Daily_Euro_4_2006_2009__manual

DAILY EURO 4REPAIR MANUAL

MECHANICALELECTRIC/ELECTRONIC

B.U. TECHNICAL PUBLISHINGIveco Technical PublicationsLungo Stura Lazio, 1510156 Torino (TO) - Italy

Produced by:

This document provides data, characteristics, instructions andmethodology to perform repair interventions on the vehicleand its components.

Anyhow, this document is addressed to qualified andspecialised personnel. Iveco commercial and assistancenetwork personnel as well as all Iveco authorised points ofassistance are specifically qualified and equipped to performthe repair interventions that are indicated in this document.

Before performing any intervention, check to have availablethe document relating to the vehicle model on which theintervention is being performed and also make sure that allaccident prevention devices, such as, as a rough guide, goggles,helmet, gloves, shoes, as well as work tooling, lifting andtransport tooling, etc., are available and efficient, and furthermake sure that the vehicle is put such a way that anintervention can be made in safety conditions.

Making interventions strictly observing the indications givenhere, as well as using specific tooling indicated, assures acorrect repair intervention, execution timing observance andoperators safety.

Each repair intervention must be finalised to the recovery offunctionality, efficiency and safety conditions that are providedby Iveco.Each intervention, on the vehicle, that is finalised to amodification, alteration or else, which is not authorised byIveco, involves the exclusion of any responsibility for Iveco,and, in particular, where the vehicle is covered by a guarantee,each such intervention involves an immediate lapse of theguarantee.

Responsibility for Iveco in repair intervention execution isexcluded.

Iveco is available to provide all clarifications necessary tomakeinterventions, as well as to provide indications in cases andsituations not included in this document.

Data and information contained in this document could resultnot to be updated owing to modifications made by Iveco atany moment for technical or commercial reasons, or becauseof the need to adapt the vehicle to law requirements indifferent countries.

In the case of a difference between what contained here andwhat actually found on the vehicle, please contact Iveconetwork before making any intervention.

The data contained in this publication might fail to reflect thelatest changes which the Manufacturer may introduce at anytime, for technical or sales purposes, or to meet therequirements of local legislation.

Copy, even partial, of text and drawings is forbidden.

Publication Edited by:IVECO S.p.A.Customer ServiceLungo Stura Lazio, 1510156 Torino (TO) - Italy

Print 603.93.651 - 1st Ed. 2006

Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicatedin 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 ofunits to/from the vehicle, overhauls at the bench and relating troubleshooting.On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electricschemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of theelectric system.The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,there have been defined a set of symbols to classify warnings and a set for assistance operations.

PRELIMINARY REMARKS

General dangerIt includes the dangers of above described signals.

Danger of serious damage for the vehiclePartial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimesguarantee lapse too.

Environment protectionIt indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.

Danger for personsMissing or incomplete observance of these prescriptions can cause serious danger for persons safety.

SYMBOLS - WARNINGS

It indicates an additional explanation for a piece of information.

!

NOTE

Print 603.93.651 Base - March 2006I

Base - March 2006 Print 603.93.651II

SYMBOLS - ASSISTANCE OPERATIONS

RemovalDisconnection

Intake

RefittingConnection

Exhaust

RemovalDisassembly

Operation

Fitting in placeAssembly Compression ratio

Tighten to torqueToleranceWeight difference

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

RegulationAdjustment

AngleAngular value

Visual inspectionFitting position check

Preload

MeasurementValue to findCheck

Number of revolutions

Equipment Temperature

Surface for machiningMachine finish bar

Pressure

InterferenceStrained assembly

OversizedHigher than.Maximum, peak

ThicknessClearance

UndersizedLess than.Minimum

LubricationDampGrease

SelectionClassesOversizing

SealantAdhesive

Temperature < 0 CColdWinter

Air bleedingTemperature > 0 CHotSummer

ReplacementOriginal spare parts

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 andTROUBLE CODE document.As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).

Product Code:

The first and second figures identify the PRODUCT within motor vehicle.

Example :

Product 50 = Vehicle chassis;Product 52 = Axles;Product 53 = Transmission;Product 76 = Electric ssystem.

Unit Code:

The third and fourth figures identify the UNIT within the PRODUCT.

Example :

Product 50 = Vehicle chassis;Unit 01 = Chassis;Unit 02 = Bumpers;Unit 03 = Alternator.

Sub-assembly Code:

The fifth and sixth figures exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT.

Example :

Product 50 = Vehicle chassis;Unit 01 = Chassis;Sub-assembly 40 = Chassis cross members;Sub-assembly 13 = Rotor.

PRODUCT CODE

5 0PRODUCT UNIT SUB-ASSEMBLY

COMPONENT

0 1

4 0

7 6

0 3

1 3

PRODUCT UNIT SUB-ASSEMBLYCOMPONENT





Print 603.93.651 Base - March 2006III

GENERAL WARNINGS

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contactimmediate superiors where a danger situation occurs which is not described.

Use both specific and general-purpose toolings according to the prescriptions contained in respective use andmaintenance 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 onthe 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. The use of said meansis 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 fromaccidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could bedangerous 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. Scrupulouslyobserve all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repairintervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph Controlscare of user of Use and Maintenance handbook.

In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave unmanneda vehicle in motion during repair interventions.

Keep the vehicle stationary by proper chocks.

In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special supportstands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated.

When it is necessary to perform an intervention on methane-fed vehicles, observe the indications contained inside thedocument, as well as all specific safety regulations provided.

Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressureout.

Inflammable fuel and all inflammable fluids and liquidsmust be handledwith care, according towhat contained on harmfulmaterials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flamesor sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquidsaccording to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitablecontainers.

Worn out, damaged or consumable parts must be replaced by Iveco original spares.

Duringworkshop activity, always keep thework place clean; timely clear or clean floors from accidental liquid or oil 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 observeindications specified in relating manual sections.

!

Base - March 2006 Print 603.93.651IV

GENERAL WARNINGS

Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up detachedor 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 isavailable to give all clarifications necessary to perform repair interventions not provided in this document.

Before welding:

- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)and detach connectors.

- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.

- Await about 15 minutes before welding.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materialsflow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic centralunits.

The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contactwith moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,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 or from paint welding because they can cause damages to health; operateoutdoors 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 seriousburns. 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.

Print 603.93.651 Base - March 2006V

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

To start up the engine, do not use fast chargers. Start upmust only be performedwith either separate batteries or specialtruck.

A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of 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 tighteningtorque.

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/bodystructure.

Once the intervention on the electric system has been completed, recover connectors and wiring harnesses accordingto original arrangement.

Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during keymemorisation:1 Pay attention that jamming sources are not present in the cab or near the keys.2. Keys not insered in the panel must be at least 1 meter away.

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 batteryterminals.

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 screeningbraiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenanceinterventions.

Measurements in drive electronic central units, plugged connections and electric connections to components can onlybe made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, whichwould later cause contact problems.

Connectors presentmust be seen from cable side. Connectors views contained in themanual are representative of cableside.

!

NOTE

Base - March 2006 Print 603.93.651VI

Print 603.93.651 Base - March 2006VII

Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and star-connected to each other, tryingthen 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 units must be connected to system bonding when they are provided with a metallic shell.

- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard openingbonding (avoiding serial or chain connections), and to battery negative terminal.

- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).

- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).

- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTORd. DISTANCE! 0

88039

Figure 1

Figure 2

Base - March 2006 Print 603.93.651VIII

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONSAccessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mountinginstructions (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) sockets inorder to simplify and normalise the electrical intervention that is care of preparation personnel.For any exception to mounting instructions, IVECOs authorisation is necessary.Lack of observance of above described prescriptions involves guarantee lapse.

It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,the data interconnection line between central units (CAN line) is to be considered inviolable.

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THEINTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power1 kW = 1.36 metric HP1 kW = 1.34 HP1 metric HP = 0.736 kW1 metric HP = 0.986 HP1 HP = 0.746 kW1 HP = 1.014 metric HP

Torque1 Nm = 0.1019 kgm1 kgm = 9.81 Nm

Revolutions per time unit1 rad/s = 1 rpm x 0.10461 rpm = 1 rad/s x 9.5602

Pressure1 bar = 1.02 kg/cm2

1 kg/cm2 = 0.981 bar1 bar = 105 Pa

Where accuracy is not particularly needed:

- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1

1 kgm = 10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1

1 kg/cm2 = 1 bar.

Temperature0 C = 32 F1 C = (1 x 1.8 + 32) F

Print 603.93.651 Base - March 2006

DAILY EURO 4

Print 603.93.651 1st editionBase March 2006

UPDATE DATA

Section Description Page Revision date

Base - March 2006 Print 603.93.651


Section

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

INDEX OF SECTIONS

GENERAL 1DAILY EURO 4


Print 603.43.671

SECTION 1

General

Page

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

- Vehicle Identification Plate 3. . . . . . . . . . . . . . . .

COMPOSITION OF MODELS 4. . . . . . . . . . . . . .

ALPHANUMERICAL CODING FORBUS IDENTIFICATION 6. . . . . . . . . . . . . . . . .

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

2 GENERAL DAILY EURO 4


Print 603.43.671

Vehicle identification plate

Plate legend

Manufacturer tagFor vehicle identification according

to the EC directive(on the front crosspiece)

ChassisStamping

(at the front on the chassis right-hand side-member)

EngineStamping

(on the right side on the engine base)

1) Approval number2) Chassis number3) PTT - Total weight on ground4) MTC - Total combined weight5) Max. weight permitted on the front axle6) Max. weight permitted on the rear axle7) Specific indication of type8) Wheelbase (mm)9) Type of engine

10) Engine rating11) Permitted smoke level12) Place of manufacture13) Number of vehicle axles

Figure 1

Figure 2

108533

108534



IDENTIFICATION DATA



COMPOSITION OF MODELS

ASSEMBLIES

MODELS

29L10

29L12

29L14

35S10

35S12

35S14

35S18

35C10

35C12

35C14

35C15

35C18

40C10

40C12

40C15

40C18

F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV o o o o

F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV o o o o

F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV o o o

F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV o o

F1CE0481F*C (DPF series) 146 CV

F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV o o

F1CE0481H*C (DPF series) 176 CV o

Single disk 9 1/4 o o o o o o o o

Single disk 10 1/2 o o o o Single disk 11 o o o o o

ZF 5 S300 V V V V V V V V V V V

ZF 6 S400 O.D. V V V V V

ZF 6 S400A O.D. V V V V V V V V V V V V V V V V

5817 o o o o o o o

5818

5819 o o o o

5823

NDA R.S. o o o o o o o

NDA R.G. o o o o o

450511 o o o o

450517/2

Rack-and-pinion Powered steering o o o o o o o o o o o o o o o o

FRONT MECHANICAL SUSPENSIONS:independent with transverse leaf spring (MK3) o o o o o o o o o o o

independent with torsion bars () () () () () o o o oREARMECHANICAL

Parabolic o o o o o o o Z Z Z Z Z Z Z Z ZMECHANICALSUSPENSIONS:

- single leaf o o o o o o oSUSPENSIONS:

- reinforced o o o o o o o

Semi-elliptical s s s s s s s s sSemi-ellipticwith leaf spring

z z z z z z z z z

REAR AIR SUSPENSIONS V V V V V V V V V V V V V V V V

O.D. = Over Drive() Optional extra (with max load of 1900 kg)o Standard with ZF 6 S 400 A O.D. gearboxV Alternative

Vehicles with front suspension with transverse leaf springVehicles with front suspension with torsion bars

z Chassis cabs only, as an alternative

s Standard on chassis cabs, Alternatively on Vans Chassis Cowlsand Cut Aways

Z Standard onVans, Chassis Cowls andCut Aways Alternativelyon Chassis Cabs

S Single rear wheelsL Light with single rear wheelsC Twin rear wheels



COMPOSITION OF MODELS

ASSEMBLIES

MODELS

45C15

45C18

50C15

50C18

60C15

60C18

65C15

65C18

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 o o o o

Single disk 9 1/4Single disk 10 1/2Single disk 11 o o o o o o o oZF 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

5819 o o o o

5823 o o o o

NDA R.S.

NDA R.G.

450511 o o o o

450517/2 o o o o

Rack-and-pinion Power steering o o o o o o o o

FRONT MECHANICAL SUSPENSIONS:independent with transverse leaf spring (MK3)independent with torsion bars o o o o o o o o

Parabolic Z Z Z Z Z Z Z Z- single leaf- reinforced

Semi-elliptical s s s s s s s s

Semi-ellipticwith leaf spring

z z z z z z z z

REAR AIR SUSPENSIONS V V V V V V V V

O.D. = Over Drive() Optional extra (with max load of 1900 kg)o StandardV Alternative

Vehicles with front suspension with transverse leaf springVehicles with front suspension with torsion bars

z Chassis cabs only, as an alternative

s Standard on chassis cabs, Alternatively on Vans Chassis Cowlsand Cut Aways

Z Standard onVans, Chassis Cowls andCut Aways Alternativelyon Chassis Cabs

S Single rear wheelsL Light with single rear wheelsC Twin rear wheels



ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION

A LIGHT ROAD VEHICLES

A T 25C 29 L

B T 30C 35 S

C T 35C 35 C

D T 40C 40 C

E T 50C50 C45 C

F T 65C60 C65 C

CUSTOMIZED VEHICLE (V.P.)

PROGRAMMING FAMILY

MARKET VEHICLE (V.M.)

STANDARD VEHICLE (V.C.B.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

RANGE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14

CHASSIS CABS AND DERIVATIVES



H T 25V 29 L

K T 30V 35 C

J T 35V 35 C

L T 40V 40 C

M T 50V50 C45 C

N T 65V60 C65 C

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

E4 = Euro 4LD = Light DutyHD = Heavy Duty

ENGINE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

PROGRAMMING FAMILY

1 2 3 4 5 6 7 8 9 10 11 12 13 14

VANS AND DERIVATIVES



A Mechanical suspension: front with transverse leaf spring.

B Mechanical suspension: front with torsion bars.

C Mechanical front suspension with transverse leaf spring rear air suspension.

D Mechanical front suspension with torsion bars rear air suspension.

29 L10 () - 29 L12 () - 29 L14 ()35 S10 () - 35 S12 () - 35 S14 () - 35 S18 ()

1 CHASSIS

35 S10 () - 35 S12 () - 35 S14 () - 35 S18 ()35 C10 () - 35 C12 () - 35 C15 () - 35 C18 ()40 C10 () - 40 C15 () - 40 C18 ()1 CHASSISCAB 40 C10 () - 40 C15 () - 40 C18 ()45 C15 () - 50 C15 () - 50 C18 ()60 C15 () 60 C18 ()60 C15 () - 60 C18 ()65 C15 () - 65 C18 ()

29 L10 D () - 29 L12 D () - 29 L14 D () -35 S10 D () - 35 S12 D () - 35 S14 D () -

6CHASSISCAB

35 S10 D () - 35 S12 D () - 35 S14 D () -35 S18 D () - 35 C10 D () - 35 C12 D () -35 C15 D () 35 C18 D () - 40 C10 D () -6 CAB

6 + 135 C15 D () - 35 C18 D () - 40 C10 D () -40 C12 D () - 45 C15 D () - 45 C18 D ()50 C18 D () 60 C15 D () 60 C18 D ()50 C18 D () - 60 C15 D () - 60 C18 D () -65 C15 D () - 65 C18 D ()

35 S12 CC () - 35 S 14 CC () - 35 S18 CC () -35 C12 CC () 35 C15 CC () 35 C18 CC ()

0 CHASSIS35 C12 CC () - 35 C15 CC () - 35 C18 CC () -40 C12 CC - 40 C15 CC () - 40 C18 CC ()0 CHASSISCOWL40 C12 CC 40 C15 CC ( ) 40 C18 CC ( )45 C15 CC - 45 C18 CC ()50 C15 CC () - 50 C18 CC ()50 C15 CC () - 50 C18 CC ()60 C18 CC () - 65 C18 CC ()

35 S12 CCR () - 35 S14 CCR () - 35 S18 CCR()35 C12 CCR () 35 C15 CCR () 35C18CCR()

RCHASSISCOWL

35 C12 CCR () - 35 C15 CCR () - 35C18CCR()40 C12 CCR () - 40 C15 CCR () - 40C18CCR()R COWL

SHORT

40 C12 CCR ( ) 40 C15 CCR ( ) 40C18CCR( )45 C15 CCR () - 45 C18 CCR ()50 C15 CCR () - 50 C18 CCR ()50 C15 CCR () - 50 C18 CCR ()60 C18 CCR () - 65 C18 CCR ()

() Also available in the A (automatic transmission) and /P (pneumatic rear suspensions) versions.

SUSPENSION

1 2 3 4 5 6 7 8 9 10 11 12 13 14

VERSION

1 2 3 4 5 6 7 8 9 10 11 12 13 14



35 C10 CA () - 35 C12 CA ()A CUT-AWAY

35 C10 CA () - 35 C12 CA ()40 C10 CA () - 40 C12 CA ()

A CUT-AWAY40 C10 CA ( ) 40 C12 CA ( )45 C18 CA () - 50 C18 CA ()60 C18 CA ( ) 65 C18 CA ( )

( ) ( )60 C18 CA () - 65 C18 CA ()

29 L10 V () - 29 L12 V () - 29 L14 V ()35 S10 V () - 35 S12 V () - 35 S14 V ()35 S18 V ()

4 VAN

35 S18 V ()35 C10 V () - 35 C12 V () - 35 C15 V ()35 C18 V ()4 VAN 35 C18 V ( )40 C12 V () - 40 C15 V () - 40 C18 V ()45 C15 V () - 45 C18 V ()50 C15 V () - 50 C18 V ()50 C15 V () - 50 C18 V ()60 C15 V () - 60 C18 V ()65 C15 V () - 65 C18 V ()

29 L10 SV () - 29 L12 SV () - 29 L14 SV ()35 S10 SV () - 35 S12 SV () - 35 S14 SV () -35 S18 SV ()

V SEMI-GLAZE

35 S18 SV ()35 C10 SV () - 35 C12 SV () - 35 C15 SV () -35 C18 SV ()V SEMI GLAZED VAN35 C18 SV ( )40 C10 SV () - 40 C12 SV () - 40 C15 SV () -40 C18 SV () -45 C15 SV () - 45 C18 SV ()45 C15 SV () - 45 C18 SV ()50 C15 SV () - 50 C18 SV ()

VENDOR 35 S12 CV () - 35 S14 CV ()U

VENDORVERSION

35 S12 CV () - 35 S14 CV ()35 C12 CV () - 40 C12 CV -

U VERSIONCITY35 C12 CV ( ) 40 C12 CV45 C15 CV () - 45 C18 CV ()50 C15 CV ( ) 50 C18 CV ( )VAN

( ) ( )50 C15 CV () - 50 C18 CV ()

5 COMBI 29 L14 C () - 35 S14 C ()5 COMBI 29 L14 C () - 35 S14 C ()

8 CAMPER 35 S14 () - 35 S18 ()8 CAMPER 35 S14 ( ) 35 S18 ( )35 C14 () - 35 C18 ()35 C14 ( ) 35 C18 ( )

CHASSIS-COWL

9COWLSHORTVERSION FOR

35 S14 CCRC () - 35 S18 CCRC -35 C14 CCRC () - 35 C18 CCRCVERSION FOR

CAMPER VAN

35 C14 CCRC ( ) 35 C18 CCRC

() Also available in the A (automatic transmission) and /P (pneumatic rear suspensions) versions.

VERSION

1 2 3 4 5 6 7 8 9 10 11 12 13 14



13000 mm(T25C - T30C - T35C - T40C - T25V - T30V -T35V - T40V - T50V)

2 3000 L mm(T25V - T30V - T35V - T40V - T50V)

3 3300 mm(T25V - T30V - T35V - T40V - T50V)

4 3450 mm(T25C - T30C - T35C - T40C - T50C - T65C)

5 3750 mm(T30C - T35C - T40C - T50C - 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)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

WHEELBASE



A 5 SPEED (5 S 300)

B 6 SPEED (6 S 400 O.D.)

C 6 SPEED (6 S 400 A O.D.)

A AutomatedO.D. Over Drive

1 2 3 4 5 6 7 8 9 10 11 12 13 14

GEARBOX



LEFT-HAND DRIVE(T25C - T30C - T35C - T40C - T50C) 1

LEFT-HAND DRIVE AND INTERNAL HEIGHT OFLOADING BAY H1 = 1545 mm(T25V - T30V - T35V - T40V - T50V)

1

LEFT-HAND DRIVE AND INTERNAL HEIGHT OFLOADING BAY H2 = 1900 mm(T25V - T30V - T35V - T40V - T50V)

2

LEFT-HAND DRIVE AND INTERNAL HEIGHT OFLOADING BAY H3 = 2100 mm(T30V - T35V - T40V - T50V)

3

RIGHT-HAND DRIVE(T25C - T30C - T35C - T40C - T50C) A

RIGHT-HAND DRIVE AND INTERNAL HEIGHT OFLOADING BAY H1 = 1545 mm(T25V - T30V - T35V - T40V - T50V)

A


B


C

DRIVE INTERNAL HEIGHT OF LOADING BAY

1 2 3 4 5 6 7 8 9 10 11 12 13 14

MANDATORY MARKET OPTIONAL EXTRAS

1 2 3 4 5 6 7 8 9 10 11 12 13 14

OPTIONAL EXTRAS REQUIRED BY THE CUSTOMER

1 2 3 4 5 6 7 8 9 10 11 12 13 14



REPLENISHING FLUIDS

IVECO RECOMMENDED LUBRICANTS PARTS TO BE REPLENISHED QuantityLitres kg

Quantity of oil in circulation in the car-tridge filter and heat exchanger 1.4 1.23

Total dry engine capacity 5.7 5.02

Urania DailyUrania LD 5

Sump capacity:- max level- min level

4.33

3.782.65y

Urania LD 5Quantity of oil in circulation in the car-tridge filter and heat exchanger 1 0.88

Total dry engine capacity 7.6 6.79Sump capacity:- max level- min level

6.64.29

5.813.78

Max. gradient negotiable by vehicle uphill/downhill with oil at minimum level 30%!

GearboxZF 5S 300 2 1.8

Tutela TRUCK GEARLITE ZF 6S 400 O.D. 2.2 1.98

ZF 6S 400 A O.D. 2.7 2.43

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

TutelaW140/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

Paraflu11 * Cooling system 9 -

* = Protective anti-freeze (concentration 50%, freezing point 35C)



International lubricant description FL Group products

Engine oil meets specifications:ACEA B5 with synthetic base SAE 5W30ACEA E3/E5 with mineral base SAE 15W40

Urania DailyUrania LD5

Differential and wheel hub oil meets specifications:API GL-5 with mineral base SAE 85W140API GL-5 with mineral base SAE 80W90

Tutela W 140/M - DA (1)Tutela W 90/M - DA (2)

Mechanical gearbox oil containing non-EP anti-wear additivesMeets specification API GL 4 SAE 75W80

Tutela Truck Gearlite

Hydrostatic transmission and power steering oilMeets specifications: ATF-DEXRON II D

Tutela GI/A

General-purpose greaselithium soap based grease N.L.G.I. fluidity no. 2

Tutela MR 2

Specific grease for wheel hubs and bearingslithium soap based grease N.L.G.I. fluidity no. 3

Tutela MR 3

Hydraulic brake and clutch control fluidIn conformity with N.H.T.S.A. standards No. 116, ISO 4925Standard SAE J 1703, IVECO STANDARD 18-1820

Tutela TRUCK DOT SPECIAL

Windscreen washer liquidMixture of spirits, water and surfactants CUNA NC 956-11

Tutela Professional SC 35

Concentrated protective radiator fluidethylene glycol based containing corrosion inhibitors,in conformity with Iveco Standard 18-1830

Paraflu11(3)

(1) Hot or temperate climate(2) Specific for cold climes.(3) 100% Paraflu to be diluted with water to 50%

3595

50 10

032

14 -10

-15

-25oCoF

-13

5

SAE 40

SAE 30

SAE20W

SAE10W

SAE15W/40

SAE 5W 30

Figure 3

108535

F1A ENGINE 1DAILY EURO 4

Base - March 2006Print 603.93.651

SECTION 2

5401 Engine

Page

F1A ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1C ENGINE 157. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 F1A ENGINE DAILY EURO 4




F1A Engine

Page

MAIN OPERATIONS ON ENGINE MOUNTEDON VEHICLE 7. . . . . . . . . . . . . . . . . . . . . . . . .

- Service procedures to be performed after replacinghigh-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 steering pump-alternator belt replacement 14

- Disassembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Assembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing air-conditioning compressor 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD REMOVAL AND REFITTING 19

- Removal 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING HIGH-PRESSURE PUMP CPH1 22. . .

- Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING WATER PUMP 22. . . . . . . . . . . . . . .

- Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREHEATING PLUG REMOVAL/REFITTING 23. . .

- Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE VALVE ASSEMBLY REMOVAL-REFITTING 23



Page

- Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E.G.R. VALVE REMOVAL/REFITTING 24. . . . . . . . .

- Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEAT EXCHANGER REMOVAL/REFITTING 24. . .

- Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BURNT GAS EXHAUST SYSTEM 25. . . . . . . . . . . .

- Description 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OXICAT - OXYDIZER CATALYST 25. . . . . . . . . .

- Description 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST PIPE ASSEMBLY REMOVAL/REFITTING 27

- Removal 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLYCOMPONENTS (SYSTEMS EQUIPPED WITH D.P.F.CATALYST) 28. . . . . . . . . . . . . . . . . . . . . . . . . .

- Exhaust silencer removal 28. . . . . . . . . . . . . . . . .

- Replacing D.P.F. catalyst 29. . . . . . . . . . . . . . . . . .

- Refittingl 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- D.P.F. catalyst removal 28. . . . . . . . . . . . . . . . . . .

- Replacing differential sensor (delta-p) 29. . . . . . . .

ENGINE VIEWS 30. . . . . . . . . . . . . . . . . . . . . . . . . .

EMISSIONS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE IDENTIFICATION CODE 34. . . . . . . . . . .

CHARACTERISTICS CURVES 35. . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS 39. . . . . . . . . . . . . . .

ASSEMBLY DATA CLEARANCES 40. . . . . . . . . .

TOOLS 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPERIMENTAL TOOLS 52. . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE 63. . . . . . . . . . . . . . . . . . .

OVERHAULING ENGINE 68. . . . . . . . . . . . . . . . . .

DISASSEMBLING THE ENGINE AT THE BENCH 68

REPAIRS 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER BLOCK 78. . . . . . . . . . . . . . . . . . . . . . .

- Checks and measurements 78. . . . . . . . . . . . . . . .

- Checking head mating surfae on cylinder block 78

CRANKSHAFT 79. . . . . . . . . . . . . . . . . . . . . . . . . .

Page

- Measuring main journals and crank pins 79. . . . . .

- Checking crankshaft 80. . . . . . . . . . . . . . . . . . . . .

- Replacing timing control gear 82. . . . . . . . . . . . . .

ENGINE ASSEMBLY 82. . . . . . . . . . . . . . . . . . . . . .

- Assembling main bearings 82. . . . . . . . . . . . . . . . .

- Measuring main journal assembly clearance 82. . .

- Checking crankshaft end float 83. . . . . . . . . . . . . .

- Assembling rear seal 84. . . . . . . . . . . . . . . . . . . . .

ENGINE FLYWHEEL 85. . . . . . . . . . . . . . . . . . . . . .

- Replacing bearing supporting gearbox input shaft 85

CONNECTING ROD PISTON ASSEMBLY 86. . .

- Pistons 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Disassembly 86. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring piston diameter 87. . . . . . . . . . . . . . . .

- Piston pins 87. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Conditions for correct pin-piston coupling 87. . . .

- Piston rings 87. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connecting rods 88. . . . . . . . . . . . . . . . . . . . . . . .

- Bushes 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking connecting rod 89. . . . . . . . . . . . . . . . .

- Checking bending 89. . . . . . . . . . . . . . . . . . . . . . .

- Assembling connecting rod-piston assembly 89. . .

- Checking for connecting rod piston distortion 90

- Fitting piston rings 90. . . . . . . . . . . . . . . . . . . . . . .

- Assembling connecting rod piston assembliesin cylinder barrels 90. . . . . . . . . . . . . . . . . . . . . . .

- Measuring crankpin assembly clearance 91. . . . . .

- Checking piston protrusion 91. . . . . . . . . . . . . . .

CYLINDER HEADS 92. . . . . . . . . . . . . . . . . . . . . . .

- Disassembly 92. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing valves 92. . . . . . . . . . . . . . . . . . . . . . . .

- Checking cylinder head seal 93. . . . . . . . . . . . . . .

- Checking cylinder head mating surface 93. . . . . . .

VALVES 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing deposits, refacing and checking valves 93

- Checking clearance between valve stem and valveguide and centring valves 94. . . . . . . . . . . . . . . . .

VALVE GUIDE 94. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing valve guide 94. . . . . . . . . . . . . . . . . . . .



Page

- Boring valve guides 94. . . . . . . . . . . . . . . . . . . . . .

VALVE SEATS 95. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Recutting and replacing valve seats 95. . . . . . . . . .

VALVE SPRINGS 96. . . . . . . . . . . . . . . . . . . . . . . . .

ROCKER ARMS TAPPETS 96. . . . . . . . . . . . . . . .

- Checks 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING CYLINDER HEADS 97. . . . . . . . . . .

- Overhead 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Overhead removal 98. . . . . . . . . . . . . . . . . . . . . .

TIMING SYSTEM 99. . . . . . . . . . . . . . . . . . . . . . . . .

- Description 99. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checks 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking cam lift and pin alignment 100. . . . . . . . .

- Assembling overhead 102. . . . . . . . . . . . . . . . . . . .

- Assembling front seal ring 103. . . . . . . . . . . . . . . . .

- Refitting cylinder head 106. . . . . . . . . . . . . . . . . . .

- Camshaft drive 107. . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION 115. . . . . . . . . . . . . . . . . . . . . . . . . .

- General 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL VACUUM PUMP ASSEMBLY (GPOD) 117. . . . .

- Oil pump 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Characteristic data 117. . . . . . . . . . . . . . . . . . . . . .

- Vacuum pump 117. . . . . . . . . . . . . . . . . . . . . . . . .

- Oil pressure control valve 118. . . . . . . . . . . . . . . .

- Oil filter 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Modine heat exchanger 118. . . . . . . . . . . . . . . . . .

- Oil vapour recirculation system 119. . . . . . . . . . . .

- Description 119. . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Description 121. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Operation 121. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Electromagnetic pulley 123. . . . . . . . . . . . . . . . . . .

- Water pump 123. . . . . . . . . . . . . . . . . . . . . . . . . .

- Thermostat 123. . . . . . . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGING 124. . . . . . . . . . . . . . . . . . . . . .

- Description 124. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

- Turbocharger (KKK K03-2074-CCB 5.88 type) 125

REPAIRS 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Pressure relief valve 126. . . . . . . . . . . . . . . . . . . . .

- Checking pressure relief valve 126. . . . . . . . . . . . . .

- GARRET GT 17 variable geometryturbosupercharger 127. . . . . . . . . . . . . . . . . . . . . .

- General 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Operation at low engine rpm 127. . . . . . . . . . . . . .

- Operation at high engine rpm 127. . . . . . . . . . . . .

- Proportional solenoid valve controlling turbochargeractuator 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Actuator 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPAIRS 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking and adjusting the actuator 129. . . . . . . . .

EXHAUST GAS RECIRCULATION (EGR) SYSTEM(EXHAUST GAS RECIRCULATION) 130. . . . . . .

- EGR system operation 130. . . . . . . . . . . . . . . . . . .

- Main system components 131. . . . . . . . . . . . . . . . .

- E.G.R. valve 131. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Modulator solenoid valve 131. . . . . . . . . . . . . . . . .

- Air flow rate meter (flow meter) 131. . . . . . . . . . .

- Heat exchanger 132. . . . . . . . . . . . . . . . . . . . . . . .

- Throttle valve assembly 132. . . . . . . . . . . . . . . . . .

EXHAUST POLLUTANT REDUCTION SYSTEM WITHDPF CATALYST (ON REQUEST) 133. . . . . . . . .

- General 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.P.F. (DIESEL PARTICULATE FILTER) CATALYST 134

- Description 134. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTICULATE FILTER REGENERATION SYSTEM 135

- Operation 135. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Forced regeneration 136. . . . . . . . . . . . . . . . . . . . .

- Refilling engine oil 136. . . . . . . . . . . . . . . . . . . . . . .

FUEL SUPPLY 137. . . . . . . . . . . . . . . . . . . . . . . . . . .

HIGH-PRESSURE ELECTRONICINJECTION SYSTEM (MS 6.3 - EDC 16) 137. . . .

- General 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM OPERATION 139. . . . . . . . . . . . . . . . . . . .

- Self-diagnosis BLINK CODE 139. . . . . . . . . . . . .



Page

- Immobilizer recognition 139. . . . . . . . . . . . . . . . . .

- Checking fuel temperature 139. . . . . . . . . . . . . . . .

- Checking engine coolant temperature 139. . . . . . .

- Checking quantity of fuel injected 139. . . . . . . . . . .

- Checking idling adjustment 139. . . . . . . . . . . . . . . .

- Fuel cut-off in release phase 139. . . . . . . . . . . . . . .

- Checking cylinder balancing on idling 139. . . . . . . .

- Checking regular engine rotation (anti-sawing) 139.

- Checking smokiness at exhaust on acceleration 139

- Checking exhaust gas recirculation (E.G.R.) 139. . .

- Checking top speed limit 139. . . . . . . . . . . . . . . . .

- Checking regular rotation on acceleration 139. . . .

- Checking glow plug control unit 139. . . . . . . . . . . .

- Checking activation of air-conditioning system 139.

- Checking fuel pump 139. . . . . . . . . . . . . . . . . . . . .

- Checking diesel warming 140. . . . . . . . . . . . . . . . .

- Checking cylinder position 140. . . . . . . . . . . . . . . .

- Checking pilot and main injection timing 140. . . . .

- Checking injection pressure closed cycle 140. . . . .

- Fuel supply 140. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Correcting flow rate according to watertemperature 140. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Correcting flow rate to avoid noise, smokeor overloading 140. . . . . . . . . . . . . . . . . . . . . . . . .

- De-rating 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Injection timing electronic test 140. . . . . . . . . . . . .

- Speed governor 140. . . . . . . . . . . . . . . . . . . . . . . .

- Engine starting 140. . . . . . . . . . . . . . . . . . . . . . . . .

- Cold starting 141. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Warm starting 141. . . . . . . . . . . . . . . . . . . . . . . . .

- Run up 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- After run 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Cut-off 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Cylider balancin 141. . . . . . . . . . . . . . . . . . . . . . . .

- Synchronisation search 141. . . . . . . . . . . . . . . . . . .

OPERATION 143. . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM 146. . . . . . . . . . . . . . . . . . . . .

Page

- Fuel pump 146. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fuel filter UFIfilters 147. . . . . . . . . . . . . . . . . . . .

- Fuel filter Filtrauto 148. . . . . . . . . . . . . . . . . . . . .

- Fuel pipes 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- High-pressure pump CPH1 149. . . . . . . . . . . . . . .

- Pressure control valve 150. . . . . . . . . . . . . . . . . . .

- Replacing pressure regulator 150. . . . . . . . . . . . . . .

- Hydraulic accumulator (rail) 151. . . . . . . . . . . . . . .

ELECTRO-INJECTORS 152. . . . . . . . . . . . . . . . . . . .

- Operation 152. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing an electrical injector 152. . . . . . . . . . . . .

ELECTRIC/ELECTRONIC COMPONENTS 153. . . . .

- Electronic control unit EDC 16 153. . . . . . . . . . . .

- Glow plug electronic control unit 154. . . . . . . . . . .

- Glow plugs 154. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SENSORES 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Engine speed sensor 154. . . . . . . . . . . . . . . . . . . . .

- Camshaft timing sensor 154. . . . . . . . . . . . . . . . . .

- Air temperature and pressure sensor 155. . . . . . . .

- Fuel temperature sensor 155. . . . . . . . . . . . . . . . .

- Fuel pressure sensor 155. . . . . . . . . . . . . . . . . . . . .

- Atmospheric pressure sensor 155. . . . . . . . . . . . . .

- Engine coolant temperature sensor 155. . . . . . . . .

- Throttle pedal position sensor 155. . . . . . . . . . . . .

- Clutch pedal position sensor 155. . . . . . . . . . . . . .

- Brake pedal position sensor 155. . . . . . . . . . . . . . .

- Vehicle speed sensor 155. . . . . . . . . . . . . . . . . . . .

- Differential pressure sensor - deltap (p) 155. . . .- Exhaust gas temperature sensor 155. . . . . . . . . . . .

ACTUATORS 156. . . . . . . . . . . . . . . . . . . . . . . . . . .

- PWM (Pulse Width Modulation) controls 156. . . .

MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE

Keep to the following instructions before doing any work on the engine involving components of the fuel supply system.

- Before doing any work on the engine, perform the engine/vehicle fault diagnosis with specific IVECO diagnosisequipment and print out the results.

- Replacement of the MS6.3 or EDC 16control unit must be authorized by the Help Desk. Replacing operationrequires reprogramming as described in specific section.

- Following components in feed system cannot be overhauled but have to be replaced: pressure relief valve, if present,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 by the supplier in sheets of oiled paper and are stored incardboard 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 thisreason, the plugs protecting the hydraulic parts and sensors must be removed just prior to positioning in their seats.

- Take care over the direction of assembly for all electrical connections.

- All threaded connections must be tightened to the prescribed torque.

- All the quick-coupling connectors (on the engine they are found on the high-pressure pump and on the diesel drainmanifold) must be fully inserted. To drive them out, press on the tabs at the base of the connectors.

Electro-injectorNone of the couplings/unions/nuts on the injector body may be handled. It is neither necessary nor permitted todismantle 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 springmust 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. Whenassembling, rest the recirculation connector in its seat and apply a vertical force while keeping the retaining springpressed in the direction of the engine. Fitting in has to be easy.Replacing one or more electrical injectors requires central unit programming as described in specific section.

CP1H High-pressure pumpIf 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 pipesEach 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 pumpwell secured and taking care to keep the hexagon on the component side stationary, space permitting.

Hydraulic accumulator (rail) and accessoriesThe pressure sensor can be assembled five consecutive times; after that, it must be replaced. They must be lubricatedwith a thin layer of oil before being mounted..Replacing the sensor requires central unit programming as described in specific section.



Service procedures to be performed afterreplacing high-pressure feeding system and/orexhaust gas post-treatment systemcomponents

To ensure correct operation of the engine, the CP1 controlunit 16 stores, in thememory non-labile area, the informationrelative to the engine parameters originally set or acquiredduring engine operation.

As a result, after any of the operations below is carried out:

- replacing one or several injectors,

- replacing all the injectors,

- replacing the air flow meter,

- replacing the hydraulic accumulator pressure sensor(common rail),

- replacing the EDC control unit 16;

- changing the engine oil,

- replacing the D.P.F. catalyst,

- replacing the filter differential pressure (Dp) sensor,

- replacing any significant component as regards emissionlevels,

- performing forced regeneration,

the control unit shall be programmed again by means of theIVECOMODUS - E.A.SY. - IT 2000 diagnosis instrument, andthe replacement procedure for the concerned componentshall be performed, in accordance with the indications of thediagnosis instruments used.



540110 POWER UNIT REMOVAL/REFITTING

108554

Figure 1RemovalPlace the vehicle on the pit or auto lift.

Lift the engine hood (28), undo the fastening screws (28) andthen remove the hood; remove supporting rod (30).

Disconnect negative cable (11) and positive cable (4) frombattery (10), then remove the latter from the enginecompartment.

Disconnect electric connections (5, 7, 8 and 9) and enginecable (6) from the EDC control unit, then release the enginecable from the straps securing the same to the cab.

Unhook cable (31) from the hood opening control devices.

Disconnect front headlamp electric connections (12).

Remove screws (19), then take off cover (18).

Remove fastening screws (32), then take off headlamp inserts(13).

Do not change the assembly position of headlampinsert (13) threaded bush (14, detail D).

NOTE

Remove the screws and/or fastening nuts, then removecrosspiece (33).Remove the screws and/or fastening nuts, then removebumper (17).Remove expansion tank (3) cap (2).Act as follows, from under the vehicle (see figure 4):- undo fastening screws (8 and 10), then remove lower side

guards (11);- undo fastening screws (15), then remove lower central

guard (12).Apply a tube (16) to radiator pipe union (detail C), thenunscrew cap (15) and drain the coolant into a suitablecontainer.

If the vehicle is equipped with a cab air-conditioningunit, proceed as follows.

- Fit the unit 99309146 pipes to connections (1)and (24), then blow the gas off theair-conditioning system as described in therespective charter of the Bodywork andchassis section.

- Disconnect electric connection (23) fromdrying filter pressure switch (22).

- Disconnect pipes (20) from air-conditionercompressor (21).

- Ruts (27), then disconnect pipes (25) fromexpansion valve connector (26).

NOTE

Seal the air-conditioning unit pipes and theirrespective mounts, to prevent moisture andimpurities from penetrating into the system.

NOTE



Figure 2Remove nuts (23), then properly place remote-controlswitch/fuse holder (22) aside.

Disconnect pipe (21) from the heat exchanger and theturboblower.

Disconnect pipe (13) from the heat exchanger and thethrottle valve assembly.

Remove fastening screws (12), then remove the radiator/heatexchanger assembly together with the condenser-drying filter,pipes and air conveyor (if any).

Remove oil filling cap (2), then take sound-proofing cover (1)off.

Disconnect tank (5) pressure sensor electric connection (3).

Remove tank (5) fastening nuts (4), then take the tank off thewall.

Disconnect electric connection (6) of the level sensor placedunder tank (5).

Disconnect or remove the coolant pipes:

- (14), from thermostat (11);

- (15), from engine oil heat exchanger (10);

- (19), from pipe (17);

- (18), from radiator (16);

- (20), from the cylinder head.

Properly obstruct the turboblower air outlet toavoid casual penetration of foreign bodies into theturboblower and, therefore, damage to the latter.

NOTE

108555



Figure 3Disconnect cab heater pipe (23) from E.G.R. exchanger outletpipe (22).

Disconnect:

- vacuum pipe (27) from the E.G.R. valve;

- pipe (1), from coalescence filter (25);

- pipe (21), from pipe (19).

Disconnect electric connection (15) from air flowmeter (16).Remove air pipes (14 and 19), together with air flow meter(16), from turboblower (20) and air filter (13).

Disconnect the electric connection from VGT solenoid valve(12, only 136 HP engine).

Disconnect the electric connection from EGR solenoid valve(11).

Disconnect the electric connections (18) from alternator (17).

Disconnect the electric connection from oil level sensor (26).

Disconnect the fuel pipes (3) from the low-pressure pipeassembly.

Disconnect the electric connection (6) from air-conditionercompressor (8).

Disconnect the electric connection (5) from starting motor(4).

Place a container under the power steering pump to recoverthe system oil, then disconnect oil inlet and delivery pipes (9)and (10).

Disconnect the engine ground cable (7).

Apply tool 99360544 (2) to the engine brackets to removethe engine from its own compartment and slightly pull thesame

Properly obstruct the turboblower air outlet toavoid casual penetration of foreign bodies into theturboblower.

NOTE

108556



Act from under the vehicle:

- to disconnect jointed heads (17) of lever shift controlcables (16);

- selection cable (max. pull-out load: 250 N - max. pull-inload: 60 N);

- engagement cable (max. pull-out load: 100 N - max.pull-in load: 80 N).

Use a suitable screwdriver to open out flexible cable fins (18)so that the pawls are disengaged from the support.

Undo fastening screws (22), move clutch control cylinder (23)together with its bracket and properly secure it to the chassis.

Remove the sealing from ring (1), then unscrew the same anddisconnect the speed indicator control cable.

Disconnect electric connection (2) (on 96/116HPengines) or(4) (on 136 HP engines) or (26) (on automatic transmissions)from the reversing light switch.

Figure 4

If it is necessary to detach the gearbox from the engine, takeout the fixing screws and remove the starter motor.

Take out the fixing screws and detach the gearbox from theengine.

The power unit must be removed from the enginecompartment with the greatest care, to avoiddamaging the remaining parts on the vehicle, inparticular the steering box oil pipes.

NOTE

As far as automatic transmission is concerned,strictly adhere to the operations described in therelevant chapter in the Gearbox section.

NOTE

Disconnect exhaust pipe (9) from the turboblower outletpipe.

Disconnect vacuum pipe (29) from VGT actuator (28, only136 HP engine).

Put a jack under the gearbox to support it.

Disconnect the bracket supporting the gearbox on the rearcrosspiece by undoing the four screws (5).

Unscrew the fixing screws (6) and remove the crosspiece (7)supporting the gearbox complete with the gearbox/supportbracket.

Remove nuts (14) securing elastic supports (13) to the chassis.

Remove bolts (3) securing drive shaft (4) to the gearbox;remove, if necessary, screws (24) securing elastic support (25)to the chassis, then properly secure the drive shaft to thechassis.

Take the jack out from under the gearbox.

Lift the engine assembly and take it out of the engine bay.

In case of vehicles equipped with automatictransmission, disconnect gearbox-chassis cableconnector (27) from the control unit.

NOTE

108557



Refitting

To refit the engine assembly, carry out the operationsdescribed for removal in reverse order, following theseinstructions:

- Before refitting the gearbox to the engine, it is necessaryto remove the pressure plate bearing from thediaphragm spring by opening out the retaining circlip.Fit the pressure plate bearing on the sleeve of the driveinput shaft cover, connecting it to the clutch releaselever. Spread the gearbox input shaft with Molikotemolybdenum 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 thepropeller shaft connecting flange. Push the gearbox fullyin so that the pressure plate bearing couples with thediaphragm spring correctly.As regards the 6 S 400 O.D. gearbox units, follow theprocedures described in the specific chapter.

- Pay special attention to the operations needed to installthe engine assembly in the engine bay.

- Check the conditions of the coolant pipes or sleeves andof the air ducts. Replace them if they show any sign ofdeterioration.

- Check the flexible mountings of the assemblies: engineand gearbox. Replace them if they show any sign ofdeterioration.

- Check that the exhaust pipe members have notdeteriorated and are not about to deteriorate. If this isso, replace them along with the flexible parts for securingthem.

- Tighten the screws or nuts to the required torque.

- Meticulously check the state of the vacuum pipe. It mustshow no sign of cracking, cutting, scoring or of beingcrushed. Replace it if there is any doubt at all about itssoundness. When mounting it, make sure the pipe doesnot come into contact with sharp metal parts or cornersor with any particularly hot parts. In addition, afterassembly, the pipe must have no bends or constrictions,its radius of curvature should be broad and it must besecured to the vacuum pump fitting with a suitableclamp.

- make sure that fuel pipes rapid engagement fittings areaccurately clean, and result to have been fully insertedand not going to be disconnected after their beingconnected to relating engagement unions.

- Fill the cooling system with coolant.

- Fill the hydraulic power steering circuit and bleed the airas described under the relevant heading.

- Check the level of oil in the engine and gearbox.

- recharge climate control system (if present) as describedin chapter relating to section Body and chassis;

- check the inclination of light from headlights, if needed.

- no coolant leaks from coolant hose and cab interiorheating hose connection sleeves. Tighten hose clips, ifnecessary;

- no oil leaks from between cover and cylinder head, oilsump and crankcase, oil filter and housing, heatexchanger and crankcase or from lubrication circuit lines;

- no fuel leaks from injection pump and injector lines.Tighten fittings if necessary;

- check that injection pump control linkage allows the flowregulation to perform its full travel in both directions.Otherwise adjust the travel by acting on nuts (1-2, Fig.6);

- check that the engine shut-off device is working properly;

- check that the indicator lights on the instrument paneland relating to the devices disconnected when theengine was removed are working properly.

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 idlefor some time.Check there is no oil leakage from the hydraulic circuit andcheck the level in the tank.Slowly turn the steering wheel in both directions of steeringso that the air in the hydraulic system comes out.Check the level of oil in the tank again and top up if necessary.

501430 Power steering system airbleed

Checks and tests

Start up engine, leave running at a speed slightly inexcess of idle speed and wait for coolant to heatsufficiently to open thermostat. Then check the fol-lowing:

When positioning the engine in the engine bay,take special care not to damage the top pipe of thepower steering and the soundproof-heatproofcladding of the engine bay.Once positioned, meticulously check that the toppipe of the power steering is sound.Before using it again, check that the power steeringoil and coolant contain no impurities. If they do,filter with suitable mesh filters. For any topping up,refer to the REPLENISHING FLUIDS table in theGENERAL section.

NOTE



75248

Figure 5

Disassemble the compressor drive belt, if there is one, asdescribed under the relevant heading.Slacken off the tension of the belt (1) using a specific wrenchon the automatic tightener (2) and remove the belt.

543910 Power steering pump-alternatorbelt replacement

Disassembly

AssemblyMount the drive belt (1) taking care to position itsribs correctly in the respective races of the pulleys.Release the automatic tightener (2). Turn thecrankshaft by one turn to settle the belt.Mount the compressor drive belt, if there is one, andadjust the tension as described under the relevantheading.Fit the middle soundproofing guard back on.

543910 Replacing air-conditioningcompressor drive belt

Disassembly

90155

Cut elastic belt (3), as it cannot be reused.

Figure 6

AssemblyFit the flexible belt (3) equipped with tool 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 fastenthe ring on the compressor support.Turn the drive shaft clockwise until the belt fitsperfectly on the pulley (1).



REPLACING BELTS

108558

Remove the air-conditioner compressor drive belt (11) (ifthere is one) and the water pump / alternator drive belt asdescribed under the relevant headings.Remove the fan (10) from the electromagnetic coupling (8).Disconnect the electrical connection (9) from theelectromagnetic coupling (8).Take out the fixing screws (2) and (3) and remove themounting together with the electromagnetic coupling (8).Take out the screws and remove the fixed tightener (4) andthe automatic tightener (5).Remove screws (7), then disassemble pulley (6).Remove the wiring from the timing cover (12) and dismantlethis.Take off the cap (2) and remove the soundproofing cover(20).Disassemble valve gear cover (12).Disconnect the pipes (19) from the pipe (18).Disconnect the electric connection (28) from sensor (27).Take out the fixing screws (26) and remove the expansiontank (29); disconnect the electrical connection for the levelindicator from the expansion tank and put the tank (29) asideappropriately.Take out the screws (23) and remove the bracket (22) fixingthe soundproofing cover (20).Remove the plugs (24) from the overhead and the plug (14)from the oil pump vacuum pump assembly mounting.Turn the crankshaft clockwise so as to be able to insert the pins99360614 (25) through the holes in the plugs (24) into therelevant holes of the camshafts and pin 99360615 (15)through the hole in the plug (14) into the crankshaft.Loosen the screw (17) securing the automatic tightener (16)and remove the timing belt (13).

541257 Replacing timing drive belt

Remove, by following the power unit detachment procedures,the radiator assembly together with the heat exchanger andthe drying filter condenser (if any), then place it aside properly.

Disassembly

Figure 7



85844

Assembling

Only for the engines featuring intake valve distributing shafts withtapered shank (full section).Insert tool 99360608 (8) into the hole of the toothed pulley (7)and into the corresponding hole of the overhead to preventchanging the assembly position of the toothed pulley (7) in thefollowing operations.Loosen the screw (9) fixing the toothed pulley (7) and, using tool99340028, drive the pulley (7) out of the camshaft.

See frame C: holding the tightener plate (3) stationary with the wrenchinserted in its hexagon, loosen the fixing screw (2).Keeping the fixing screw (2) stationary, turn the plate (3) clockwise until itsreference mark (4) coincides with the reference hole (5) of the fixedportion of the tightener.In the above conditions, tighten the screw (2) to a torque of 36 4 Nm.Rotate the engine by two turns in its direction of rotation until the point oftool 99360615 (1) engagement into the drive shaft is reached. When thispoint is exceeded, the drive shaft shall be rotated by two more turns. Verify,under the above conditions, that reference hole (5) is found within index (4)as represented in box C; otherwise, the aforesaid operations shall berepeated.After assembly, the belt (10) tension measured using tool 99395849 mustbe as follows in the following points: X, 212 12 Hz - X2, 178 10 Hz.Then complete assembly by carrying out the steps described for disassemblyin reverse order.

Keeping the screw (2) stationary and using a suitable wrench on the hexagonof the plate (3) of the tightener, turn it anticlockwise to cover the referencehole (5) located on the fixed portion of the tightener (see frame B).In the above conditions, tighten the fixing screw (2) to a torque of 36 4Nm.Tighten screw (9) to the torque values below:- screw (9) securing pulley (7) to the distributing shaft with tapered shank

(full section): 90 Nm;- screw (9) securing pulley (7) to the distributing shaft with cylindrical

shank (hollow section): 130 Nm.Remove the tools 99360614 (6) and 99360615 (11) for the timing.Turn the engine in its direction of rotation by 8 turns to be able to put thetools (6) and (11) back in to do the timing.In these conditions, the notches of the timing belt (10) must coincide withthose of the pulley (7) and the gear (12).

Turn the automatic tightener (1) clockwise, positioning it as shown in frameA.Turn the timing belt (10) as shown in the figure observing the precautionsbelow.Do not bend the timing belt. Arrows indicating the direction of assemblyof the timing belt on the engine are shown on the back of the belt. Thearrows must correspond to the direction of rotation of the belt and thenotches must coincide with those on the pulley (7) and the gear (12).

x = direction of movement of the tightenery = direction of rotation of the wrench

Do not turn the engine in the opposite direction; if, on turning theengine, you pass the point for inserting the tools (6) and (11), turnthe engine clockwise by another two turns.

NOTE

NOTE

Only for the engines featuring intake valve distributing shafts withtapered shank (full section).If required to fit the timing belt (10) on the pulley (7), remove tool99360608 (8) and turn the pulley (7) clockwise by no more thanhalf a pulley tooth.

NOTE

Figure 8



Figure 9When electrical injectors mounted on the vehicle must bereplaced, meet following warnings:- where electrical injectors are dismounted and do not

need to be replaced, their mounting position has to benoted down in order to remount them later in the sameposition; this is done to avoid to reprogram the centralunit;

- after replacing one or more injectors, the central unit hasto be reprogrammed;

- before mounting a new electrical injector, note downIMA code printed on the injector, because the code isdifficult to read after the injector has been mounted;

- where the central unit is replaced, reprogram the newcentral unit with the IMA codes of the electrical injectorsmounted on the engine and copy down the rectificationcoefficients (ZFC) of replaced central unit; where it is notpossible, they must be reset and self-learning processmust be started up again.

During engine running, EDC 16 central unit performs somechecks on electrical injectors minimum flow rate.In certain conditions (overrun: vehicle deceleration withpedal released) an increasing (very small) fuel quantitystarting from zero is injected and its effect on engine rotationsmoothness is observed.Injection start threshold is detected and stored by the centralunit.This self-learning process is carried out on each singlecylinder.Therefore, replacing an electrical injector involves the needof reprogramming the central unit by entering the IMA codesof new electrical injectors and resetting the rectificationfactors (ZFC) of the cylinder considered.Replacing all electrical injectors extends the need of resettingto all the rectification coefficients (ZFC) of each singleelectrical injector.

105067

At assistance, code written in clear has to be used (3, Figure 9)for central unit replacement and reprogramming procedures.In the table there is shown the conversion of OCR charactersinto Arial characters.

105066

Figure 10

1. IMA Matrix code- 2. Bosch spare part no.-3. IMA code in clear - 4. Iveco spare part no. - 5. Code -

6. Series no. - 7. Production dateElectrical injectors are not assigned any more to classes Min (01)- Med (02) - Max (03); therefore, flow rate deviations fromdesign values are detected, during final check step, by themanufacturer on each single injector and printed with I.M.A.(Injector Menge Abgleichung) [Injector Quantity Offset] codeon injector magnet.At engine production plant, I.M.A. code is read on line from anautomatic reading station, converted into bar code, printed onengine identification label and applied on the engine itself.At vehicles production plant, at line end, E.D.C. 16 central unitis programmed automatically reading the engine identificationlabel.

Conversion table of OCRcharacters into ARIAL characters



755010 REPLACING THE ELECTRIC INJECTORS

108559

Figure 11

Thoroughly clean the seat of the electro-injectors, taking careno foreign bodies get into the cylinder barrels.Fit a fresh gasket (12) onto the electro-injector (10) and fitthis in the overhead.

Complete assembly by carrying out the operations describedfor disassembly in reverse order, taking the followingprecautions:

- With each disassembly, the fuel pipes must be replacedwith fresh ones.

- Tighten the nuts, screws and fittings to the prescribedtorque.

- To tighten the fittings of the fuel pipes, use the wrenchin the 99317915 series and the torque wrench99389829.

- After assembly, replenish the coolant as described underthe relevant heading.

Check assembly of the timing sensor as described under therelevant heading.

Partly drain the coolant off from the radiator.Remove the plug (21, Figure 9) and detach thesoundproofing cover (20, Figure 9).Disconnect the pipes (19, Figure 9) from the pipe (18,Figure 9).Remove fastening screws (26, Figure 9), then take offexpansion tank (29, Figure 9) and disconnect level gaugeelectric connections (6, figure 7) and sensor (27) electricconnections (28, figure 7) from the expansion tank.Disconnect the pipe (20, Figure 12) from the coalescencefilter (1, Figure 12).Disconnect the electrical connections (1) from theelectro-injectors (10) and (2) from the fuel pressure sensor(8).Press the springs (3) in the direction shown by the arrow anddisconnect the fittings of the pipe (4) to recover fuel from theelectro-injectors (10).Disconnect the fuel pipes (7) from the electro-injectors (10)and from the hydraulic accumulator (9).Take out the screws (6) and the brackets (5) fixing theelectro-injectors (10) to the cylinder head.Using tool 99342153 (11) extract the electro-injectors (10)from the overhead.

Removal

Refitting



Figure 12

Removal

108560

Take off the camshaft drive belt, as described in therespective chapter (operation 541257).Disconnect coolant pipes (15) and (14) from pipe (13).Disconnect the electric connection from pressure sensor(18).Remove the fastening screws, then take off expansion tank(17) by disconnecting from the latter the electric connectionfrom the level sensor.Remove oil dipstick pipe (12) from the inlet manifold.Disconnect oil vapour pipes (20) and (19) from coalescencefilter (1), then remove the latter from the overhead.Disconnect pipe (2) from the heat exchanger engine coolantoutlet pipe.

Take off electric injectors (4), as described in the Replacingthe electric injectors chapter (operation 775010).Disconnect the electric connections from phase sensor (3),water temperature sensor (8), air pressure/temperaturesensor (9), preheating plugs (6), throttle valve assemblyactuator (10), fuel pressure sensor (16).Take fuel pipe (7) off hydraulic accumulator (5),high-pressure pump and inlet manifold.



540610 CYLINDER HEAD REMOVAL AND REFITTING

Take off the overhead gasket.Take out the tappets and carefully put them aside.Using the bushing 99355041, take out the glow plugs.Take out the screws fixing the cylinder head and detach thisfrom the crankcase.Remove the cylinder head gasket.

Figure 13

Loosen clamp (9), then take the air conveyor off.Take air suction sleeve (10) off turboblower (8).Disconnect the oil pipe (11) from the cylinder head and fromthe turbocharger (8).Loosen the clamp (7) and disconnect the oil pipe (5) fromthe crankcase union.Take out the screws and disconnect the exhaust pipe (4)from the turbocharger (8).Take off the nuts (3) and remove the turbocharger (8) withits gasket from the exhaust manifold.

Take out the screws and remove the overhead together withthe pins 99360614.

Close the turbocharger air outlet/inletappropriately to prevent foreign bodiesaccidentally getting inside and damaging it.

NOTE

The pins 99360614 applied so as not to alter thetiming after removing the timing belt must beremoved from the overhead only if this is to beremoved.

NOTE

108561

Disconnect the vacuum pipes from E.G.R. valve (2) andturboblower (if any) actuator (6).



Refitting

Refitting requires carrying out the operations for removal inreverse order, while taking the following precautions:Check that the timing tools:

- 99360614 (6, Figure 13) and 99360608 (8, Figure 13)are inserted in the overhead;

- 99360615 (11, Figure 13) is inserted in the crankcase asdescribed in Replacing timing belt.

Check that the mating surfaces of the cylinder head andcrankcase are clean.Keep the cylinder head gasket clean.Position the cylinder head gasket with the lettering TOPfacing the cylinder head.

Figure 14

Diagram of the tightening sequence for the cylinder headfixing screws:

- 1st phase: pre-tightening with torque wrench screws 1-2-3-4-5-6 to a torque of 100 5 Nm; screws 7-8-9-10 to a torque of 50 2.5 Nm.

- 2nd phase: angle closing screws 1-2-3-4-5-6 90 5; screws 7-8-9-10 60 3.

- 3rd phase: angle closing screws 1-2-3-4-5-6 90 5; screws 7-8-9-10 60 3.

A = flywheel side.

- Tighten the screws and nuts to the prescribed torque.

- The seals and gaskets must not be reused, but replacedwith new ones.

75494

Mount the cylinder head. Insert the screws and tighten them,in three successive stages, following the order and methodshown in the following figure.

To tighten the glow plugs, use the bushing 99355041 andtorque wrench 99389819.

A

It is essential to keep the gasket sealed in its packageuntil just before assembly.

NOTE

The angle closure is done with tool 99395216.NOTE

If the engine has run for a period equivalent to =25,000 km, the toothed timing drive belt must bereplaced with a fresh one, no matter what its stateof wear.

NOTE



75271

75272

75273

75569

Figure 16

Figure 15

Figure 17

Figure 18

Lock rotation of the high-pressure pump gear (1) by applyingtool SP. 2263 (2) as illustrated in the figure. Remove the nut(3) and take out the tool (2).

Using tool 99340035 (2) applied as shown in the figure,extract the gear (1) from the shaft of the high-pressure pump(3).

Take out the screws (1) and remove the high-pressure pump(2) from the water pump mounting (3).

Take out the screw (2) and remove the fixed tightener (1).Take out the screws (3) and remove the water pumpmounting (4).

Removal

RefittingRe-attachment is carried out by reversing the orderof detachment operations. In particular, take care ofthe following: replace the seal rings, gaskets andhigh-pressure pipe with new parts; tighten the nuts,screws and fittings to the specified torque values.

543210 REPLACINGWATER PUMP

Removal

Refitting

If the engine has run for a period equivalent to =25,000 km, the toothed timing drive belt must bereplaced with a fresh one, no matter what its stateof wear.

NOTE

Remove the high-pressure pump as describedunder the relevant heading.

Fit two new seals on the water pump and fit it backon the crankcase, carrying out the operationsdescribed for removal in reverse order andtightening the screws or nuts to the prescribedtorque.

Remove the timing drive belt, as described in the relevantchapter (operation 541257).Disconnect the following items:- electric connection from the pressure sensor;- fuel pipes from the high-pressure pump.



771010 REPLACING HIGH-PRESSUREPUMP CPH1

Figure 19

108562

Remove oil filling plug (1) and take off sound deadening cover(2).Loosen clamp and disconnect air tube (8) from radiator andthrottle valve assembly (7).Disconnect electrical connection (6) from pressure switch(5).Remove expansion tank (4), disconnect electrical connection(3) from the level sensor placed under the tank and put thetank on one side.

Release engine cable (1) from the fastening clampsDisconnect electric connections (2) from the electricinjectors, then move channel (3) aside.Disconnect electric connection (4) from throttle valveassembly actuator (6).Remove screws (5) securing throttle valve assembly (6) tothe inlet manifold.

Figure 20

Figure 21

108563

108564

Remove nuts (2) securing pipe (3) to throttle valve assembly(1).Loosen screws (4) securing pipe (3) to heat exchanger (5),then take throttle valve assembly (1) off the inlet manifold.

RefittingFor refitting, reverse the operations described fordisconnection observing following warnings:

- replace gasket by new parts;

- tighten nuts and screws at prescribed torque.

Removal

PREHEATINGPLUGREMOVAL/REFITTING

Figure 22

108565

RefittingFor refitting, reverse the operations described fordisconnection observing following warnings:

- replace gasket by new parts;

- tighten nuts and screws at prescribed torque.

Take off the throttle valve assembly, as described in therespective chapter.Disconnect electric connections (3) from preheating plugs(2).Use wrench SP 2275 (1) to take off preheating plugs (2).

Removal



THROTTLE VALVE ASSEMBLY REMOVAL-REFITTING

Figure 23

108566

Partially drain the engine coolant.Take the full exhaust pipe off the engine and the chassis, asdescribed in the respective chapter.Loosen the clamps, then disconnect coolant pipes (1 and 3)from E.G.R. valve (7).Disconnect vacuum pipe (6) from E.G.R. valve (7).Remove fastening screws (5-9-10), then remove E.G.R. valve(7), together with elbow (11), from heat exchanger (2), pipe(8) from bracket (4).

Act from inside the engine compartment to take off thecylinder head sound-proofing cover.Disconnect cab heater coolant pipe (2) from the similarE.G.R. valve outlet pipe (1).Remove the nut, then take the pipe off coalescence paperfilter (3).

Figure 24

Figure 25

Documents

Daily_Euro_4_2006_2009__manual