Jaws and Projectors
679
Electronic Balancing of Rim Eccentricity
680
Wheel Alignment
680
Checking Toe-In
681
Checking King-Pin Angle and Caster Angle
682
Checking Camber
682
Checking Steering Angles
683
Checking Rear Axle Alignment
683
Suspensions
685
Front and Rear Mechanical Suspensions
687
Front Mechanical Suspensions
693
Mechanical Front Suspensions
695
Front Leaf Spring
696
Composite Leaf Spring
696
Steel Leaf Spring
697
Front Shock Absorbers
698
Front Stabilizer Bar
698
Vehicles 29 L - 35 S
699
Vehicles 35 C
700
Vehicles 29 L - 35 S - 35C
701
Check the Clearance of Upper Swinging Arm Articulated Head
702
Check the Clearance of Lower Swinging Arm Articulated Head
703
Suspension Arms
703
Replacing Suspension Arm Bushings
703
Leaf Spring
707
Torsion Bar Suspension
709
Stabilizer Bar Diameter
710
Vehicles 35 C - 40 C - 45 C - 50 C
713
Tie Rods
717
Replacing Swivel Heads
717
Torsion Bars
718
Replacing Link Pins
719
Replacing Silentbloc and Limit Stops
719
Adjusting Torsion Bar Pre-Load
722
Stabilizer Bar
723
Axle 5823 - Vehicles 60C - 65C
725
Suspension Overhaul
730
Lower Tie Rod Articulated Heads Replacement
730
Rubber Bush Replacement
731
Torsion Bar Preload Adjustment
734
Rear Mechanical Suspensions
735
Rear Suspension with Semi-Elliptical Leaf Spring
761
Disassembling the Leaf Spring
762
Assembling the Leaf Spring
762
Replacing the Bushings
762
Rear Air Suspensions
765
Pneumatic Suspensions - Wabco Type (for 29L - 35S Vehicles)
768
Air System Components
769
Rear Leaf Spring
770
Rear Shock Absorbers
770
Levelling and Height Values
770
Electric System WABCO (ECAS)
771
Pneumatic System WABCO (ECAS)
772
Pneumatic System on Vehicle
773
Vehicles Without ABS
773
Vehicles with ABS
774
Chassis Self-Levelling, Lifting and Lowering
775
Pneumatic Supply Unit
775
Electronic Control Unit
775
ECU Programming/Setting
776
Level Sensor Replacement
776
Level Sensor
776
Level Sensor Adjustment
776
Air Spring
777
Load Sensing Valve
777
Air Spring Replacement
777
Load Sensing Valve Replacement
778
Load Sensing Valve Adjustment on Vehicle
778
Rear Suspension Overhaul
779
Rear Stabilizer Bar
779
Panhard Reaction Bar
780
Wheel and Tyres
781
Tyre Pressure
784
Static Wheel Balancing
788
How Tyre Behaviour Depends on Pressure
789
Steering Gear
791
Steering Gear Diagram
793
Power Steering Specifications and Data
794
Power Steering Description
801
Hydraulic Power Steering System Diagram
801
Power Steering Type TRW
802
Hydraulic Power Steering Operation Diagram: Neutral Position
802
Hydraulic Power Steering Operation Diagram: Right Steering
803
Hydraulic Power Steering Operation Diagram: Left Steering
804
Power Steering Type ZF
804
Swivel Heads
806
Protection Casings
806
Checks and Operations on the Vehicle
806
Steering Gear Control
806
Preliminary Standards
807
Repairs and Inspections Required after an Accident
807
Accidents with or Without Air-Bag Module Activation
807
Accidents with Air-Bag Module Activation
807
Painting
808
Risks for Health
808
Overexposure Effects
808
Safety Standards to Observe When Handling Air-Bag Modules
808
Air-Bag Module Scrapping
809
Safety Standards to Observe When Handling Pretensioners
809
Pretensioners Scrapping
810
Operations on System Components
810
Removing and Scrapping Non-Activated Air-Bag Module from a Repairable Vehicle
810
Removing and Scrapping Activated Air-Bag Module and Pretensioner from Vehicle
810
Air-Bag Module Deployment
811
Activating Air-Bag Modules and Electronic Pretensioners Installed on Unrecoverable Vehicles
811
Upper Steering Gear Shaft Removal
813
For Vehicles Equipped with Air-Bag
813
For All Vehicles
813
Lower Steering Gear Shaft Removal
814
Hydraulic Power Steering
815
Hydraulic Power Steering Removal
815
Steering Linkage Replacement
816
Rubber Bushing Replacement Procedure
816
Power Steering Pump
817
F1A Engine Power Steering Pump
817
Power Steering Pump Overhaul Procedure
817
F1C Engine Power Steering Pump
817
Hydro-Pneumatic System
819
Brakes
819
Graphic Symbols for Air/Hydraulic System Circuit Diagrams (Miscellaneous and Generators)
823
Graphic Symbols for Air/Hydraulic System Circuit Diagrams (Valves)
824
Graphic Symbols for Air/Hydraulic System Circuit Diagrams (Tanks and Accumulators)
830
Graphic Symbols for Air/Hydraulic System Circuit Diagrams (Converters, Cylinders and Calipers)
831
Graphic Symbols for Air/Hydraulic System Circuit Diagrams (Calipers and Cylinders)
832
Graphic Symbols for Air/Hydraulic System Circuit Diagrams (Semi-Couplings and Coupling Heads)
833
Graphic Symbols for Air/Hydraulic System Circuit Diagrams (Indicators and Switches)
835
Graphic Symbols for Air/Hydraulic System Circuit Diagrams (Brakes)
836
Pipes and Couplings
837
Re-Flanging Rigid Pipes
837
Bending Rigid Pipes
838
Cutting Rigid Pipes
838
Replacing Flexible Hoses with Threaded Couplings
839
Replacing Flexible Hoses with Quick Release Couplings
840
Braking System
842
Outline Diagram for Vehicles 29L - 35S Without ABS
842
Outline Diagram for Vehicles 29L - 35S with ABS 8
843
Outline Diagram for Vehicles 29L - 35S with ESP 8
844
Outline Diagram for Vehicles 35C - Without ABS
845
Outline Diagram for Vehicles 35C with ABS 8
846
Outline Diagram for Vehicles 35C with ESP 8
847
Outline Diagram for Vehicles 40C - 45C - 50C - 60C - 65C with ABS 8
848
Outline Diagram for Vehicles 40C-45-50C-60C-65 with ESP 8
849
Braking System Main Components Layout
850
Vehicles 29L-35S
850
Vehicles 35C - 40C - 45C - 50C - 60C - 65C
851
Location of the Main Brake System Components on Vehicles with ABS
852
Location of the Main Brake System Components on Vehicles with ESP
854
Service Brake
855
Front and Rear Disc Brakes
855
Emergency Brake
855
Parking Brake
855
Specifications and Data - Hydraulic System
869
Specifications and Data - Brakes
870
Functional Check of Vacuum Brake System
872
Brake System Main Components
873
Vacuum Pump
873
Vacuum Servo Brake
873
Bleeding Air from the Hydraulic Circuit (Vehicles Not Equipped with ABS)
874
Bleeding Air from the Hydraulic Circuit with Deaerator Device (Vehicles Not Equipped with ABS)
874
Air Bleeding from the ABS/ESP System Hydraulic Circuit
875
ABS 8/ESP 8 System Bleeding Procedure Sequence
876
Mechanically Controlled Load Sensing Valve (Vehicles 35C)
877
Regulation of Load Proportioning Valve on Vehicle
877
Dual Mechanically Controlled Load Sensing Valve (Vehicles 29L - 35S)
878
Adjusting the Load Sensing Valve
878
Stability Control and Anti-Skid Devices
879
ABS System Functions
879
Functions Included in the ESP System Only
879
Electro-Hydraulic Modulator/Control Unit for 29L - 35S Vehicles
880
ESP System Sensors
882
Rev Sensor
882
Phonic Wheels
882
Longitudinal Acceleration Sensor
882
Brake Repair Operations
883
Replacing Brake Linings
883
Removal/Re-Fitting of Brake Calipers
885
Rear Brakes
886
Removal/Refitting of Brake Calipers
886
Overhaul of Brake Calipers
888
Removal/Refitting Brake Calipers
888
2X44 - 2X48 - 2X60 Brembo Brake Calipers
888
1X52 - 1X60 Brembo Brake Calipers
889
Overhaul of Brake Discs
890
Machining and Grinding of Disc Brakes
890
Wheel Nut Tightening Sequence
891
Overhauling Parking Brake
891
For Models 35C - 40C (Not Including Vehicles with NDA R.G. Rear Axle) - 45C - 50C
892
View of the Parking Drum Brake
892
Adjusting Parking Brake
893
Replacing the ESP Components
894
Steering Angle Sensor
894
YAW Sensor
896
Electrohydraulic Modulator/Control Unit
897
Bench Overhauling
898
Bodywork
899
Chassis Frame
899
Cab Air-Conditioning
899
Safety Standards to Observe When Working on Vehicles Equipped with the Air-Bag System
901
Ventilation
901
Air-Conditioning System Main Components and Functional Diagram
902
Air-Conditioning and Heating
902
Compressor
903
Condenser
903
Drier Filter
904
Expansion Valve
904
Evaporator
904
Control and Safety Devices
905
Three-Level Pressure Switch
905
Outside Air Temperature Sensor
905
Air-Conditioning Unit (“M. Marelli” or “Denso” Type)
906
”M. MARELLI” Type Heater/Air-Conditioner
907
Heater Unit
908
R134A Refrigerant Recovery and Refilling Station (99305146)
909
Control Fascia
910
Filler Cylinder
910
Safety Standards
912
Operation Flow Chart
913
Recovering Refrigerant from the Vehicle System
914
Demonstrative Figure
914
Creating a Vacuum in the System
916
Restoring Oil in the System
918
Filling the System with Refrigerant
919
Checking the Pressures in the System
921
Operations Prior to Disconnecting the Station from the System
921
Leak Finder for Air-Conditioning Systems with HFC R134A (9905147)
921
Scheduled Maintenance
923
Table of Maintenance Services
925
F1A Engine Vehicles
926
Inspection And/Or Maintenance Interventions (F1A Engine Vehicles)
926
Extra Plan Operations (to be Carried out Possibly in Combination with Maintenance Service)
927
F1C Engine Vehicles
928
Inspection And/Or Maintenance Interventions (F1C Engine Vehicles)
928
Diagram of Check And/Or Maintenance Points
930
Maintenance Operations
931
Changing Engine Oil Filter
931
Replacing UFI Filters Type Fuel Filter
931
Checking Hydraulic Brake System Fluid Level
931
Replacing the Mechanic and Automatic Transmission Gearbox Oil
932
Cleaning Rear Axle Oil Breather
932
Checking Steering Column, Articulation and Linkage
932
Checking Steering Box Fixing
932
Checking Universal Joints and Propeller Shaft Flange Fixing
933
Headlamp Orientation Check
933
Changing Rear Axle Oil
933
General Information
933
Engine
934
Checking the Antifreeze Concentration in the Engine Coolant
935
Changing the Engine Coolant
935
Replacing the Air Filter Cartridge and Cleaning the Container
935
Electric/Electronic System
937
Clutch
939
Gearbox
940
Abbreviations and Graphic Symbols
941
General Conditions for Laying Electric Circuits
942
Concept of Earth and Electromagnetic Compatibility
943
Earth Network
943
Practical Advice
944
Ultrasonic Cable Welding
945
Connection between Components
945
Technical Codes
946
Rear Axles
947
Power Network
950
Positive Network (CBA)
951
Instrument Panel Interconnection Central Units (CPL) "75002"
953
Fuses / Remote Control Switches Identification
955
Internal Electrical Scheme
956
Junction Connectors
957
Junction Connector “L”
958
Junction Connector “M”
959
Junction Connector “R”
960
Junction Connector “H”
961
Engine Opening Central Unit (CVM) "75001"
962
Junction Connectors “D”
969
Junction Connectors “E”
969
Junction Connectors “F”
969
Negative Network
970
Earth Points
970
Battery
973
BOSCH KCBI 14V 110A Alternator
974
EV 12V - 2.3 KW Starter Motor
975
Junction Welds
976
Wiring Harness Section
978
Bonnet - Instrument Panel Junction (600/601H)
981
Bonnet - Instrument Panel Junction (600/601B)
982
Bonnet - Instrument Panel Junction (600/601D)
983
Bonnet - Instrument Panel Junction (600/601G)
984
Bonnet - Instrument Panel Junction (600/601A)
985
Bonnet - Instrument Panel Junction (600/601C)
986
Instrument Cluster
987
Display Screen
989
Steering Column Switch Unit
990
Central Instrument Panel
991
Instrument Panel Switch Assembly
992
Optional Box
993
"Can Lines" System Description
996
“C” CAN Line
997
“B” CAN Line
998
Body Computer
999
Black Cab Junction Connector “LN”
1002
Blue Instrument Panel Junction Connector “PF”
1004
Blue Bonnet Junction Connector “AV”
1005
Fitter Connector
1007
Electronic Injection EDC16
1009
Particular Features of Engines Euro 4
1009
E.G.R. (Exhaust Gas Recirculation) System
1011
Particulate Filter (Components Location)
1013
Replacing the Components
1015
Replacing Particulate Filter
1015
Replacing Flow Meter
1016
Replacing Rail Pressure Sensor in Hydraulic Accumulator
1016
Replacing Engine Oil
1016
Replacing an Injector
1017
Electronic Injection Control
1018
EDC System Components
1022
Bosch EDC16 Control Unit
1024
Control Unit Connection to the Injection Cable on Engine Side (Housing A)
1025
Control Unit Connection to Cab-Bonnet Cable (Housing K)
1027
Accelerator Pedal Sensor
1029
Brake Pedal Switches (53501)
1030
Clutch Pedal Switch (42374)
1030
Preheat Plug Electronic Centre (F1A/F1C Engine)
1031
R.p.M. / Timing Sensors (F1C)
1032
Timing Sensor (Stroke) (F1C)
1033
RPM Sensor
1034
Timing Sensor
1035
Rail (Pressure Accumulator) F1C
1037
Air Temperature/Pressure Sensor
1038
Atmospheric Pressure Sensor
1039
Engine Coolant Temperature Sensor
1039
Fuel Temperature Sensor
1039
Injectors
1040
Electromagnetic Junction Fan
1041
Camshaft Sensor (F1A) 48042
1042
Flywheel and Rpm Sensor
1043
Characteristics of Flywheel Rpm and Timing System Sensors
1043
Rail (Pressure Accumulator) F1A
1045
Air Temperature / Pressure Meter
1047
Fuel Filter
1049
Fuel Pump/Fuel Level
1050
Abs 8/Esp 8
1051
The ABS 8 System Integrates the Following Functions
1051
The ESP 8 System, in Addition to the EBS 8 System, Incorporates the Following Functions
1051
Four Crossed Channel System (X)
1052
Electro-Hydraulic Modulator/Control Unit
1052
Front Axle
1052
Four Parallel Channel System (II)
1053
ABS 8 Control Unit PIN out (X - Crossed Channels, II - Parallel Channels)
1054
ESP 8 Control Unit PIN out (X - Crossed Channels, II - Parallel Channels)
1055
PIN out of Central Unit ASR 8 (4 Channels -X)
1056
4 Channels - II
1057
ESP (Electronic Stability Program) Operation
1058
Control Strategy
1058
Sudden Obstacle
1058
Sudden Steering
1059
Vehicle Running on a Slippery Road
1059
ASR Deactivation Strategies
1060
Recovery Strategy in Case of Component Failure
1060
Warning Light Legend
1061
Installing the Esp Components
1061
ESP System Components and Calibration
1062
Yaw Sensor with Built-In Side Acceleration Sensor
1062
Longitudinal Acceleration Sensor Calibration
1063
Steering Angle Sensor Calibration
1064
ESP Control Unit Programming
1065
Front and Rear Suspensions
1065
Air Bag
1066
Intervention Logics
1068
Maintenance
1068
Electric/Electronic System
1069
Operations after an Accident
1070
Painting Work
1070
Health Hazards
1070
Effects of Over-Exposure
1070
Rules of Safety in Handling Air Bag Modules
1071
Air Bag Module Scrapping
1071
Rules of Safety in Handling Pretensioners
1072
Scrapping Pretensioners
1072
Removing and Scrapping an Activated Air Bag Module and Pretensioner from a Vehicle
1073
Removing or Scrapping an Air Bag Module that Has Not Been Deployed from a Reparable Vehicle
1073
Deployment of an Air Bag
1074
Deployment of Air Bag Modules and Electronic Pretensioners Still on Board of Irreparable Vehicles
1075
De-Activating Passenger Air-Bag
1077
Print 603.93.651 Base - March
1077
Central Unit Pin out
1079
Spiral Contact
1080
Pretensioners
1081
Curtain Air Bag
1082
Component Replacement Interventions
1083
Drive Side Air Bag Module
1084
Passenger Side Air Bag Module
1084
Immobilizer
1086
Warning Lamp
1089
Antenna
1089
Immobilizer New Procedures
1090
6AS 400 a O.D. VD Automatic Transmission
1091
Electronic Management
1092
Composition of the System
1093
System Control Unit
1093
Connector Control Unit PIN-OUT — Gearbox Side (A)
1094
Connector Control Unit PIN-OUT — Vehicle Side (B)
1095
Wiring Diagram
1097
Remote Control Switches/Fuses Assembly
1102
Pto
1103
PTO Engaging Procedure
1104
PTO Disengaging Procedure
1104
Diagnosis (Connector EOBD)
1107
Circuit Cards
1109
Cab Interior Components
1112
Window Winders — Electric Mirrors
1113
Various Loads
1115
Telma Decelerator
1116
Differential Locking - Heated Rear Window and Windscreen
1117
Air Spring Suspension
1118
Additional Heater - Power Take-Off
1119
Cruise Control - Climate Control System
1120
Automatic Gearbox
1121
Esp 8
1122
External Illumination
1123
Asr
1124
Camera
1125
“CAN” Lines
1132
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