Iveco Daily Euro 4

DAILY EURO 4
REPAIR MANUAL
MECHANICAL
ELECTRIC/ELECTRONIC
IVECO
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”This document provides data, characteristics, instructions and
methodology to perform repair interventions on the vehicle
and its components.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistance are specifically qualified and equipped to perform
the repair interventions that are indicated in this document.
Before performing any intervention, check to have available
the document relating to the vehicle model on which the
intervention is being performed and also make sure that all
accident prevention devices, such as, as a rough guide, goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transport tooling, etc., are available and efficient, and further
make sure that the vehicle is put such a way that an
intervention can be made in safety conditions.
Making interventions strictly observing the indications given
here, as well as using specific tooling indicated, assures a
correct repair intervention, execution timing observance and
operators’ safety.
Each repair intervention must be finalised to the recovery of
functionality, efficiency and safety conditions that are provided
by Iveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, 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 the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Iveco is available to provide all clarifications necessary to make
interventions, as well as to provide indications in cases and
situations not included in this document.
Data and information contained in this document could result
not to be updated owing to modifications made by Iveco at
any moment for technical or commercial reasons, or because
of the need to adapt the vehicle to law requirements in
different countries.
In the case of a difference between what contained here and
what actually found on the vehicle, please contact Iveco
network before making any intervention.”
The data contained in this publication might fail to reflect the
latest changes which the Manufacturer may introduce at any
time, for technical or sales purposes, or to meet the
requirements of local legislation.
Copy, even partial, of text and drawings is forbidden.
Produced by:
Publication Edited by:

IVECO S.p.A.
Customer Service
Lungo Stura Lazio, 15
B.U. TECHNICAL PUBLISHING
10156 Torino (TO) - Italy
Iveco Technical Publications
Lungo Stura Lazio, 15
Print 603.93.651 - 1st Ed. 2006 10156 Torino (TO) - Italy
PRELIMINARY REMARKS
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections — disconnections of
units 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, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric 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.
SYMBOLS - WARNINGS
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
Danger of serious damage for the vehicle

Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes
guarantee lapse too.
General danger
! It includes the dangers of above described signals.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
NOTE It indicates an additional explanation for a piece of information.
Print 603.93.651 I Base - March 2006

SYMBOLS - ASSISTANCE OPERATIONS
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly
ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

α
Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

Pressure
Machine finish bar
Oversized
Interference
Higher than….
Strained assembly
Maximum, peak
Undersized
Thickness
Less than….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 °C
Sealant
Cold
Adhesive
Winter
Temperature > 0 °C
Air bleeding Hot
Summer
Replacement
Original spare parts
Base - March 2006 II Print 603.93.651

PRODUCT CODE
Each title or subtitle concerning operations being performed is preceded by a six-figure number named PRODUCT CODE.
This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and
TROUBLE CODE document.
As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).
Product Code: 5 0 7 6
PRODUCT UNIT SUB-ASSEMBLY PRODUCT UNIT SUB-ASSEMBLY
COMPONENT COMPONENT
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: 0 1 0 3
COMPONENT COMPONENT
The third and fourth figures identify the UNIT within the PRODUCT.
Example :

Unit 01 = Chassis;
Unit 02 = Bumpers;
Unit 03 = Alternator.
Sub-assembly Code: 4 0 1 3
COMPONENT COMPONENT
The fifth and sixth figures exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT.
Example :

Unit 01 = Chassis;
Sub-assembly 40 = Chassis cross members;
Sub-assembly 13 = Rotor.
Print 603.93.651 III Base - March 2006

GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
! immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously
observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph “Controls
care 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 unmanned
a 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 support
stands 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 the
document, 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 pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by Iveco original spares.
During workshop activity, always keep the work 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 observe
indications specified in relating manual sections.
Base - March 2006 IV Print 603.93.651

GENERAL WARNINGS
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, 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; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up detached
or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all 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 materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
Print 603.93.651 V Base - March 2006

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be 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, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
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 tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key
memorisation:
1 Pay 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.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.
Base - March 2006 VI Print 603.93.651

Bonding and screening
Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central 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 opening
bonding (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.
Figure 1
1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR

d. DISTANCE ! 0
Print 603.93.651 VII Base - March 2006

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Accessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mounting
instructions (specific document “Instructions for transformation and preparation” is available at Assistance Network workshops).
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
For any exception to mounting instructions, IVECO’s 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 THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 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.
Temperature
0° C = 32° F
1° C = (1 x 1.8 + 32) ° F
Base - March 2006 VIII Print 603.93.651

DAILY EURO 4
Print 603.93.651 — 1st edition

Base — March 2006
UPDATE DATA
Section Description Page Revision date
Print 603.93.651 Base - March 2006

Base - March 2006 Print 603.93.651
INDEX OF SECTIONS
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

DAILY EURO 4 GENERAL 1
Print 603.43.671
SECTION 1
General
Page
IDENTIFICATION DATA . . . . . . . . . . . . . . . . . . 3
- Vehicle Identification Plate . . . . . . . . . . . . . . . . 3
COMPOSITION OF MODELS . . . . . . . . . . . . . . 4
ALPHANUMERICAL CODING FOR

BUS IDENTIFICATION . . . . . . . . . . . . . . . . . 6
REPLENISHING FLUIDS . . . . . . . . . . . . . . . . . . . 13

2 GENERAL DAILY EURO 4
Print 603.43.671

IDENTIFICATION DATA
Vehicle identification plate Figure 1
Plate legend
1) Approval number
2) Chassis number
3) PTT - Total weight on ground
4) MTC - Total combined weight
5) Max. weight permitted on the front axle
6) Max. weight permitted on the rear axle
7) Specific indication of type
8) Wheelbase (mm)
9) Type of engine
10) Engine rating
11) Permitted smoke level
12) Place of manufacture
13) Number of vehicle axles
108534
Figure 2
Manufacturer tag
For vehicle identification according
to the EC directive
(on the front crosspiece)
Chassis Engine
Stamping Stamping
(at the front on the chassis right-hand side-member) (on the right side on the engine base)
108533

COMPOSITION OF MODELS
MODELS
35 C 10
35 C 12
35 C 14
35 C 15
35 C 18
40 C 10
40 C 12
40 C 15
40 C 18
29 L 10
29 L 12
29 L 14
35 S 10
35 S 12
35 S 14
35 S 18
ASSEMBLIES
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:
o o o o o o o o o o o
independent with transverse leaf spring (MK3)
independent with torsion bars o o o o
(•) (•) (•) (•) (•)
REAR Parabolic o o o o o o o Z Z Z Z Z Z Z Z Z
MECHANICAL
- single leaf o o o o o o o
SUSPENSIONS:
- reinforced o o o o o o o
Semi-elliptical s s s s s s s s s
Semi-elliptic
z z z z z z z z z
with leaf spring
REAR AIR SUSPENSIONS V V V V V V V V V V V V V V V V
O.D. = Over Drive s Standard on chassis cabs, Alternatively on Vans — Chassis Cowls
(•) Optional extra (with max load of 1900 kg) and Cut Aways
o Standard Z Standard on Vans, Chassis Cowls and Cut Aways — Alternatively
• with ZF 6 S 400 A O.D. gearbox on Chassis Cabs
S Single rear wheels
V Alternative L Light with single rear wheels
Vehicles with front suspension with transverse leaf spring C Twin rear wheels
Vehicles with front suspension with torsion bars
z Chassis cabs only, as an alternative

COMPOSITION OF MODELS
MODELS
45 C 15
45 C 18
50 C 15
50 C 18
60 C 15
60 C 18
65 C 15
65 C 18
ASSEMBLIES
F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV
F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV
F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV
F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV
F1CE0481F*C (DPF series) 146 CV o o o o
F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV
F1CE0481H*C (DPF series) 176 CV o o o o
Single disk 9” 1/4
Single disk 10” 1/2
Single disk 11 o o o o o o o o
ZF 5 S300
ZF 6 S400 O.D. V V V V V V V V
ZF 6 S400A O.D. V V V V V V V V
5817
5818
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-elliptic
z z z z z z z z
with leaf spring
REAR AIR SUSPENSIONS V V V V V V V V
O.D. = Over Drive s Standard on chassis cabs, Alternatively on Vans — Chassis Cowls
(•) Optional extra (with max load of 1900 kg) and Cut Aways
o Standard Z Standard on Vans, Chassis Cowls and Cut Aways — Alternatively
V Alternative on Chassis Cabs
Vehicles with front suspension with transverse leaf spring S Single rear wheels
Vehicles with front suspension with torsion bars L Light with single rear wheels
z Chassis cabs only, as an alternative C Twin rear wheels

ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION

CUSTOMIZED VEHICLE (V.P.)
MARKET VEHICLE (V.M.)
STANDARD VEHICLE (V.C.B.)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RANGE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A LIGHT ROAD VEHICLES
PROGRAMMING FAMILY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A T 25C 29 L
B T 30C 35 S
C T 35C 35 C
CHASSIS CABS AND DERIVATIVES
D T 40C 40 C
50 C
E T 50C
45 C
60 C
F T 65C
65 C

PROGRAMMING FAMILY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
H T 25V 29 L
K T 30V 35 C
J T 35V 35 C
VANS AND DERIVATIVES

L T 40V 40 C
50 C
M T 50V
45 C
60 C
N T 65V
65 C
ENGINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
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 4
LD = Light Duty
HD = Heavy Duty

SUSPENSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
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.
VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
29 L10 (•) - 29 L12 (•) - 29 L14 (•)
35 S10 (•) - 35 S12 (•) - 35 S14 (•) - 35 S18 (•)
35 C10 (•) - 35 C12 (•) - 35 C15 (•) - 35 C18 (•)
CHASSIS
1 40 C10 (•) - 40 C15 (•) - 40 C18 (•)
CAB
45 C15 (•) - 50 C15 (•) - 50 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 (•) -
CHASSIS 35 S18 D (•) - 35 C10 D (•) - 35 C12 D (•) -
6 CAB 35 C15 D (•) - 35 C18 D (•) - 40 C10 D (•) -
6+1 40 C12 D (•) - 45 C15 D (•) - 45 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 (•) -
CHASSIS 40 C12 CC - 40 C15 CC (•)( ) - 40 C18 CC (•)
( )
0
COWL 45 C15 CC - 45 C18 CC (•)
50 C15 CC (•) - 50 C18 CC (•)
60 C18 CC (•) - 65 C18 CC (•)
35 S12 CCR (•) - 35 S14 CCR (•) - 35 S18 CCR(•)

CHASSIS 35 C12 CCR (•) - 35 C15 CCR (•) - 35C18CCR(•)
R COWL 40 C12 CCR ((•)) - 40 C15 CCR ((•)) - 40C18CCR(•)
40C18CCR( )
SHORT 45 C15 CCR (•) - 45 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.

VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
35 C10 CA (•) - 35 C12 CA (•)

40 C10 CA (•)
( ) - 40 C12 CA (•)
( )
A CUT-AWAY 45 C18 CA (•)
( ) - 50 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 (•)
35 C10 V (•) - 35 C12 V (•) - 35 C15 V (•)
35 C18 V (•)
( )
4 VAN
40 C12 V (•) - 40 C15 V (•) - 40 C18 V (•)
45 C15 V (•) - 45 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 (•)
35 C10 SV (•) - 35 C12 SV (•) - 35 C15 SV (•) -
SEMI GLAZE
SEMI-GLAZE 35 C18 SV (•)
( )
V
D VAN 40 C10 SV (•) - 40 C12 SV (•) - 40 C15 SV (•) -
40 C18 SV (•) -
45 C15 SV (•) - 45 C18 SV (•)
50 C15 SV (•) - 50 C18 SV (•)
VENDOR 35 S12 CV (•) - 35 S14 CV (•)

VERSION 35 C12 CV ((•)) - 40 C12 CV -
U 45 C15 CV (•)
( ) - 45 C18 CV (•)
( )
CITY
VAN 50 C15 CV (•)
( ) - 50 C18 CV (•)
( )
5 COMBI 29 L14 C (•) - 35 S14 C (•)
35 S14 ((•)) - 35 S18 (•)

( )
8 CAMPER 35 C14 (•)
( ) - 35 C18 (•)
( )
CHASSIS-
COWL
9 SHORT 35 S14 CCRC (•) - 35 S18 CCRC -
35 C14 CCRC ((•)) - 35 C18 CCRC
VERSION FOR
CAMPER VAN
(•) Also available in the A (automatic transmission) and /P (pneumatic rear suspensions) versions.

WHEELBASE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3000 mm
1 (T25C - T30C - T35C - T40C - T25V - T30V -
T35V - T40V - T50V)
3000 L mm
2
(T25V - T30V - T35V - T40V - T50V)
3300 mm
3
(T25V - T30V - T35V - T40V - T50V)
3450 mm
4
(T25C - T30C - T35C - T40C - T50C - T65C)
3750 mm
5
(T30C - T35C - T40C - T50C - T65C)
3950 L mm
6
(T30V - T35V - T40V - T50V - T65V)
4100 mm
7
(T35C - T40C)
4350 mm
8
(T50C - T65C)
4750 mm
9
(T50C - T65C)

GEARBOX
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A 5 SPEED (5 S 300)
B 6 SPEED (6 S 400 O.D.)
C 6 SPEED (6 S 400 A O.D.)
A Automated
O.D. Over Drive

DRIVE — INTERNAL HEIGHT OF LOADING BAY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
LEFT-HAND DRIVE
1
(T25C - T30C - T35C - T40C - T50C)
LEFT-HAND DRIVE AND INTERNAL HEIGHT OF

LOADING BAY H1 = 1545 mm 1
(T25V - T30V - T35V - T40V - T50V)

(T25V - T30V - T35V - T40V - T50V)

(T30V - T35V - T40V - T50V)
RIGHT-HAND DRIVE
A
(T25C - T30C - T35C - T40C - T50C)
RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF

LOADING BAY H1 = 1545 mm A
(T25V - T30V - T35V - T40V - T50V)

LOADING BAY H2 = 1900 mm B
(T25V - T30V - T35V - T40V - T50V)

LOADING BAY H3 = 2100 mm C
(T30V - T35V - T40V - T50V - T65V)
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 Quantity
Litres 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
Sump capacity:
- max level 4.3 3.78
Urania Dailyy - min level 3 2.65
Urania LD 5
Quantity of oil in circulation in the car-
tridge filter and heat exchanger 1 0.88
Total dry engine capacity 7.6 6.79
Sump capacity:
- max level 6.6 5.81
- min level 4.29 3.78
! Max. gradient negotiable by vehicle uphill/downhill with oil at minimum level 30%
Gearbox
ZF 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
Tutela W140/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 —35°C)

International lubricant description FL Group products

Engine oil meets specifications:
ACEA B5 with synthetic base SAE 5W30 Urania Daily
ACEA E3/E5 with mineral base SAE 15W40 Urania LD5
Differential and wheel hub oil meets specifications:
API GL-5 with mineral base SAE 85W140 Tutela W 140/M - DA (1)
API GL-5 with mineral base SAE 80W90 Tutela W 90/M - DA (2)
Mechanical gearbox oil containing non-EP anti-wear additives
Tutela Truck Gearlite
Meets specification API GL 4 SAE 75W80
Hydrostatic transmission and power steering oil
Tutela GI/A
Meets specifications: ATF-DEXRON II D
General-purpose grease
Tutela MR 2
lithium soap based grease N.L.G.I. fluidity no. 2
Specific grease for wheel hubs and bearings
Tutela MR 3
lithium soap based grease N.L.G.I. fluidity no. 3
Hydraulic brake and clutch control fluid
In conformity with N.H.T.S.A. standards No. 116, ISO 4925 Tutela TRUCK DOT SPECIAL
Standard SAE J 1703, IVECO STANDARD 18-1820
Windscreen washer liquid
Tutela Professional SC 35
Mixture of spirits, water and surfactants CUNA NC 956-11
Concentrated protective radiator fluid
ethylene glycol based containing corrosion inhibitors, Paraflu11(3)
in conformity with Iveco Standard 18-1830
(1) Hot or temperate climate
(2) Specific for cold climes.
(3) 100% Paraflu to be diluted with water to 50%
Figure 3
95 35
50 10 SAE 40
32 0 SAE 30
SAE
14 -10 20W
SAE
5 -15
15W/40
SAE SAE 5W 30
-13 -25 10W
oF oC 108535

DAILY EURO 4 F1A ENGINE 1
SECTION 2
5401 Engine
Page
F1A ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F1C ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

2 F1A ENGINE DAILY EURO 4

F1A Engine
Page
MAIN OPERATIONS ON ENGINE MOUNTED

ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Service procedures to be performed after replacing
high-pressure feeding system and/or exhaust gas post-
treatment system components . . . . . . . . . . . . 8
POWER UNIT REMOVAL/REFITTING . . . . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Checks and tests . . . . . . . . . . . . . . . . . . . . . . . 13
- Power steering system air bleed . . . . . . . . . . . 13
REPLACING BELTS . . . . . . . . . . . . . . . . . . . . . . . 14
- Power 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 Page
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 - Measuring main journals and crank pins . . . . . . 79
E.G.R. VALVE REMOVAL/REFITTING . . . . . . . . . 24 - Checking crankshaft . . . . . . . . . . . . . . . . . . . . . 80
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - Replacing timing control gear . . . . . . . . . . . . . . 82
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 82
HEAT EXCHANGER REMOVAL/REFITTING . . . 24 - Assembling main bearings . . . . . . . . . . . . . . . . . 82
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - Measuring main journal assembly clearance . . . 82
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - Checking crankshaft end float . . . . . . . . . . . . . . 83
BURNT GAS EXHAUST SYSTEM . . . . . . . . . . . . 25 - Assembling rear seal . . . . . . . . . . . . . . . . . . . . . 84
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . 85
OXICAT - OXYDIZER CATALYST . . . . . . . . . . 25 - Replacing bearing supporting gearbox input shaft 85
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CONNECTING ROD — PISTON ASSEMBLY . . . 86
EXHAUST PIPE ASSEMBLY REMOVAL/REFITTING 27 - Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - Measuring piston diameter . . . . . . . . . . . . . . . . 87
REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY - Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

COMPONENTS (SYSTEMS EQUIPPED WITH D.P.F. - Conditions for correct pin-piston coupling . . . . 87
CATALYST) . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
- Exhaust silencer removal . . . . . . . . . . . . . . . . . 28
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 88
- Replacing D.P.F. catalyst . . . . . . . . . . . . . . . . . . 29
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
- Refittingl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Checking connecting rod . . . . . . . . . . . . . . . . . 89
- D.P.F. catalyst removal . . . . . . . . . . . . . . . . . . . 28
- Checking bending . . . . . . . . . . . . . . . . . . . . . . . 89
- Replacing differential sensor (delta-p) . . . . . . . . 29
- Assembling connecting rod-piston assembly . . . 89
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Checking for connecting rod — piston distortion 90
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Fitting piston rings . . . . . . . . . . . . . . . . . . . . . . . 90
ENGINE IDENTIFICATION CODE . . . . . . . . . . . 34
- Assembling connecting rod — piston assemblies
CHARACTERISTICS CURVES . . . . . . . . . . . . . . . 35 in cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . 90
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 39 - Measuring crankpin assembly clearance . . . . . . 91
ASSEMBLY DATA — CLEARANCES . . . . . . . . . . 40 - Checking piston protrusion . . . . . . . . . . . . . . . 91
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . 92
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . . 52 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . 63 - Removing valves . . . . . . . . . . . . . . . . . . . . . . . . 92
OVERHAULING ENGINE . . . . . . . . . . . . . . . . . . 68 - Checking cylinder head seal . . . . . . . . . . . . . . . 93
DISASSEMBLING THE ENGINE AT THE BENCH 68 - Checking cylinder head mating surface . . . . . . . 93
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 78 - Removing deposits, refacing and checking valves 93
- Checks and measurements . . . . . . . . . . . . . . . . 78 - Checking clearance between valve stem and valve
- Checking head mating surfae on cylinder block 78 guide and centring valves . . . . . . . . . . . . . . . . . 94
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 79 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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

Page Page
- Boring valve guides . . . . . . . . . . . . . . . . . . . . . . 94 - Turbocharger (KKK K03-2074-CCB 5.88 type) 125
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
- Recutting and replacing valve seats . . . . . . . . . . 95 - Pressure relief valve . . . . . . . . . . . . . . . . . . . . . 126
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 96 - Checking pressure relief valve . . . . . . . . . . . . . . 126
ROCKER ARMS — TAPPETS . . . . . . . . . . . . . . . . 96 - GARRET GT 17 variable geometry
turbosupercharger . . . . . . . . . . . . . . . . . . . . . . 127
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ASSEMBLING CYLINDER HEADS . . . . . . . . . . . 97
- Operation at low engine rpm . . . . . . . . . . . . . . 127
- Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
- Operation at high engine rpm . . . . . . . . . . . . . 127
- Overhead removal . . . . . . . . . . . . . . . . . . . . . . 98
- Proportional solenoid valve controlling turbocharger
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 99 actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 - Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 - Checking and adjusting the actuator . . . . . . . . . 129
- Checking cam lift and pin alignment . . . . . . . . . 100 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
- Assembling overhead . . . . . . . . . . . . . . . . . . . . 102 (EXHAUST GAS RECIRCULATION) . . . . . . . 130
- Assembling front seal ring . . . . . . . . . . . . . . . . . 103 - EGR system operation . . . . . . . . . . . . . . . . . . . 130
- Refitting cylinder head . . . . . . . . . . . . . . . . . . . 106 - Main system components . . . . . . . . . . . . . . . . . 131
- Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . 107 - E.G.R. valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - Modulator solenoid valve . . . . . . . . . . . . . . . . . 131
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - Air flow rate meter (flow meter) . . . . . . . . . . . 131
OIL VACUUM PUMP ASSEMBLY (GPOD) . . . . . 117 - Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 132
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 - Throttle valve assembly . . . . . . . . . . . . . . . . . . 132
- Characteristic data . . . . . . . . . . . . . . . . . . . . . . 117 EXHAUST POLLUTANT REDUCTION SYSTEM WITH

DPF CATALYST (ON REQUEST) . . . . . . . . . 133
- Vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . 117
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
- Oil pressure control valve . . . . . . . . . . . . . . . . 118
D.P.F. (DIESEL PARTICULATE FILTER) CATALYST 134
- Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
- Modine heat exchanger . . . . . . . . . . . . . . . . . . 118
PARTICULATE FILTER REGENERATION SYSTEM 135
- Oil vapour recirculation system . . . . . . . . . . . . 119
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
- Forced regeneration . . . . . . . . . . . . . . . . . . . . . 136
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
- Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . 136
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
HIGH-PRESSURE ELECTRONIC
- Electromagnetic pulley . . . . . . . . . . . . . . . . . . . 123 INJECTION SYSTEM (MS 6.3 - EDC 16) . . . . 137
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 123 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . 139
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . 124 - Self-diagnosis — BLINK CODE . . . . . . . . . . . . . 139
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Page Page
- Immobilizer recognition . . . . . . . . . . . . . . . . . . 139 - Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
- Checking fuel temperature . . . . . . . . . . . . . . . . 139 - Fuel filter “UFIfilters” . . . . . . . . . . . . . . . . . . . . 147

- Checking engine coolant temperature . . . . . . . 139
- Fuel filter “Filtrauto” . . . . . . . . . . . . . . . . . . . . . 148
- Checking quantity of fuel injected . . . . . . . . . . . 139
- Fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
- Checking idling adjustment . . . . . . . . . . . . . . . . 139
- High-pressure pump CPH1 . . . . . . . . . . . . . . . 149
- Fuel cut-off in release phase . . . . . . . . . . . . . . . 139
- Checking cylinder balancing on idling . . . . . . . . 139 - Pressure control valve . . . . . . . . . . . . . . . . . . . 150
- Checking regular engine rotation (anti-sawing) . 139 - Replacing pressure regulator . . . . . . . . . . . . . . . 150
- Checking smokiness at exhaust on acceleration 139
- Hydraulic accumulator (rail) . . . . . . . . . . . . . . . 151
- Checking exhaust gas recirculation (E.G.R.) . . . 139
ELECTRO-INJECTORS . . . . . . . . . . . . . . . . . . . . 152
- Checking top speed limit . . . . . . . . . . . . . . . . . 139
- Checking regular rotation on acceleration . . . . 139 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
- Checking glow plug control unit . . . . . . . . . . . . 139 - Replacing an electrical injector . . . . . . . . . . . . . 152
- Checking activation of air-conditioning system . 139 ELECTRIC/ELECTRONIC COMPONENTS . . . . . 153
- Checking fuel pump . . . . . . . . . . . . . . . . . . . . . 139
- Electronic control unit EDC 16 . . . . . . . . . . . . 153
- Checking diesel warming . . . . . . . . . . . . . . . . . 140
- Glow plug electronic control unit . . . . . . . . . . . 154
- Checking cylinder position . . . . . . . . . . . . . . . . 140
- Checking pilot and main injection timing . . . . . 140 - Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
- Checking injection pressure closed cycle . . . . . 140 SENSORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

- Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 - Engine speed sensor . . . . . . . . . . . . . . . . . . . . . 154
- Correcting flow rate according to water
temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 - Camshaft timing sensor . . . . . . . . . . . . . . . . . . 154
- Correcting flow rate to avoid noise, smoke - Air temperature and pressure sensor . . . . . . . . 155
or overloading . . . . . . . . . . . . . . . . . . . . . . . . . 140
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 155
- De-rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
- Injection timing electronic test . . . . . . . . . . . . . 140 - Fuel pressure sensor . . . . . . . . . . . . . . . . . . . . . 155
- Speed governor . . . . . . . . . . . . . . . . . . . . . . . . 140 - Atmospheric pressure sensor . . . . . . . . . . . . . . 155
- Engine starting . . . . . . . . . . . . . . . . . . . . . . . . . 140
- Engine coolant temperature sensor . . . . . . . . . 155
- Cold starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
- Throttle pedal position sensor . . . . . . . . . . . . . 155
- Warm starting . . . . . . . . . . . . . . . . . . . . . . . . . 141
- Run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 - Clutch pedal position sensor . . . . . . . . . . . . . . 155
- After run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 - Brake pedal position sensor . . . . . . . . . . . . . . . 155

- Cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 - Vehicle speed sensor . . . . . . . . . . . . . . . . . . . . 155
- Cylider balancin . . . . . . . . . . . . . . . . . . . . . . . . 141
- Differential pressure sensor - deltap (∆p) . . . . 155
- Synchronisation search . . . . . . . . . . . . . . . . . . . 141
- Exhaust gas temperature sensor . . . . . . . . . . . . 155
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 146
- 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 diagnosis
equipment and print out the results.
- Replacement of the MS6.3 or EDC 16control unit must be authorized by the Help Desk. Replacing operation
requires 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 in
cardboard boxes. They must therefore be protected against moisture and unpacked just prior to assembly.
- The greatest care must be taken over the cleanliness of parts, making sure that when handling or assembling
(starting with straightforward filter and pre-filter replacement) no dirt of foreign bodies can get inside. For this
reason, 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 drain
manifold) must be fully inserted. To drive them out, press on the tabs at the base of the connectors.
Electro-injector
None of the couplings/unions/nuts on the injector body may be handled. It is neither necessary nor permitted to
dismantle the nozzle body or the electromagnet.
If working on the high-pressure pipe, the hexagon on the injector side must be kept stationary with a wrench.
Before working on pipes, make sure the injector is stationary in its seat on the cylinder head.
When assembling/disassembling the injector drain, the retaining spring must not be removed from its seat in the injector:
pushing the spring towards the engine and applying a vertical force on the connector frees the recirculation. When
assembling, rest the recirculation connector in its seat and apply a vertical force while keeping the retaining spring
pressed in the direction of the engine. Fitting in has to be easy.
Replacing one or more electrical injectors requires central unit programming as described in specific section.
CP1H High-pressure pump

If working on the high-pressure pipe, the hexagon on the pump side must be kept stationary with a wrench.
Before working on the high-pressure pipe, make sure the pump is secured in its seat.
High-pressure pipes
Each high-pressure pipe must be replaced after disassembly operations.
The couplings must be tightened or loosened with the injectors, hydraulic accumulator (rail) and high-pressure pump
well secured and taking care to keep the hexagon on the component side stationary, space permitting.
Hydraulic accumulator (rail) and accessories

The pressure sensor can be assembled five consecutive times; after that, it must be replaced. They must be lubricated
with a thin layer of oil before being mounted..
Replacing the sensor requires central unit programming as described in specific section.

Service procedures to be performed after

replacing high-pressure feeding system and/or
exhaust gas post-treatment system components
To ensure correct operation of the engine, the CP1 control

unit 16 stores, in the memory non-labile area, the information
relative to the engine parameters originally set or acquired
during engine operation.
As a result, after any of the operations below is carried out:
- replacing one or several injectors,
- replacing 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 emission
levels,
- performing forced regeneration,
the control unit shall be programmed again by means of the
IVECO MODUS - E.A.SY. - IT 2000 diagnosis instrument, and
the replacement procedure for the concerned component
shall be performed, in accordance with the indications of the
diagnosis instruments used.

540110 POWER UNIT REMOVAL/REFITTING

Removal
Place the vehicle on the pit or auto lift. Figure 1
Lift the engine hood (28), undo the fastening screws (28) and
then remove the hood; remove supporting rod (30).
Disconnect negative cable (11) and positive cable (4) from
battery (10), then remove the latter from the engine
compartment.
Disconnect electric connections (5, 7, 8 and 9) and engine
cable (6) from the EDC control unit, then release the engine
cable 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).
NOTE Do not change the assembly position of headlamp

insert (13) threaded bush (14, detail D).
Remove the screws and/or fastening nuts, then remove

crosspiece (33).
bumper (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), then
unscrew cap (15) and drain the coolant into a suitable
container.
NOTE If the vehicle is equipped with a cab air-conditioning

unit, proceed as follows.
- Fit the unit 99309146 pipes to connections (1)
and (24), then blow the gas off the
air-conditioning system as described in the
respective charter of the ”Bodywork and
chassis” section.
- Disconnect electric connection (23) from
drying filter pressure switch (22).
- Disconnect pipes (20) from air-conditioner
compressor (21).
- Ruts (27), then disconnect pipes (25) from
expansion valve connector (26).
NOTE Seal the air-conditioning unit pipes and their

respective mounts, to prevent moisture and
impurities from penetrating into the system.
108554

Remove nuts (23), then properly place remote-control Figure 2

switch/fuse holder (22) aside.
Disconnect pipe (21) from the heat exchanger and the
turboblower.
throttle valve assembly.
NOTE Properly obstruct the turboblower air outlet to

avoid casual penetration of foreign bodies into the
turboblower and, therefore, damage to the latter.
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.
Remove fastening screws (12), then remove the radiator/heat
exchanger 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 the
wall.
Disconnect electric connection (6) of the level sensor placed
under tank (5).
108555

Disconnect cab heater pipe (23) from E.G.R. exchanger outlet Figure 3
pipe (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 flow meter (16).
Remove air pipes (14 and 19), together with air flow meter
(16), from turboblower (20) and air filter (13).

turboblower.
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 pipe
assembly.
Disconnect the electric connection (6) from air-conditioner
compressor (8).
Disconnect the electric connection (5) from starting motor
(4).
Place a container under the power steering pump to recover
the 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 remove
the engine from its own compartment and slightly pull the
same
108556

Act from under the vehicle: Figure 4

- to disconnect jointed heads (17) of lever shift control
cables (16);
- selection cable (max. pull-out load: 250 N - max. pull-in
load: 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 and
disconnect the speed indicator control cable.
Disconnect electric connection (2) (on 96/116 HP engines) or
(4) (on 136 HP engines) or (26) (on automatic transmissions)
from the reversing light switch.
NOTE In case of vehicles equipped with automatic

transmission, disconnect gearbox-chassis cable
connector (27) from the control unit.
Disconnect exhaust pipe (9) from the turboblower outlet

pipe.
Disconnect vacuum pipe (29) from VGT actuator (28, only
136 HP engine).
Put a jack under the gearbox to support it.
Disconnect the bracket supporting the gearbox on the rear
crosspiece by undoing the four screws (5).
Unscrew the fixing screws (6) and remove the crosspiece (7)
supporting the gearbox complete with the gearbox/support
bracket.
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 the
chassis.
Take the jack out from under the gearbox.
Lift the engine assembly and take it out of the engine bay.
NOTE The power unit must be removed from the engine

compartment with the greatest care, to avoid
damaging the remaining parts on the vehicle, in
particular the steering box oil pipes.
If it is necessary to detach the gearbox from the engine, take

out the fixing screws and remove the starter motor.
Take out the fixing screws and detach the gearbox from the
engine.
NOTE As far as automatic transmission is concerned,

strictly adhere to the operations described in the
relevant chapter in the “Gearbox” section.
108557

Refitting
NOTE When positioning the engine in the engine bay,
take special care not to damage the top pipe of the
To refit the engine assembly, carry out the operations power steering and the soundproof-heatproof
described for removal in reverse order, following these cladding of the engine bay.
instructions: Once positioned, meticulously check that the top
pipe of the power steering is sound.
- Before refitting the gearbox to the engine, it is necessary Before using it again, check that the power steering
to remove the pressure plate bearing from the oil and coolant contain no impurities. If they do,
diaphragm spring by opening out the retaining circlip. filter with suitable mesh filters. For any topping up,
Fit the pressure plate bearing on the sleeve of the drive refer to the REPLENISHING FLUIDS table in the
input shaft cover, connecting it to the clutch release “GENERAL” section.
lever. Spread the gearbox input shaft with Molikote
molybdenum disulphide grease.
As regards the 5 S 300 - 6 S 400 O.D. gearbox units,
proceed as follows.
Engage a gear to let the main shaft turn, rotating the
propeller shaft connecting flange. Push the gearbox fully
in so that the pressure plate bearing couples with the
diaphragm spring correctly.
As regards the 6 S 400 O.D. gearbox units, follow the Checks and tests
procedures described in the specific chapter.
- Pay special attention to the operations needed to install Start up engine, leave running at a speed slightly in
the engine assembly in the engine bay. excess of idle speed and wait for coolant to heat
sufficiently to open thermostat. Then check the fol-
- Check the conditions of the coolant pipes or sleeves and lowing:
of the air ducts. Replace them if they show any sign of
deterioration.
- Check the flexible mountings of the assemblies: engine
and gearbox. Replace them if they show any sign of - no coolant leaks from coolant hose and cab interior
deterioration. heating hose connection sleeves. Tighten hose clips, if
necessary;
- Check that the exhaust pipe members have not
deteriorated and are not about to deteriorate. If this is - no oil leaks from between cover and cylinder head, oil
so, replace them along with the flexible parts for securing sump and crankcase, oil filter and housing, heat
them. exchanger and crankcase or from lubrication circuit lines;
- Tighten the screws or nuts to the required torque. - no fuel leaks from injection pump and injector lines.
Tighten fittings if necessary;
- Meticulously check the state of the vacuum pipe. It must
show no sign of cracking, cutting, scoring or of being - check that injection pump control linkage allows the flow
crushed. Replace it if there is any doubt at all about its regulation to perform its full travel in both directions.
soundness. When mounting it, make sure the pipe does Otherwise adjust the travel by acting on nuts (1-2, Fig.
not come into contact with sharp metal parts or corners 6);
or with any particularly hot parts. In addition, after - check that the engine shut-off device is working properly;
assembly, the pipe must have no bends or constrictions,
its radius of curvature should be broad and it must be - check that the indicator lights on the instrument panel
secured to the vacuum pump fitting with a suitable and relating to the devices disconnected when the
clamp. engine was removed are working properly.
- make sure that fuel pipes rapid engagement fittings are 501430 Power steering system air
accurately clean, and result to have been fully inserted
bleed
and not going to be disconnected after their being
connected to relating engagement unions.
- Fill the cooling system with coolant. Check the level of oil in the tank and top it up if necessary.
Lift the vehicle at the front, start up the engine and let it idle
- Fill the hydraulic power steering circuit and bleed the air for some time.
as described under the relevant heading. Check there is no oil leakage from the hydraulic circuit and
- Check the level of oil in the engine and gearbox. check the level in the tank.
Slowly turn the steering wheel in both directions of steering
- recharge climate control system (if present) as described so that the air in the hydraulic system comes out.
in chapter relating to section ”Body and chassis”; Check the level of oil in the tank again and top up if necessary.
- check the inclination of light from headlights, if needed.

REPLACING BELTS
543910 Replacing air-conditioning
compressor drive belt
Disassembly
Figure 5
90155
Cut elastic belt (3), as it cannot be reused.
Assembly
Fit 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 fasten
the ring on the compressor support.
Turn the drive shaft clockwise until the belt fits
perfectly on the pulley (1).
543910 Power steering pump-alternator

belt replacement
Disassembly
Figure 6
75248
Disassemble the compressor drive belt, if there is one, as

described under the relevant heading.
Slacken off the tension of the belt (1) using a specific wrench
on the automatic tightener (2) and remove the belt.
Assembly
Mount the drive belt (1) taking care to position its
ribs correctly in the respective races of the pulleys.
Release the automatic tightener (2). Turn the
crankshaft by one turn to settle the belt.
Mount the compressor drive belt, if there is one, and
adjust the tension as described under the relevant
heading.
Fit the middle soundproofing guard back on.

541257 Replacing timing drive belt Figure 7
Disassembly
Remove, by following the power unit detachment procedures,

the radiator assembly together with the heat exchanger and
the drying filter condenser (if any), then place it aside properly.
Remove the air-conditioner compressor drive belt (11) (if

there is one) and the water pump / alternator drive belt as
described under the relevant headings.
Remove the fan (10) from the electromagnetic coupling (8).
Disconnect the electrical connection (9) from the
electromagnetic coupling (8).
Take out the fixing screws (2) and (3) and remove the
mounting together with the electromagnetic coupling (8).
Take out the screws and remove the fixed tightener (4) and
the automatic tightener (5).
Remove screws (7), then disassemble pulley (6).
Remove the wiring from the timing cover (12) and dismantle
this.
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 expansion
tank (29); disconnect the electrical connection for the level
indicator from the expansion tank and put the tank (29) aside
appropriately.
Take out the screws (23) and remove the bracket (22) fixing
the 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 pins
99360614 (25) through the holes in the plugs (24) into the
relevant 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).
108558

Assembling Figure 8
NOTE Only for the engines featuring intake valve distributing shafts with
tapered shank (full section).
Insert tool 99360608 (8) into the hole of the toothed pulley (7)
and into the corresponding hole of the overhead to prevent
changing the assembly position of the toothed pulley (7) in the
following operations.
Loosen the screw (9) fixing the toothed pulley (7) and, using tool
99340028, drive the pulley (7) out of the camshaft.
Turn the automatic tightener (1) clockwise, positioning it as shown in frame

A.
Turn the timing belt (10) as shown in the figure observing the precautions
below.
Do not bend the timing belt. Arrows indicating the direction of assembly
of the timing belt on the engine are shown on the back of the belt. The
arrows must correspond to the direction of rotation of the belt and the
notches must coincide with those on the pulley (7) and the gear (12).
NOTE Only for the engines featuring intake valve distributing shafts with
tapered shank (full section).
If required to fit the timing belt (10) on the pulley (7), remove tool
99360608 (8) and turn the pulley (7) clockwise by no more than
half a pulley tooth.
Keeping the screw (2) stationary and using a suitable wrench on the hexagon
of the plate (3) of the tightener, turn it anticlockwise to cover the reference
hole (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 ± 4 Nm.
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 the
tools (6) and (11) back in to do the timing.
In these conditions, the notches of the timing belt (10) must coincide with
those of the pulley (7) and the gear (12).
NOTE Do not turn the engine in the opposite direction; if, on turning the
engine, you pass the point for inserting the tools (6) and (11), turn
the engine clockwise by another two turns.
See frame C: holding the tightener plate (3) stationary with the wrench
inserted in its hexagon, loosen the fixing screw (2).
Keeping the fixing screw (2) stationary, turn the plate (3) clockwise until its
reference mark ∧ (4) coincides with the reference hole (5) of the fixed
portion 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 of
tool 99360615 (1) engagement into the drive shaft is reached. When this
point 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 be
repeated.
After assembly, the belt (10) tension measured using tool 99395849 must
be as follows in the following points: X, 212 ± 12 Hz - X2, 178 ± 10 Hz.
Then complete assembly by carrying out the steps described for disassembly x = direction of movement of the tightener
in reverse order. y = direction of rotation of the wrench 85844

755010 REPLACING THE ELECTRIC INJECTORS

When electrical injectors mounted on the vehicle must be
Figure 9 replaced, meet following warnings:
- where electrical injectors are dismounted and do not
need to be replaced, their mounting position has to be
noted down in order to remount them later in the same
position; this is done to avoid to reprogram the central
unit;
- after replacing one or more injectors, the central unit has
to be reprogrammed;
- before mounting a new electrical injector, note down
IMA code printed on the injector, because the code is
difficult to read after the injector has been mounted;
- where the central unit is replaced, reprogram the new
central unit with the IMA codes of the electrical injectors
mounted on the engine and copy down the rectification
coefficients (ZFC) of replaced central unit; where it is not
possible, they must be reset and self-learning process
105066
must be started up again.
During engine running, EDC 16 central unit performs some
1. IMA Matrix code- 2. Bosch spare part no.- checks on electrical injectors minimum flow rate.
3. IMA code in clear - 4. Iveco spare part no. - 5. Code -
6. Series no. - 7. Production date In certain conditions (overrun: vehicle deceleration with
Electrical injectors are not assigned any more to classes Min (01) pedal released) an increasing (very small) fuel quantity
- Med (02) - Max (03); therefore, flow rate deviations from starting from zero is injected and its effect on engine rotation
design values are detected, during final check step, by the smoothness is observed.
manufacturer on each single injector and printed with I.M.A. Injection start threshold is detected and stored by the central
(Injector Menge Abgleichung) [Injector Quantity Offset] code unit.
on injector magnet. This self-learning process is carried out on each single
At engine production plant, I.M.A. code is read on line from an cylinder.
automatic reading station, converted into bar code, printed on Therefore, replacing an electrical injector involves the need
engine identification label and applied on the engine itself. of reprogramming the central unit by entering the IMA codes
At vehicles production plant, at line end, E.D.C. 16 central unit of new electrical injectors and resetting the rectification
is programmed automatically reading the engine identification factors (ZFC) of the cylinder considered.
label. Replacing all electrical injectors extends the need of resetting
to all the rectification coefficients (ZFC) of each single
electrical injector.
Figure 10
Conversion table of OCR

characters into ARIAL characters 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 characters
into Arial characters.

Figure 11
Removal
108559
Partly drain the coolant off from the radiator. Refitting

Remove the plug (21, Figure 9) and detach the
soundproofing cover (20, Figure 9).
Disconnect the pipes (19, Figure 9) from the pipe (18, Thoroughly clean the seat of the electro-injectors, taking care
Figure 9). no foreign bodies get into the cylinder barrels.
Remove fastening screws (26, Figure 9), then take off Fit a fresh gasket (12) onto the electro-injector (10) and fit
expansion tank (29, Figure 9) and disconnect level gauge this in the overhead.
electric connections (6, figure 7) and sensor (27) electric
Complete assembly by carrying out the operations described
connections (28, figure 7) from the expansion tank.
for disassembly in reverse order, taking the following
Disconnect the pipe (20, Figure 12) from the coalescence
precautions:
filter (1, Figure 12).
Disconnect the electrical connections (1) from the - With each disassembly, the fuel pipes must be replaced
electro-injectors (10) and (2) from the fuel pressure sensor with fresh ones.
(8). - Tighten the nuts, screws and fittings to the prescribed
Press the springs (3) in the direction shown by the arrow and torque.
disconnect the fittings of the pipe (4) to recover fuel from the - To tighten the fittings of the fuel pipes, use the wrench
electro-injectors (10). in the 99317915 series and the torque wrench
Disconnect the fuel pipes (7) from the electro-injectors (10) 99389829.
and from the hydraulic accumulator (9). - After assembly, replenish the coolant as described under
Take out the screws (6) and the brackets (5) fixing the the relevant heading.
electro-injectors (10) to the cylinder head.
Check assembly of the timing sensor as described under the
Using tool 99342153 (11) extract the electro-injectors (10)
relevant heading.
from the overhead.

540610 CYLINDER HEAD REMOVAL AND REFITTING

Figure 12
108560
Removal
Take off the camshaft drive belt, as described in the Take off electric injectors (4), as described in the ”Replacing
respective chapter (operation 541257). the electric injectors” chapter (operation 775010).
Disconnect coolant pipes (15) and (14) from pipe (13). Disconnect the electric connections from phase sensor (3),
Disconnect the electric connection from pressure sensor water temperature sensor (8), air pressure/temperature
(18). sensor (9), preheating plugs (6), throttle valve assembly
Remove the fastening screws, then take off expansion tank actuator (10), fuel pressure sensor (16).
(17) by disconnecting from the latter the electric connection Take fuel pipe (7) off hydraulic accumulator (5),
from the level sensor. high-pressure pump and inlet manifold.
Remove oil dipstick pipe (12) from the inlet manifold.
Disconnect oil vapour pipes (20) and (19) from coalescence
filter (1), then remove the latter from the overhead.
Disconnect pipe (2) from the heat exchanger engine coolant
outlet pipe.

Figure 13
108561
Loosen clamp (9), then take the air conveyor off. Take out the screws and remove the overhead together with
Take air suction sleeve (10) off turboblower (8). the pins 99360614.
Disconnect the oil pipe (11) from the cylinder head and from
the turbocharger (8).
Loosen the clamp (7) and disconnect the oil pipe (5) from NOTE The pins 99360614 applied so as not to alter the
the crankcase union. timing after removing the timing belt must be
Take out the screws and disconnect the exhaust pipe (4) removed from the overhead only if this is to be
from the turbocharger (8). removed.
Take off the nuts (3) and remove the turbocharger (8) with
its gasket from the exhaust manifold.
Take off the overhead gasket.

Take out the tappets and carefully put them aside.
NOTE Close the turbocharger air outlet/inlet Using the bushing 99355041, take out the glow plugs.
appropriately to prevent foreign bodies Take out the screws fixing the cylinder head and detach this
accidentally getting inside and damaging it. from the crankcase.
Remove the cylinder head gasket.
Disconnect the vacuum pipes from E.G.R. valve (2) and

turboblower (if any) actuator (6).

Refitting Figure 14
Refitting requires carrying out the operations for removal in

A
reverse 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 as
described in “Replacing timing belt.”
Check that the mating surfaces of the cylinder head and
crankcase are clean.
Keep the cylinder head gasket clean. 75494
Position the cylinder head gasket with the lettering ”TOP”
facing the cylinder head. Diagram of the tightening sequence for the cylinder head
fixing 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.
NOTE It is essential to keep the gasket sealed in its package
until just before assembly. - Tighten the screws and nuts to the prescribed torque.
- The seals and gaskets must not be reused, but replaced
with new ones.
Mount the cylinder head. Insert the screws and tighten them,
in three successive stages, following the order and method
shown in the following figure. NOTE If the engine has run for a period equivalent to =
25,000 km, the toothed timing drive belt must be
replaced with a fresh one, no matter what its state
of wear.
NOTE The angle closure is done with tool 99395216.
To tighten the glow plugs, use the bushing 99355041 and

torque wrench 99389819.

771010 REPLACING HIGH-PRESSURE

PUMP CPH1 Figure 17
Removal
Remove the timing drive belt, as described in the relevant

chapter (operation 541257).
Disconnect the following items:
- electric connection from the pressure sensor;
- fuel pipes from the high-pressure pump.
Figure 15
75273
Take out the screws (1) and remove the high-pressure pump
(2) from the water pump mounting (3).
Refitting
Re-attachment is carried out by reversing the order
of detachment operations. In particular, take care of
the following: replace the seal rings, gaskets and
high-pressure pipe with new parts; tighten the nuts,
screws and fittings to the specified torque values.
NOTE If the engine has run for a period equivalent to =

25,000 km, the toothed timing drive belt must be
replaced with a fresh one, no matter what its state
75271 of wear.
Lock rotation of the high-pressure pump gear (1) by applying

tool SP. 2263 (2) as illustrated in the figure. Remove the nut
(3) and take out the tool (2).
543210 REPLACING WATER PUMP
Removal
Remove the high-pressure pump as described
under the relevant heading.
Figure 18
Figure 16
75569
Take out the screw (2) and remove the fixed tightener (1).
75272
Take out the screws (3) and remove the water pump
mounting (4).
Using tool 99340035 (2) applied as shown in the figure,
extract the gear (1) from the shaft of the high-pressure pump Refitting
(3). Fit two new seals on the water pump and fit it back
on the crankcase, carrying out the operations
described for removal in reverse order and
tightening the screws or nuts to the prescribed
torque.

THROTTLE VALVE ASSEMBLY REMOVAL-

REFITTING
Figure 21
Removal
Figure 19
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.
108562 Refitting
Remove oil filling plug (1) and take off sound deadening cover For refitting, reverse the operations described for
(2). disconnection observing following warnings:
Loosen clamp and disconnect air tube (8) from radiator and - replace gasket by new parts;
throttle valve assembly (7).
Disconnect electrical connection (6) from pressure switch - tighten nuts and screws at prescribed torque.
(5).
Remove expansion tank (4), disconnect electrical connection
(3) from the level sensor placed under the tank and put the
tank on one side.
PREHEATING PLUG REMOVAL/REFITTING
Removal
Figure 20
Figure 22
108565
Take off the throttle valve assembly, as described in the

respective chapter.
Disconnect electric connections (3) from preheating plugs
(2).
108563
Use wrench SP 2275 (1) to take off preheating plugs (2).
Release engine cable (1) from the fastening clamps Refitting
Disconnect electric connections (2) from the electric For refitting, reverse the operations described for
injectors, then move channel (3) aside. disconnection observing following warnings:
Disconnect electric connection (4) from throttle valve - replace gasket by new parts;
assembly actuator (6).
Remove screws (5) securing throttle valve assembly (6) to - tighten nuts and screws at prescribed torque.
the inlet manifold.

5407 E.G.R. VALVE REMOVAL/REFITTING

Removal Remove nut (4) used for upper securing of throttle valve
assembly (5) connecting pipe (9) to heat exchanger (7).
Figure 23 Lower fastening nut (6) shall be removed from under the
vehicle.
Act from under the vehicle to remove the heat exchanger
supporting and engine lifting bracket (8) fastening screws.
Figure 25
108566
Partially drain the engine coolant.

Take the full exhaust pipe off the engine and the chassis, as
described 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 108624
(7), together with elbow (11), from heat exchanger (2), pipe
Take off the E.G.R. valve, as described in the respective
(8) from bracket (4).
chapter.
Refitting
Loosen connecting pipe (6) fastening nuts (5) in order to
For refitting, reverse the operations described for make screws (7) able to be accessed.
disconnection observing following warnings:
Remove screws (7), then take off engine lifting bracket (8).
- replace gasket by new parts; Remove screws (9), take pipe union (2) off the cylinder head,
- tighten nuts and screws at prescribed torque. then take off heat exchanger (1) together with pipes (3 and
4) and pipe union (2).
- fill expansion tank with coolant.
Refitting
HEAT EXCHANGER REMOVAL/REFITTING For refitting, reverse the operations described for
Removal - replace gasket by new parts;
Figure 24 - tighten nuts and screws at prescribed torque.
108623
Act from inside the engine compartment to take off the

cylinder head sound-proofing cover.
Disconnect cab heater coolant pipe (2) from the similar
E.G.R. valve outlet pipe (1).
Remove the nut, then take the pipe off coalescence paper
filter (3).

BURNT GAS EXHAUST SYSTEM 507130 OXICAT - OXYDIZER CATALYST

Description
Description
The following exhaust systems are available on light-duty
(LD) vehicles with a total weight on ground (P.T.T.) of up to
2,840 kg: The oxidizing catalyst (1) is a post-treatment device for ex-
haust gases. It is used to oxidize CO, HC transforming them
- two standard exhaust systems: into carbon dioxide (CO2) and steam (H2O).
- F1A engines: single-monolith catalyst;
This catalyst also treats saturated and aromatic hydrocarbons
- F1C engines: double-monolith catalyst; forming part of the particulate, such as the carbon in the form
- the catalyst may be equipped with an optional of soot, metals, water and sulphur compounds that are ex-
continuous-regeneration particulate filter (DPF). hausted.
The standard exhaust system is made up of three The cylindrical-shaped catalyst consists of a ceramic honey-
components: comb monolith whose cells are platinum-impregnated, a ca-
talyzing substance of oxidation reactions. Its total volumetric
A. system length with hose; capacity is equal to 600 cm3 with a density of 400 cells per
B. Oxicat catalyst; square inch.
C. silencer.
The exhaust gases passing through the cells heat the catalyst,
The exhaust system is made by two different manufacturers: converting the pollutants into inert compounds.
CorTubi and ArvinMeritor (ArM). The components of both The chemical oxidation reaction of CO, HC and of the parti-
systems cannot be interchanged with each other. culate is efficient with temperatures ranging between
200°C ÷350°C.
With temperatures higher than 350°C it starts oxidizing the sul-
phur contained in the diesel oil, generating sulphur dioxide
(SO2) and sulphur trioxide (SO3), which are the cause of acid
rain.
Correct catalyst sizing enables limiting the temperature, ob-
taining the greatest percentage of conversion of polluting
emissions, while reducing the freezing of sulphur compounds.
Figure 26
108625

The optional exhaust system is made up of three

components:
A. system length with hose;
B. catalyst with particulate filter (DPF);
C. silencer
This system is manufactured by ArvinMeritor (ArM).
Figure 27
108626

EXHAUST PIPE ASSEMBLY REMOVAL/REFITTING

Figure 28
108627
Removal Refitting
For refitting, reverse the operations described for
Place the vehicle on a pit or auto lift.
- check the conditions of the elastic dowels,
Disconnect oxygen sensor electric connection (4). taking care to replace the defective
Remove fasteners (2), then disconnect exhaust pipe terminal ones (if any);
(3) from turboblower flange (1). - replace gasket by new parts;
Properly support the assembly, then use a suitable lever to - tighten nuts and screws at prescribed torque.
release supporting hooks (6 and 8) from elastic dowels (5 and
7) and take the assembly off the vehicle.
Take the assembly components apart, by loosening the
retaining clamps.

REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY COMPONENTS (SYSTEMS EQUIPPED

WITH D.P.F. CATALYST)
Figure 29
105073
Refitting
Exhaust silencer removal disconnection observing following warnings:
Place the vehicle on a pit or auto lift. - check the conditions of the elastic dowels,
taking care to replace the defective
Carry out the following operations by acting from under the ones (if any);
vehicle:
- unscrew nuts (2) securing silencer (3) supporting - replace gasket by new parts;
bracket (1) to the vehicle chassis; - tighten nuts and screws at prescribed torque.
- unscrew and remove fastening screws (4) of flanges (5)
connecting exhaust silencer (3) and D.P.F. particulate
filter (8);
After the operation has been completed, and in the event
- remove exhaust silencer (3). that either the D.P.F. catalyst or the differential sensor
(delta-p) needs replacing, follow the instructions given in the
D.P.F. catalyst removal respective chapters.
- unscrew and remove the exhaust gas temperature
sensors at the catalyst inlet
(16) and outlet (17);
- unscrew to disconnect couplings (6 and 12) securing
rigid pipes (7 and 11)
running to the pressure sensor to D.P.F. catalyst (8);
- properly secure D.P.F. catalyst (8) to the vehicle chassis;
- unscrew nuts (9) securing D.P.F. catalyst (8) filter
supporting bracket (10) to the
vehicle chassis;
- unscrew and remove fastening screws (13) of flanges
(15) connecting D.P.F.
catalyst (8) filter to the exhaust gas outlet pipe from
turbine (14);
- remove D.P.F. catalyst (8) filter.
507130 Replacing D.P.F. catalyst 540743 Replacing differential sensor

Replacing D.P.F. catalyst needs that all the counters of below (delta-p)
indicated parameters are reset in the central unit, as: Pressure difference between gas pressure at catalyst module
- particulate quantity in new filter is zero, so, if particulate inlet and gas pressure at ceramic walls filter outlet is
quantity is not reset, filter regeneration will start even if it converted into a voltage signal (Vout) by pressure sensor.
is not necessary; During engine running, E.D.C. 16 central unit performs
- quantity of accumulated ashes is zero, so, if ashes counter checks on differential pressure sensor drift and calculates
is not reset, regeneration frequency will be greater than engine compensation and running values, and corrects them.
needed, consequently increasing fuel consumption, and Consequently, after replacing the sensor, it is necessary to
particulate filter thermal fatigue; and, in extreme cases, reset rectification coefficients.
there will be an unnecessary request to refill engine oil;
- post-injected fuel quantity is zero, so, if post-injected fuel
counter is not reset, there may be an early request to refill The meters used to evaluate the above-mentioned
engine oil. parameters can be reset by means of the IVECO MODUS -
E.A.SY. - IT 2000 diagnosis instruments, by programming the
control unit again and performing the differential sensor
replacement procedure, in accordance with the instructions
given by the diagnosis instruments.
NOTE Where both DPF catalyst is replaced and engine oil
is refilled, resetting post-injected fuel counter is not
necessary.
- regeneration status: regeneration unnecessary, in progress,

interrupted, resumed;
- miles covered and times from last complete regeneration;
- differential pressure (delta-p) sensor drift self-rectification;
- oxidiser catalyst drift; consequently, if catalyst ageing
function is not reset, quantities of unnecessary
post-injections might be present.
The meters used to evaluate the above-mentioned

parameters can be reset by means of the IVECO MODUS -
E.A.SY. - IT 2000 diagnosis instruments, by programming the
control unit again and performing the DPF catalyst

ENGINE VIEWS
Figure 30
108321

Figure 31 Figure 33
108157 108159
LEFT-HAND SIDE VIEW

FRONT VIEW
Figure 32
108158
REAR VIEW

Figure 34
108160
RIGHT-HAND SIDE VIEW

A. Turbocharger with pressure relief valve (Waste-Gate, ENGINES 96/116 HP)
Figure 35
108161
TOP VIEW

EMISSIONS
Gas emissions Smokiness
The engines conform to the Euro 4 standards on gas The engines conform to the limits of smokiness required with
emissions (measurement on engine bench according to ECE the following exhaust smoke values:
15 + EUDC cycle), with the following limits fixed by the ESC Maximum power (Bosch BSU opacimeter degrees) 1.5
and ELR 1999/96-2001/27 standards: Maximum torque (Bosch BSU opacimeter degrees) 1.5
level B:
- CO (carbon monoxide) 0,74 g/km Noise emissions
- NOx (nitrogen oxide) 0,39 g/km Maximum mean noise level, Lpa, of the standard engines
measured according to ISO Std. 3745 (microphones at 1 m
- HC (unburnt hydrocarbons) + NOX from the engine surfaces):
(nitric oxide) 0,46 g/km Idling (800 rpm) 72 dBA
- Particulate 0,06 g/km At the maximum torque 84 dB A
Full power (3800 rpm) 93 dBA.
Test fuel: CEC RTF 73-T90. 5 = 0.05%.

ENGINE IDENTIFICATION CODE
F 1 A E 0 4 8 1 F * A +
Emission level
Type approval power
Use No.
Supply / injection
No. cylinders
Engine cycle — cylinder position
Engine
Family development 0= 4-stroke,

vertical
Engine family
4 = 4 cylind.
6 = 6 cylind.
8 = DI. TCA
1 = Truck
2 = Bus
4 = E.M. mach.
& tractors
6 = Nautical
9 = Military
0481 F = 71 kW - ( 96 CV)3000-3700 rpm -244 Nm / 1800÷2800 rpm

0481 G = 85 kW - ( 116 CV)3000-3900 rpm -270 Nm / 1800÷2800 rpm
0481 H = 100 kW - ( 136 CV)3600-3900 rpm -320 Nm / 1700÷2900 rpm

CHARACTERISTIC CURVES
Figure 36
rpm 102408
CHARACTERISTIC CURVES OF ENGINE F1AE0481F
Max OUTPUT 71 kW 96 HP at 3000÷3700 rpm
Max TORQUE 240 Nm 24.4 kgm at 1800÷2800 rpm

Figure 37
rpm 102409
CHARACTERISTIC CURVES OF ENGINE F1AE0481G

Figure 38
rpm 102410
CHARACTERISTIC CURVES OF ENGINE F1AE0481H

Figure 39
SELF-ADHESIVE LABEL
Engine variant
Iveco drawing number
— 9 digits
Engine serial number
— 7 digits
GAN — 9 characters
Electro-injector class
108448
Figure 40
CRANKCASE MARKING
112216
EXAMPLE
A = IVECO trademark IVECO
B = IVECO name of engine variant ** F1AE0481A * A001
C = Engine serial number 1359862
D = 1st digit, main journal no. 1 (engine front)
E = Main bearing selection diameters 12345
F = Barrel selection diameters 1234
G = 1st digit, cylinder no. 1 (engine front)
(**) Data obtainable from “XZ” engine ordering number information

GENERAL SPECIFICATIONS
Type F1AE0481 F F1AE0481 G F1AE0481 H
Cycle Diesel 4 strokes

Supply Turbocharged with intercooler
Injection Direct
Number of cylinder 4 in line
∅
Bore mm 88
Stroke mm 94
+ + +.. = Total displacement cm3 2300
ρ Compression ratio 18
Maximum power kW 71 85 100

(HP) (96) (116) (136)
rpm 3900 3900 3900
Maximum torque kW 240 270 310

(HP) (24.4) (27.5) (31.6)
rpm 1800 ÷ 3200 1800 ÷ 3150 1800
Slow running of engine

with no load rpm 800
Fast idling speed of
engine with no load rpm 4600
Pressure at T.D.C.
*bar 20 ÷ 26
bar Minimum permissible
pressure at T.D.C.
*bar 16
(*) The pressure is measured by setting the engine turning with the aid of just the starter motor, with an oil temperature of
40 — 50°C.

A
TIMING SYSTEM
Start before T.D.C. A 14°
end after B.D.C. B 27°

B
Start before T.D.C. D 54°
end after B.D.C. C 10°

D
For timing check
mm -
X
mm -
X
Operation
mm -
X
mm -
High pressure fuel feed system BOSCH EDC16

Composed of CP1 high-pressure pump, electro-injectors,
SUPPLY
hydraulic accumulator (rail), EDC control unit, pressure and
temperature sensors
Pump setting -
With piston no.1 at T.D.C.
X
Start of delivery mm -
Electro injectors type

Electro-injectors BOSCH CR1 2-2
22
Injection sequence 1- 3 - 4 - 2
ba
r Injection pressure bar 1600

TURBOCHARGING With intercooler

KKK K03-2074-CCB 5.88 Garrett GT17
Turbocharger type
Turbocharger shaft radial play - -
Turbocharger shaft end float - -
Maximum stroke of pressure relief valve opening mm 3.35 ±0.5 -
Pressure corresponding to the maximum stroke bar 1.6 ±0.005 -
Actuator calibration:
-vacuum: 0 mmHg valve fully open - -
- vacuum: 0.2 bar valve travel mm - 2÷4
-vacuum: 0.64 bar valve travel mm - 10.5 ÷ 12.5
forced by gear pump, pressure relief valve, oil filter with
LUBRICATION
integral cartridge with total filtering
Oil pressure with engine hot
bar (100°C ±5°C):
at idling speed bar ≥0.6
at top speed bar 4
by centrifugal pump, thermostat for adjustment, coolant
COOLING temperature, fan with electromagnetic coupling, radiator,
heat exchanger
Water pump control: by belt
Thermostat: N. I.
start of opening: 82 ±2ºC
FLUIDS
Capacity:
engine sump liters 3
at minimum level kg 2.65
Urania Daily engine sump litres

Urania LD 5 at maximum level kg 4.3
3.78
quantity of oil for first liters

filling kg 5.3
5.02

ASSEMBLY DATA — CLEARANCES
CYLINDER ASSEMBLY AND CRANK MEMBERS mm

Cylinder liners:
∅1
∅1 88.002 ÷ 88.022
Cylinder liners: -
L outside diameter ∅ -
∅2 length L -
Cylinder liners —
crankcase seats -
(interference)
Outside diameter ∅2 -
∅3
Cylinder liners:
(protrusion from bottom -
X of crankcase)
inside diameter ∅3 -
Pistons: MAHLE MONDIAL

∅1 supplied as spares type
X 8
measurement X
outside diameter ∅1 87 896 ÷ 87.910
87.896 87 910
∅2 seat for pin ∅2 31.003
31 003 ÷ 31.009
31 009
Piston - cylinder sleeve 0.092 ÷ 0.126
Piston diameter ∅1 0.4
X
Piston protrusion
from crankcase X 0.3 ÷ 0.6
∅3 Piston gudgeon pin ∅3 30.990 ÷ 30.996
Piston gudgeon pin — pin seat 0.07 ÷ 0.019


Type of piston
MAHLE MONDIAL
X1*
X1 2 200 ÷ 2.230
2.200 2 230
Piston ring slots X2
X2 2 050 ÷ 2.070
2.050 2 070
X3 X3
2 540 ÷ 2.560
2.540 2 560
* measured on ∅ of 85 mm
Piston rings: S 1* 2.068 ÷ 2.097
S1 S2 1.970 ÷ 1.990
S2
S3 2.470 ÷ 2.490
S3
* Measured at 2.5 mm
from the outer diameter
Piston rings — slots 1 0.103 ÷ 0.162
2 0.060 ÷ 0.100
3 0.050 ÷ 0.090
Piston rings 0.4
X1 Piston ring end opening in

cylinder liner:
X2
X1 0.20 ÷ 0.35
X3
X2 0.60 ÷ 0.80
X3 0.25 ÷ 0.50
∅1 Small end bushing seat
34.460 ÷ 34.490
Ø1
Connecting rod bearing seat*

∅2 62.833 ÷ 62.841
Ø2
* connecting rod supplied as
spare part
∅4 Small end bushing diameter
∅3 outside ∅4 34.560 ÷ 34.585
inside ∅3 31.010 ÷ 31.020

S
Big end bearing shells
supplied as spare part S -
Small end bushing — seat
0.07 ÷ 0.125
(interference)
Piston gudgeon pin — bushing 0.014 ÷ 0.030
Big end bearing shells 0.254 - 0.508


X
Measurement X 125
Maximum error
on alignment of
connecting rod axes = 0.09
Main journals ∅1
∅1 ∅2 No. 1-2-3-4 71.182 ÷ 71,208
No. 5 76.182 ÷ 76.208
Crankpins ∅2 59.015 ÷ 59.038
Main bearing shells
S1* 2.165 ÷ 2.174
S1 S 2 Big end bearing shells
S2* 1.883 ÷ 1.892
* supplied as spare parts
Main bearing housings ∅ 3
75.588 ÷ 75.614
∅3 No. 1-2-3-4
No. 5 80.588 ÷ 80,614
Bearing shells -
0.032 ÷ 0.102
main journals
Bearing shells —
0.035 ÷ 0.083
crankpins
Main bearing shells 0.254 - 0.508
Big end bearing shells 0.254 - .,508
Main journal
31.020 ÷ 31.170
for shoulder X1
X 1
Main bearing housing

25.790 ÷ 25.840
for shoulder X2
X 2
X3
Half thrust washers X3 30.810 ÷ 30.960
Crankshaft shoulder 0.060 ÷ 0.260

CYLINDER HEAD — TIMING SYSTEM mm

∅ 1
Guide valve seats

on cylinder head ∅1 9.980 ÷ 10.000
∅ 2
∅2 6.023 ÷ 6.038
Valve guide
∅3 10.028 ÷ 10.039
∅ 3
Valve guides and seats on head

0.028 ÷ 0.059
(interference)
Valve guides 0.05 - 0.10 - 0.25
∅ 4 Valves:
∅4 5.975 ÷ 6.000
α 44°45’ ±7.5’
∅4 5.975 ÷ 5.990
α α 44°45’ ±7.5’
Valve stem and relevant guide
0.023 ÷ 0.063
0.033 ÷ 0.063
Seat on head for valve seat:
∅1 31.390 ÷ 31.415
∅ 1 31.390 ÷ 31.415
∅1
Outside diameter of valve

∅ 2 seats; angle of valve seats on
cylinder
y head:
∅2 31 495 ÷ 31.510
31.495 31 510
α 44.5° ±5’
α ∅2 31.495 ÷ 31.510
α 44.5° ±5’
X 0.5 ÷ 0.8
X Recessing X 0.5 ÷ 0.8

0.08 - 0.12
Between valve
seat and head
0.08 - 0.12
Valve seats -
Valve spring height:

free height H 54
H under a load of:
H1
H 2 N243 ± 12 H1 45
N533 ± 24 H2 35
Injector protrusion X 2.77 ÷ 3.23

X
∅ Seats for tappets on

cylinder head normal ∅ 12.016 ÷ 12.034
Normal diameter tappets 11.988 ÷ 12.000

∅
Between tappets and seats 0.016 ÷ 0.046

Camshaft pin seats in
cylinder overhead
1⇒7
∅1 48.987 ÷ 49.013
∅ ∅ ∅ ∅2 46 987 ÷ 47.013
46.987 47 013
∅3 35.987 ÷ 36.013
∅ 2
Camshaft bearing journals
∅1 48.925 ÷ 48.950
∅2 46 925 ÷ 46.950
46.925 46 950
∅1 ∅2 ∅3
∅3 35.925 ÷ 35.950
Supporting pins and seats 0.037 ÷ 0.088
Useful cam height
H H
3.811
H
4.230

TOOLS
TOOL NO. DESCRIPTION
99305047 Appliance to check spring loads
99317915 Set of six box-type wrenches (14-17-19 mm)
Rotary telescopic stand for overhauling assemblies

99322205 (capacity 700 daN, torque 120 daN/m)
99340028 Extractor for camshaft pulley
99340035 High-pressure pump toothed pulley extractor
99340059 Tool to remove crankshaft front gasket

TOOLS
99340058 Tool to remove crankshaft rear gasket
99342153 Tool to extract injectors
99346254 Keying device for mounting crankshaft front gasket
99346255 Keying device for mounting crankshaft rear gasket
99360076 Tool to remove cartridge filters
99360183 Pliers for mounting rings on engine pistons

TOOLS
99360191 Guide for flexible belt
99360260 Tool for removing and refitting engine valves
99360306 Tool to retain engine flywheel
99360544 Arm for removing and refitting engine
99360605 Band to insert standard and oversized pistons into the cylinders
99360608 Tool for positioning timing gear

TOOLS
99360614 Tool (2) for camshaft timing
99360615 Tool for crankshaft timing
99361038 Brackets securing engine to rotary stand 99322205
99367121 Manual pump to measure pressure and vacuum
Comparator holder base

99370415
Keying device for mounting oil seal gasket on camshaft front cover
99374458

TOOLS
99389819 Torque wrench (0-10 Nm) with square 1/4” connection
99389829 9x12 coupling torque wrench (5-60 Nm)
Milling cutter to regrind injector seat

99394038 (8140.63 engine excluded)
Pair of meters for angular tightening with square 1/2” and 3/4”
99395216 connection
99395363 Complete square to check for connecting rod distortion
99395603 Comparator (0-5 mm)

TOOLS
99395687 Bore meter (50 — 178 mm)
Device for checking belt tension

99395849 (frequency from 10.0 to 600 Hz)
Centring ring for crankshaft front gasket cover

99396037
EXPERIMENTAL TOOLS
This section shows the working drawings for the experimental tools (S.P.) used in overhauling the engine described in this
section, which may be made by the repair shops.











TIGHTENING TORQUE
TORQUE
PART
Nm kgm
Cylinder head central fixing screw M14x1.5
first phase: pre-tightening 100 9.8
second phase: angle 90º
third phase: angle 90º
Cylinder head side fixing screw M14x1.5
first phase: pre-tightening 50 4.9
second phase: angle 60º
third phase: angle 60º
Hex screw with flange M8x1.25 L 40 fixing overhead 25 2.5
Hex screw with flange M8x1.25 L 77 fixing overhead 25 2.5
Central base fastening screw M11x1.25
first phase: pre-tightening 50 ± 5 5 ± 0.5
second phase: angle 60º ± 2.5º
third phase: angle 60º ± 2.5º
Outer base fastening screw M8x1,5 26 2.6
Connecting rod cap fixing screw
first phase: pre-tightening 40 4
second phase: angle 60°
Hex screw with flange M12x1.25 L 43 fixing engine flywheel
first phase: pre-tightening 30 3
second phase: angle 90°
Cylindrical socket head screw fixing phonic wheel to crankshaft 15 1.5
Nozzle union 25 2.5
Tapered threaded socket plug R 3/8” x 10 oil circuit 22 2.2
Water drain plug M14x1.50 L 10 25 2.5
Union on crankcase for oil return from turbocharger R 3/8” 50 5
Screw M6x1 fixing suction strainer 10 1
Male threaded socket plug M28x1.5 100 10
Hex screw with flange M8x1.5 L 35 fixing frame retaining oil sump 25 2.5
Hex screw with flange M6x1 L30 fixing frame retaining oil sump 10 1
Hex screw with flange M6x1 L25 fixing frame retaining oil sump 10 1
Tapered threaded socket plug M6x1x8.5* 2 0.2
Male threaded plug with O-ring M22x1.5 L16 50 ±10 5 ±1
Hex screw with flange M6x1 L20 fixing oil vacuum pump assembly 10 1
Hex screw with flange M6x1 L50 fixing oil vacuum pump assembly 10 1
Oil filter cartridge M22x1.5 L7 25 2.5
Union fixing heat exchanger M22x1.5 80 ±5 7.8 ±0.5
Hex screw with flange M12x1.25 L55 fixing toothed pulley controlling timing system 130 13
Hex screw with flange M18x1.5 L78 fixing pulley on crankshaft 300 30
Hex screw with flange M8x1.25 L45 fixing pulley on damper 30 3
Hex screw with flange M8x1.25 L60 fixing automatic tightener 36 3.6
High pressure pump gear fastening hex nut with flange M14x1.5 70 6.9
Hex screw with flange for complete guide pulley roller for timing belt M8x1.25 L45 25 2.5
* Apply Loctite on the thread.

TORQUE
PART
Nm kgm
Tapered threaded socket plug R 3/8” x 10 29 2.9
Hex screw with flange M12x1.25 L35 fixing gear for camshaft chain 115 11.5
Hex screw with flange M6x1 L25 fixing chain cover 10 1
Hex screw with flange M6x1 L35 automatic tightener 10 1
Threaded plug M14x1.5 L10 30 3
Ball joint fastening screw M6x1x9 10 1
Hex screw with split washer and flat washer fixing water pump M8x1.25 L28 25 2.5
Hex screw with split washer and flat washer fixing water pump M6x1 L20 10 1
Flanged screw M8x1.25 fixing water outlet union 25 2.5
Flanged screw M8x1.25 fixing piezometric tube on intake manifold 25 2.5
Flanged nut M8x1.25 fixing piezometric tube on bracket 18 1.8
Self-tapping screw L16 fixing bracket on coalescence filter cover 6 0.6
Flanged screw M6x1x16 fixing piezometric tube 10 1
Self-tapping flanged screw L14 fixing piezometric tube on front cover 2 0,2
Coupling M10x1x10 fixing vapour outlet 12 1.2
Hex screw with flange M8x1.25 L25 fixing thermostat 25 2.5
Hex screw with flange M8x1.25 L100 fixing air-conditioner compressor 25 2.5
Hex screw with flange M8x1.25 L120 fixing air-conditioner compressor 25 2.5
Hex screw with flange M8x1.25 L50 fixing air-conditioner compressor mounting 25 2.5
Hex screw fixing bottom of alternator M10x1.25 L40 and M10x1.5 L50 50 5
Hex screw fixing top of alternator M10x1.25 L40 - -
Hex screw with flange M10x1,25 for complete guide pulley roller for timing belt M10x1.25 L50 40 4
Allen head screw fixing automatic tightener M8x1.25 L65 25 2.5
Hex screw with flange M8x1.25 L45 fixing pulley on damper 30 3
Screw plug with washer M12x1.5 L20 30 3
Vacuum pump coupling M10x1 on oil vacuum pump assembly 10 1
Flanged screw M6x1x27 fixing timing cover 7.5 0.7
Hex screw with flange M6x1 L27 fixing coalescence filter assembly 10 1
Screw M6x1 L12 fixing sump blow-by oil drain pipes 10 1
Union M20x1.5 blow-by breather socket 35 3.5
Hex screw with flange M8x1.25 L90 fixing intake manifold 30 3
Flanged nut M8x1.25 fixing exhaust manifold 25 2.5
Flanged screw M6x1 fixing oil fillpipe 10 1
Flanged screw M8x1.25 fixing oil dipstick pipe 28 2.8
Glow plug M8x1.25 8 ÷ 11 0.8 ÷ 1.1
High-pressure injection system
Hex screw with flange fixing hydraulic accumulator M8x1.25 L50 28 2.8
Screw M8x1.25 L30 fixing high-pressure pump 25 2.5
Screw M8x1.25 fixing bracket anchoring fuel delivery pipe 25 2.5
Hex screw fixing electro-injector retaining bracket 28 2.8
Hex screw with flange fixing low-pressure fuel pipes M6x1 L30 10 1
* With Loctite.

TORQUE
PART
Nm kgm
Pipe fitting M12x1.5 to secure electric injectors side and high pressure pump side piping
25 ± 2 2.5 ± 0.2
(welded hydraulic accumulator)
Pipe fitting M14x1.5 to secure hydraulic accumulator side piping
19 ± 0.2 1.9 ± 0.2
(welded hydraulic accumulator)
Union M12x1.5 for fixing fuel pipes 25 2.5
Flanged screw M12x1.5 fixing water temperature sensor 30 3
Flanged screw M6x1 fixing air temperature sensor 10 1
Flanged screw M6x1 fixing engine speed sensor 10 1
Socket-head screw M6x1 fixing timing sensor 10 1
Cylindrical socket-head screw M6x1 for V-clamp 8 0.8
Nut M8x1.25 fixing turbocharger 25 2.5
Flanged screw (M8x1.25) for turboblower gas outlet pipe fastening 25 2.5
Fitting R1/4“ for pipe delivering oil to turbocharger 40 4
Nut (M14x1.5) for fastening the oil delivery pipe to the turboblower 40 4
Pipe union (M12x1.5) for fastening the oil delivery pipe to the turboblower 35 3.5
Fitting M22x1.5 for oil return pipe from turbocharger 45 4.5
Flanged screw fixing oil return pipe from turbocharger 10 1
Hex screw with flange M8x1.25 L40 fixing power steering pump 25 2.5
TE flanged screw (M8x1.25) for power steering pump pulley fastening 25 2.5
Hex screw with flange M12x1.25 L155 fixing electromagnetic coupling mounting 90 9
Hex screw with flange M8x1.25 L20 fixing manoeuvring hooks 25 2.5
Flanged screws M10x1.25 fixing engine mounts 50 5
Oil level sensor M12x1.25 25 2.5
Thermometric switch/transmitter M16x1.5 25 2.5
Oil pressure switch M14x1.5 40 4
Cylindrical socket-head screw M8x1.25 fixing E.G.R. valve 25 2.5
Flanged screw M8x1.25 fixing E.G.R. heat exchanger 25 2.5
Flanged nut M8x1.25 fixing elbow 25 2.5
Compensator fastening nut M8x1.25 25 2.5
Oil pressure regulation valve cap 100 10
Power unit suspension
Screw (M8x16) securing the elastic dowel to the gearbox cross-member 23.5±2.5 2.3±0.2
Nut (M12) securing the gearbox cross-member to the chassis 92±9 9.2±0.9
Nut (M12) securing the engine supports to the elastic dowels 49±4 4.9±0.4
Nut (M12) securing the gearbox bracket onto the rear cross-member elastic dowel 49±4 4.9±0.4
Locknut (M10) with flange, securing the engine supports to the chassis 52.5±5.5 5.2±0.5
Screw (M10x30) securing the gearbox support to the gearshift 46.5±4.5 4.6±0.4

Figure 41
108442
LONGITUDINAL CROSS-SECTION OF ENGINE

Figure 42
108443
TRANSVERSE CROSS-SECTION OF ENGINE

OVERHAULING ENGINE
540110 DISASSEMBLING THE ENGINE Fit the brackets 99361038 (9) to the crankcase and use these
AT THE BENCH to secure the engine to the rotary stand 99322205 (6). Drain
Figure 43 the oil from the engine by removing the plug from the oil
sump.
Take off the fan (if any) from electromagnetic joint.
If the following parts have not already been removed, do so
now:
- oil filling cap (1);
- sound-proofing cover (2);
- engine cable complete with raceway (13) by
disconnecting the electric connections of the same from:
- electric injector (3);
- preheating plugs (5)
- hydraulic accumulator pressure sensor (14);
108162
- throttle valve actuator (11);
To be able to fit the brackets 99361038 onto the crankcase - inlet manifold air pressure/temperature sensor (12);
to secure the engine to the stand for overhauling, it is - revs sensor (8);
necessary to remove the left and right engine mounts (3) and
disconnect the oil pipe (2) from the turbocharger (1) and - high-pressure pump pressure regulator (10);
from the crankcase. - phase sensor (4)
- thermostat cooling temperature sensor (7).
NOTE Block the turbocharger air/exhaust gas inlets and
outlets to prevent foreign bodies getting inside.
Figure 44
108163

ssll
Figure 45 Figure 48
108164 108165
Cut compressor (2) drive elastic belt (1),as it cannot be Take out the bolt (1), the bottom screws (3 and 4) and
reused. remove the alternator (2) from the mounting (5).
Figure 46 Figure 49
75248
75251
Using the specific wrench on the automatic tightener (2), Take out the screw (3) and remove the mounting (1) of the
slacken the tension of the belt (1) and remove it. power steering pump (4). Using a suitable wrench, remove
the oil level sensor (2).
Figure 47 Figure 50
75249 108166
Take out the screws (2) and (3) and remove the mounting
Take out the screw (4) and remove the automatic tightener (1) together with the electromagnetic coupling (4).
(3). Take out the screw (2) and remove the fixed tightener
(1). Take out the screws (5) and remove the pulley (6).

Figure 51 Figure 54
108168
75253
Remove screws (2),then take bracket (1) off.
Remove screws (4), then take oil filling pipe union (3) off.
Take out the screws (1) and remove the timing cover (2).
Figure 52
Figure 55
75254
Take out the screw (3) and remove the tightener (4). 108169
Take out the screws (1) and (5) and remove the gears (2) and
(6). Remove the toothed belt (7). Press the springs (3) in the direction shown by the arrow and
disconnect the fittings of the pipe (1) recovering fuel from the
electro-injectors (2).
Figure 53
Figure 56
108167
Loosen clamp (6), then disconnect pipe (5) from pipe union
(7).
Remove nut (4), then remove pipe (3) from filter (1). 108170
Undo screws (2), then remove coalescence filter (1).
Disconnect the fuel pipes (2) from the electro-injectors (3)
and from the hydraulic accumulator (1) (rail).

Figure 57 Figure 60
108174
108171
Loosen clamp (6), then disconnect fuel pipe (5) from
Take out the screws (2) and the brackets (3) fixing the high-pressure pump (7).
electro-injectors (1) to the cylinder overhead. Remove screw (3) securing pipe (2) retaining bracket (4) to
the inlet manifold.
Disconnect pipe (2) from hydraulic accumulator (1) and
Figure 58 high-pressure pump (7).
Figure 61
108172
108175
Using tool 99342153 (1) extract the electro-injectors (2)
from the overhead. Take out the screws (1) and remove the hydraulic
accumulator (2).
Figure 59 Figure 62
108173 108176
Remove screw (1) and nut (3), then remove pipe (2). Remove screws (4), then disconnect low-pressure pipes (5)
Take oil dipstick pipe (4) out of the engine base. from bracket (3).
Remove coupling (1), then disconnect pipes (5) from
high-pressure pump (2).

Figure 63 Figure 65
108177 108179
Loosen clamp (7), then disconnect pipe (6) from EGR valve Remove screw (4), then disassemble air pressure/temperature
(8). sensor (3).
Loosen clamp (4), then disconnect pipe (5) from heat Remove screws (1), then take off inlet manifold (2) together
exchanger (3). with its gasket.
Remove screws (2 and 9), then disconnect heat exchanger
(3, with its respective gaskets), together with EGE valve (8), Figure 66
from pipe (1) and elbow (10).
Figure 64
108180
Use wrench SP. 2275 (1) to disassemble preheating plugs (2).
Figure 67
108178
Remove nuts (4), then take pipe (5), together with its gasket,
off throttle valve assembly (1).
Remove screws (3), then take throttle valve assembly (1),
together with its gasket, off inlet manifold (2).
108181
Remove nut (1), then take off phase sensor (2). Use a suitable
wrench to take off temperature sensor (3).
Remove screws (4), then take off thermostat case (5).

Figure 68 Figure 71
108182 108185
Remove screw (2), then take off pipe union (1). Take out the screws (1) and remove the overhead (2).
Remove screws (3) securing elbow (4) to bracket (5).
Figure 72
Figure 69
75269
Take off the gasket (1) and remove the hydraulic tappets
108183 together with the rocker arms (2).
Remove coupling (5).
Disconnect oil pipe (4) from the cylinder head coupling and Figure 73
turboblower (3) coupling.
Remove nuts (2), then take turboblower (3), together with
its gasket, off exhaust manifold (1).
Figure 70
75270
Take out the screws (1) and remove the cylinder head (2).
NOTE Check the protrusion of the pistons as described

108184
under the relevant heading to check the possibility
Remove nuts (5) and spacers (4), then take off exhaust of facing the crankcase if it has deformed.
manifold (1) together with its gasket, complete with pipe (2)
and elbow (3).

Figure 74 Figure 77
75274
Take out the screws (1) and remove the water pump
75271
assembly (2).
Block rotation of the high-pressure pump gear (1) by applying
tool SP 2263 (2) as shown in the figure. Take off the nut (3) Figure 78
and remove the tool (2).
Figure 75
75275
Remove the plug (6) from the oil pump — vacuum pump
assembly (1).
Position the crankshaft so as to be able to insert tool
75272 99360615 (5) into its hole through the hole in the plug (6)
Using tool 99340035 (2), applied as in the figure, extract the and block rotation of the crankshaft.
gear (1) from the shaft of the high-pressure pump (3). Take out the screw (3) with the spacer (4) beneath and
remove the gear (2).
Figure 76 Figure 79
108186
Take out the screws (1) and remove the oil pump — vacuum
pump assembly (2).
75273
NOTE Tool 99340059 (4) is used to take seal ring (3) off
Take out the screws (1) and remove the high-pressure pump cover (2) when the engine is fitted to the vehicle.
(2) from the water pump mounting (3).

Figure 80 Figure 83
108187
108188
Using tool 99360076 (2), remove the oil filter (1).
Take out the screw (2) and remove the speed sensor (1).
Take out the screws (4) and remove the compressor
mounting (3).
Figure 81 Figure 84
75278 75281
Take out the coupling (2) and remove the heat exchanger Take out the plug (2) with the seal (3) and extract the oil
(1). pressure control valve (1).
Figure 82 Figure 85
75279 75282
Take out the screws (2) and remove the air-conditioner Undo the screws (2) and remove the oil sump (1) with the
compressor (1) (if applicable). associated gasket and frame (3).

Figure 86 Figure 88
75283
Take out the screws (2), (3), (4) and (5) and remove the 75285
suction strainer (1) together with the pipe (6).
Block rotation of the flywheel (1) with tool 99360306 (3).
Take out the screws (2) and remove the engine flywheel (1).
Take out the screw (5) and remove the guard (4).
Figure 87
Figure 89
75284
Take out the screws (2) and remove the connecting rod caps
(3).
Extract the pistons (1) from the top of the crankcase.
75286
Apply tool 99340058 (2) to the rear O-ring (1) and extract
NOTE On the same side of the connecting rod and its it from the crankcase.
associated cap, indicate the number of the cylinder
from which the connecting rod has been removed.
Keep the bearing shells in their respective housings
since, if they are used, they will need to be fitted in
the position found during removal.

Figure 90 Figure 93
75287
Using an appropriate wrench and a hex-fluted wrench, unscrew

the screws (1) and (2) and remove the crankcase base (3).
75290
Figure 91 Take out the couplings (1) and remove the oil jets (2).
NOTE On completing engine removal, it is necessary to

clean the removed parts thoroughly and check
their integrity.
The following pages give the instructions for the
main checks and measurements to make in order
to determine whether the parts can be reused.
75288
NOTE Note the assembly position of the bottom main

bearing shells (2) since, if they are reused, they will
need to be fitted in the position found during
removal.
Figure 92
75289
With the aid of a hoist and a rope, remove the crankshaft (1).
NOTE Note the assembly position of the top main bearing

shells (2) since, if they are reused, they will need to
be fitted in the position found during removal.
The central half ring (3) is fitted with thrust half-washers.

REPAIRS Figure 96
CYLINDER BLOCK
Checks and measurements
Figure 94
1st measurement
2nd measurement
3rd measurement
75293
The measurements must be made for each single cylinder at
18837
three different heights up the liner and on two planes at right
After removing the engine, thoroughly clean the angles to each other: one parallel to the longitudinal axis of
cylinder-crankcase assembly. Use the rings 99365508 to the engine (B) and the perpendicular (A); the greatest wear
carry the cylinder block. is generally found on this last plane with the first
Carefully check that the crankcase has no cracks in it. measurement.
Check the conditions of processing caps. If the caps are On finding ovalization, taper or wear, go ahead and
rusted or if you have even the slightest doubt about their bore/grind and finish the face of the cylinder liners. The
sealing efficiency, the caps shall be replaced. Apply LOCTITE refacing of the cylinder liners should be done in relation to
270 sealant (IVECO NO. 93162429) to the caps when fitting the diameter of the pistons supplied as spare parts oversized
the latter back into place.. Examine the surfaces of the by 0.4 mm of the nominal value and to the prescribed
cylinder liners; they must show no sign of meshing, scoring, assembly clearance.
ovalization, taper or excessive wear. The inside diameter of
the cylinder liners is checked, to ascertain the extent of Figure 97
ovalization, taper and wear, using the bore meter 99395687
(1) fitted with a dial gauge previously reset on the ring gauge
of the diameter of the cylinder liner or on a micrometer.
Figure 95
75292
* Surface roughness parameters:

Rt = 4 ÷ 10 μm
Rz = 3 ÷ 8 μm
Ra = 0,25 ÷ 0,6 μm
Wt < 1,5 μm
Permissible surface porosity for machined cylinder
(see Figure 97)
ZONE B1 = Area of greatest mechanical stress,
segment/liner contact:
No.2 non-continuous porosities C 100%
are permissible max. 0.5x0.5.
ZONE B2 = Surface involved in segment rubbing:
No.2 non-contiguous porosities
are permissible max. 1x0.8. C 100%

Checking head mating surface on cylinder 5408 CRANKSHAFT

block 540810 Measuring main journals and crank
Figure 98 pins
Figure 100
75296
See that the head mating surface, on the cylinder block, has
75298
no deformation.
This check can be made, after taking out the grub screws (3), On finding signs of seizure, scoring or excessive ovalization
with a surface plate spread with carbon black or with a on main journals and crankpins, it is necessary to regrind the
calibrated rule (1) and a feeler gauge (2). After ascertaining pins. Before grinding the pins (2), measure the shaft pins with
the areas of deformation, level the bearing surface with a a micrometer (1) to establish to what diameter it is necessary
grinding machine. to decrease the pins.
NOTE The crankcase can only be surfaced after making

sure that, on completing the work, the piston
protrudes from the cylinder liner by no more than NOTE It is advisable to enter the measurements in a table.
the prescribed value. See Figure 99.
NOMINAL NOMINAL
Figure 99 VALUE VALUE
MINIMUM ∅
MAXIMUM ∅
NOMINAL
VALUE
MINIMUM ∅
MAXIMUM ∅
75297
TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS
NOTE The main journals and crankpins must always be For undersized crankpins, letter M.
ground to the same undersize class. For undersized main journals, letter B.
The undersizing performed, on the main journals or For undersized crankpins and main journals, letter MB.
crankpins, must be marked by punching on the side Undersize classes are of:
of crank arm no. 1. 0.254 - 0.508 mm.

Checking crankshaft
Figure 101
75299
MAIN CRANKSHAFT TOLERANCES
TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL

Circularity ○
SHAPE
Cylindricality
Parallelism
DIRECTION
Perpendicularity ⊥
OF POSITION Concentricity or coaxiality
Circular oscillation ↗
OSCILLATION
Total oscillation ↗↗
CLASS OF IMPORTANCE ASCRIBED TO THE PRODUCT CHARACTERISTICS SYMBOL

CRITICAL E
IMPORTANT ⊕
SECONDARY ⊝
Figure 102
NOTE The checks on the tolerances indicated in the
figures must be made after grinding the crankshaft
pins.
94 ± 0,125
180° ± 15’
SYMMETRY BETWEEN MAIN JOURNALS AND CRANK-

PINS
1. Crank pins
2. Main Journals
3. Normal position.
After grinding, keep to the following:
- Round off the edges of deburring the holes for
lubrication of the main journals and crankpins.
45066

JOURNAL ON TIMING SYSTEM SIDE JOURNAL ON FLYWHEEL SIDE

Figure 103 Figure 106
honed
honed
Before rolling
waviness
in circumferential direction
waviness
in axial direction
108189
RACE AREA FOR ALL MAIN JOURNALS
(MACHINED BY TURNING) 75303
INTERMEDIATE JOURNALS No. 2-4
CRANKPINS

Before rolling
honed
honed
Before rolling
waviness
in circumferential direction
108190 waviness 108192
in axial direction
INTERMEDIATE JOURNAL No. 3 CRANKPIN GROOVE AREA
(EXTERNAL MILLING PROCESSED)
* On both races, on all 360°.
NOTE Since, during the 0.254 and 0.508 mm undersizing

Figure 105 on the diameter of the crankpins and main journals,
the rolled portion of the side races of the pins may
get involved, it is necessary to turn the races keeping
to the data given in the figure and to do the rolling
keeping to the following instructions
Rolling force:
honed - 1st main journal 925 ±25 daN.
- 2nd — 3rd — 4th — 5th main journal 1850 ±50 daN.
- crankpin 1850 ±50 daN.
Before rolling
- Rolling turns: 3 approach, 12 effective, 3 out.

- Rolling speed: 56 rpm.
108191
- Decrease in crankpin race depth after rolling: 0.15 — 0.30
mm*.
- Decrease in main journal race depth after rolling: 0.15 —
MAIN DATA OF MAIN JOURNALS AND CRANKPINS 0.30 mm*.
* Measured with calibrated rollers ∅ 2.5 mm.

Figure 108 Assembling main bearings

Figure 110
75305
Take out the screws (4) and replace the phonic wheel (3).
75307
The screws (4) hey must be tightened to a torque of 15 Nm.
NOTE Not having found it necessary to replace the main
Replacing timing control gear bearings, they need to be fitted back on in the same
On finding the timing control gear teeth (1) damaged or sequence and position found upon disassembly.
worn, remove them from the crankshaft (2) using a suitable
extractor.
The new gear is fitted onto the crankshaft by heating it to a The main bearings (1) are supplied as spare parts undersized
temperature of 200°C for no longer than 15 minutes. on the inside diameter by 0.254 ÷ 0.508 mm.
On completing assembly and after the gear has cooled, it

NOTE Do not do any accommodating on the bearings.
must withstand a torque of 150 Nm without slipping.
Thoroughly clean the top main bearing shells (1) and position
them in the crankcase.
NOTE The middle half ring (2) is fitted with thrust washers.
ENGINE ASSEMBLY
The following parts must be replaced with new ones at the 540811 Measuring main journal assembly
time of assembly: retaining rings, seals and gaskets, screws clearance
whose thread is coated with sealant.
Figure 111
Figure 109
90063
Mount the crankshaft (1).

75306
Check the clearance between the crankshaft main journals
and their respective bearings by proceeding as follows:
Fit on the oil spray nozzles (2) and tighten the couplings (1)
to the prescribed torque. - Thoroughly clean the pins.
- Apply a calibrated wire onto the main journals.

75288 75310
Thoroughly clean the bottom main bearing shells (2) and - Remove the bottom crankcase.
mount them in the crankcase base (1)
The clearance between the main bearings and their
associated pins is measured by comparing the length of the
calibrated wire (1), at the point of greatest crushing, with the
Figure 113 graduated scale on the casing containing the calibrated wire.
The numbers on the scale indicate the clearance of the
coupling in millimetres, which must be 0.032 ÷ 0.102 mm.
If the clearance is not as prescribed, replace the bearings and
repeat the check.
α
Checking crankshaft end float
Figure 115
75309
75311
Mount the crankcase base (12).
The end float is checked by setting a dial gauge (1) with a
Tighten the screws in the sequence shown in the figure in magnetic base on the crankshaft (2) as shown in the figure.
three steps: The normal assembly clearance is 0.060 — 0.310 mm.
- Step 1: with a torque wrench, to a torque of 50 Nm. If you find the clearance to be greater than as required,
- Step 2: closing to an angle of 60°. replace the rear main bearing shells carrying the thrust
bearings and repeat the clearance check between the
- Step 3: closing to an angle of 60°. crankshaft pins and the main bearing shells.
If the end float of the crankshaft does not come within the
NOTE Use tool 99395216 (11) for the angle closing. prescribed values, it is necessary to grind the crankshaft and
accordingly change the main bearing shells.
NOTE: The middle main bearing has half thrust washers
integrated in it, so it performs the function of a thrust bearing.
It is supplied as a spare part only with the normal shoulder
thickness.

85842 75406
Thoroughly clean the crankcase / crankcase base mating Then tighten the outer screws (1) to a torque of 36 — 30 Nm.
surface.
Apply, on base, sealant LOCTITE 510 IVECO no. 93162432, 540460 Assembling rear seal
as indicated in the scheme. The sealant must result to be
even, not patchy.
Figure 119
NOTE Mount the crankcase base within 10 minutes of
applying the sealant.
Figure 117
85843
Carefully clean the seal seat. Apply LOCTITE 510 IVECO nr.
2992504 on the seal (1) for 30° in the points shown in the
75309 figure.
Lubricate the rear shank of the crankshaft with engine oil.
Mount the crankcase base (12) and tighten the fixing screws Fit part (2) of tool 99346255 onto the rear shank of the
in three stages, following the sequence shown in the figure: crankshaft; secure it with the screws (3) and key the fresh seal
- Step 1: with a torque wrench, to a torque of 50 Nm. (1) onto it.
Position part (4) on part (2); screw down the nut (5) to fit
- Step 2: closing to an angle of 60°. the seal (1) fully inside the crankcase.
- Step 3: closing to an angle of 60°.
NOTE Use tool 99395216 (11) for the angle closing.

540850 ENGINE FLYWHEEL

Figure 120 540852 Replacing bearing supporting gear-
box input shaft
Figure 122
108194
Use a suitable beater to take off engine flywheel bearing (1),

75389
taking care that the bearing does not set itself sideways or get
”LUK” ENGINE FLYWHEEL FOR ENGINES FITTED TO stuck, with resulting flywheel housing damage.
THE VEHICLES EQUIPPED WITH MECHANIC To fit back into place, put engine flywheel hub (2) onto a
TRANSMISSION suitable support (4) by using a suitable beater (3) placed on
Check clutch disk rest surface: if it shows deep scoring, a bearing (1) outer race, then fit the bearing into the engine
replacement must be performed. flywheel. This operation shall be carried out by using a
hydraulic press.
NOTE The nominal thickness of the engine flywheel is 50

±0.6 mm.
Check conditions of the teeth of crown wheel (1); where

excessive cracking or wear is found, replace engine flywheel.
75390
Mount the sheet metal guard (1) and secure it to the crankcase
tightening the screw (2) to the prescribed torque.
Mount the engine flywheel (3) and screw down the screws (4).
108193
”SACHS” ENGINE FLYWHEEL FOR ENGINES FITTED

TO THE VEHICLES EQUIPPED WITH AUTOMATIC
TRANSMISSION

Figure 124 540840 Pistons

Disassembly
Figure 125
75391
Fit tool 99360351 (4) onto the crankcase to block rotation

of the engine flywheel (1).
75393
Tighten the screws (3) fixing the engine flywheel (1) in two
Remove the piston rings (1) from the piston (2) using pliers
steps:
99360183 (3).
- Step 1: with a torque wrench, to a torque of 30 Nm.
- Step 2: closing to an angle of 90°. Figure 126
5408 CONNECTING ROD — PISTON

ASSEMBLY
Check the pistons. They must show no signs of seizure, 75394

scoring, cracking or excessive wear; replace them if they do.
Take plunger (1) off the connecting rod by removing snap
ring (2) and taking pin (3) out.
Figure 127
107947
MAIN DATA ON PISTON MAHLE MONDIAL, PINS AND SPRING RINGS

ENGINE F1AE 0481B (116 HP)
* Measured on the diameter of 85 mm.

Measuring piston diameter Conditions for correct pin-piston coupling

Figure 128
Figure 131
108195
Use a micrometer (2) to measure plunger (1) diameter, in

order to determine the assembling play. The diameter shall
be measured at such a distance from the plunger base as
shown in the figure. 75397
NOTE The pistons are supplied as spare parts with the Lubricate the pin (1) and its seat on the hubs of the piston
standard, normal and 0.4mm oversize diameters (2) with engine oil. The pin must go into the piston by lightly
together with rings, pin and retaining rings. pressing with the fingers and must not drop out by gravity.
Figure 129 540842 Piston rings

Figure 132
75395
74947
The clearance between the piston and cylinder liner can also
be checked using a feeler gauge (1) as illustrated in the figure.
The trapezoidal split rings (1st slot) and the oil scraper rings
(2nd slot) have the word TOP etched in them; when fitting
them on the piston, the word TOP must be facing upwards.
540841 Piston pins
18857
16552
Measuring the diameter of the piston pin (1) with a Check the thickness of the piston rings (2) with a micrometer
micrometer (2). (1).

74948
Check the clearance between the trapezoidal ring (2) (1st 75399
slot) and the associated slot on the piston with a feeler gauge Check the opening between the ends of the piston rings (2)
(1), proceeding as follows: insert the piston into the cylinder inserted in the cylinder liner using a feeler gauge (1).
liner so that the ring (2) comes approximately half way out
of it. 540830 Connecting rods
Figure 135
Figure 138
41104
75400
DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
MAIN DATA OF THE CONNECTING ROD, BUSHING,
TRAPEZOIDAL RING PISTON PIN AND BEARING SHELLS
1. Piston slot — 2. Trapezoidal piston ring —
3. Cylinder liner * Internal diameter to obtain after driving into the small
end and grinding with a reamer.
Using a feeler gauge (1, Figure 134), check the clearance (X) ** Dimension cannot be measured in the free state.
between the ring (2) and the slot (1); this clearance must *** Thickness of the bearing shell supplied as a spare part.
have the prescribed value.
Figure 136 NOTE Each connecting rod has its cap marked:
- with a letter: O or X indicating the diameter
class of the big end mounted in production;
- with a number indicating the weight class of the

connecting rod mounted in production.
In addition, it could be stamped with the number of the
cylinder in which it is fitted.
In the event of replacement it is therefore necessary to
number the new connecting rod with the same number as
the one replaced.
The numbering must be done on the opposite side to the
bearing shell retaining slots.
75398
The connecting rods are supplied as spare parts with the
diameter of the big end 62.842 — 62.848 mm marked with the
Check the clearance between the piston rings (2) of the 2nd letter O and the weight class marked with the number 33.
and 3rd slot and the associated seats on the piston (3) with
It is not permissible to remove material.
a feeler gauge (1).

540834 Bushes Checking bending

Check that the bush in the small end has not come loose and Figure 141
shows no sign of seizure or scoring. If it does, replace the
complete connecting rod.
Checking connecting rod
Figure 139
61695
Check the bending of the connecting rod (5) by comparing

two points C and D of the pin (3) on the vertical plane of the
61696 axis of the connecting rod.
Check the alignment of the axes of the connecting rods (1) Position the vertical mount (1) of the dial gauge (2) so that
with device 99395363 (5), proceeding as follows: this rests on the pin (3) at point C.
Swing the connecting rod backwards and forwards seeking
- Fit the connecting rod (1) on the spindle of the tool
the highest position of the pin and in this condition zero the
99395363 (5) and lock it with the screw (4).
dial gauge (2).
- Set the spindle (3) on the V-prisms, resting the Shift the spindle with the connecting rod (5) and repeat the
connecting rod (1) on the stop bar (2). check on the highest point on the opposite side D of the pin
(3). The difference between point C and point D must be no
Checking torsion greater than 0.08 mm.
Figure 140
Assembling connecting rod-piston assembly
Figure 142
61694
Check the torsion of the connecting rod (5) by comparing

two points (A and B) of the pin (3) on the horizontal plane 75401
of the axis of the connecting rod.
Position the mount (1) of the dial gauge (2) so that this Etched on the top of the piston are: the type of engine (1),
pre-loads by approx. 0.5 mm on the pin (3) at point A and class selection (2) and supplier (3) as well as the direction of
zero the dial gauge (2). Shift the spindle (4) with the fitting the piston in the cylinder liner (4). The mark (5) is for
connecting rod (5) and compare any deviation on the passing the 1st slot insert adhesion test.
opposite side B of the pin (3): the difference between A and
B must be no greater than 0.08 mm.

Figure 143 After fitting the connecting rod — piston assembly together,
check for distortion with the tool 99395363 (8) as follows:
- Fit the connecting rod (7) together with the piston (3)
on the spindle (4) of tool 99395363 (8) and lock it with
the screw (5).
- Rest the connecting rod (7) on the bar (6).
- Position the mount (1) of the dial gauge (2) so that this
is positioned at point A of the piston with a pre-load of
0.5 mm and zero the dial gauge (2).
- Shift the spindle (4) so as to position the dial gauge (2)
at point B of the piston (3) and check for any deviation.
Fitting piston rings

Figure 146
75402
Connect the piston (1) to the connecting rod (2) together

with its cap so that the piston assembly reference, position
of the connecting rod and of the cap are observed as shown
in the figure.
Figure 144
41097
Fit the piston rings (1) on the piston (2) using the pliers
99360183 (3).
NOTE The 1st and 2nd slot rings need to be mounted with
the word ”TOP” facing upwards.
75394
Position the piston (1) on the connecting rod, insert the pin
(3) and secure it with the split rings (2). Assembling connecting rod — piston assemblies
in cylinder barrels
Checking for connecting rod — piston distortion Figure 147
Figure 145
75404
Lubricate the pistons well, including the piston rings and the
inside of the cylinder liners.
With the aid of the clamp 99360605 (2), fit the connecting
rod — piston assembly (1) in the cylinder liners, checking that:
75403
- The number of each connecting rod corresponds to the
cap mating number.

- The openings of the piston rings are staggered 120° apart. - Remove the cap (2) and determine the existing clearance
by comparing the width of the calibrated wire (3,
- The pistons are all of the same weight.
Figure 148) with the graduated scale on the case (2,
- The symbol punched on the top of the pistons faces the Figure 148) that contained the calibrated wire. On finding
engine flywheel, or the recess in the skirt of the pistons a clearance other than as prescribed, replace the bearing
tallies with the oil spray nozzles. shells and repeat the check. On obtaining the prescribed
clearance, lubricate the connecting rod bearing shells and
fit them permanently by tightening the connecting rod cap
NOTE Not finding it necessary to replace the connecting fixing screws as described.
rod bearings, you need to fit them back in exactly
the same sequence and position found on
disassembly. NOTE The connecting rod cap fixing screws must always
be replaced for permanent assembly.
540831 Measuring crankpin assembly
clearance Manually check that the connecting rods slide axially on the
Figure 148 pins of the crankshaft.
Checking piston protrusion

Figure 150
75405
To measure the clearance, carry out the following steps:
75409
- Thoroughly clean parts (1) and (4) and eliminate all After mounting the connecting rod — piston assemblies, check
traces of oil. the protrusion of the pistons (2) at the T.D.C. in relation to the
- Place a length of calibrated wire (3) on the crankshaft top surface of the crankcase with a dial gauge (1).
pins (4).
NOTE The difference between the minimum and
Figure 149 maximum protrusions of the four pistons must be
= 0.15 mm.
The cylinder head gasket in the set of spare gaskets
needed for complete engine overhaul is supplied
with a single thickness. Clearly, it is supplied
separately too.
α Figure 151
75408
- Fit the connecting rod caps (2) with the associated

bearing shells.
- Tighten the screws (3) in two steps:
- Step 2: closing to an angle of 60°. 75283
Mount the suction strainer (1) together with the pipe (6).
NOTE Use tool 99395216 (1) for the angle closing. Screw down the fixing screws (2-3-4-6) and tighten them to
the prescribed torque.

Figure 152 541210 Removing valves
Figure 154
75412
75410
Fit the gasket (4) and the frame (3) onto the oil sump (1). Fit part (4) of tool 99360260 onto the cylinder head (5) and
Screw down the fixing screws (2) and tighten them to the secure it with the screws (3).
prescribed torque. Fit part (2) of tool 99360260 onto part (4), screw down the
Screw down the oil drain plug (5) and tighten it to the nut (1) so that on compressing the springs (8) it is possible
prescribed torque. to remove the cotters (6). Then take out the plates (7) and
the springs (8).
Using suitable pliers, remove the oil seal (9).
Repeat these operations on the remaining valves.
560610 CYLINDER HEADS Turn the cylinder head over.
Disassembly
Figure 155
Figure 153
75413
108322
The intake (1) and exhaust (2) valves have the same diameter
Place the cylinder head (1) on the mounting SP.2271 (6). mushroom.
Remove the brackets (5) for lifting the engine. The central cavity (→) of the mushroom of the intake valve
In the event that temperature sensor (2) need disassembling, (1) is distinguished from that of the exhaust valve (2).
wrench SP 2262 shall be used.
Take out the screws (4) and remove the thermostat casing NOTE Before dismounting the valves from cylinder head,
(3). number them, to the purpose of being able to
remount them in the position that was found on
dismounting operation where they should not be
replaced.
A = intake side — S = exhaust side
Remove the intake (1) and exhaust (2) valves.

540662 VALVES
Checking cylinder head seal
Figure 157
Check the hydraulic seal using a suitable tool.
Pump in water heated to approx. 90°C at a pressure of 2 ÷ EXHAUST INTAKE
VALVE VALVE
3 bars.
Replace the cup plugs if they are found to leak at oil, using a
suitable drift for their removal — assembly.
NOTE Before mounting the plugs, apply LOCTITE 270

water-reacting sealant on their sealing surfaces.
If there is any leakage from the cylinder head, it must be

replaced.
108196
Checking cylinder head mating surface MAIN DATA OF INTAKE AND EXHAUST VALVES
Figure 156 Removing deposits, refacing and checking

valves
Figure 158
75451
18625
The mating surface of the head (1) with the cylinder block Remove the carbon deposits on the valves with a wire brush.
is checked using a rule (2) and a feeler gauge (3). Check that the valves show no signs of seizure, cracking or
The deformation found on the entire length of the cylinder burning.
head must be no greater than 0.20 mm.
For greater values, regrind the cylinder head according to the
values and instructions given in the following figure. Figure 159
The nominal thickness A of the cylinder head is 112 ±0.1 mm;
the maximum permissible removal of metal must not exceed
a thickness of 0.2 mm.
NOTE After regrinding, check the valve recessing and if

necessary regrind the valve seats to make the
prescribed valve recessing.
18882
Use micrometer (2) to measure valve (1) stem: it shall

correspond to the value shown in figure 135. Use grinding
machine 99305018 to grind, if necessary, the valve seats
(remove as less material as possible).

Checking clearance between valve stem and Figure 162

valve guide and centring valves
Figure 160
75455
Remove the valve guides (2) with the drift SP.2312 (1).
75453
The checks are made using a dial gauge (2) with a magnetic Figure 163
base, positioned as illustrated. The assembly clearance is
0.033 — 0.063 mm.
Making the valve (1) turn, check that the centring error is no
greater than 0.03 mm.
540667 VALVE GUIDE

Replacing valve guide
Figure 161
75456
Heat the cylinder head to 80 — 100°C and, using the drift

SP.2312 (1) provided with part SP.2311 (2), mount the new
valve guides (3) previously chilled in liquid nitrogen.
Where above indicated tools are not available, mount valve
guides positioning them in cylinder head according to
dimension indicated in Figure 139.
Boring valve guides

Figure 164
108197
MAIN DATA OF VALVE GUIDES — SEATS

Valve guide seat inside ∅ 9.980 ÷ 10.000 mm
Valve guide outside ∅ 10.028 ÷ 10.039 mm
* Measurement to be made after driving in the valve guides. 75457
After driving in the valve guides (2), regrind them with the
smoother SP.2310 (1).

540661 VALVE SEATS

Recutting and replacing valve seats
Figure 165
108198
Check the valve seats. On finding any slight scoring or burns, Mount the valves, block the seat of the electro-injectors and
regrind them with an appropriate tool according to the glow plugs; using a suitable tool, check the seal of the
angles given in Figure 165. valves/seats.
Having to replace them, with the same tool and taking care
not to affect the cylinder head, remove as much material
from the valve seats as possible until, with a punch, it is
possible to extract them from the cylinder head.
Heat the cylinder head to 80 ÷ 100°C and, using a suitable
drift, fit in it the new valve seats, previously chilled in liquid
nitrogen. Figure 167
Using a specific tool, regrind the valve seats according to the
angles given in Figure 165.
Figure 166
54760
Using a dial gauge (1), check that, from the plane of the
cylinder head, the valve recessing (2) and the protrusion of
the injector (3) and of the glow plug have the prescribed
value:
- Valve recessing: 0.5 ÷ 0.8 mm.
75459
- Injector protrusion: 2.77 ÷ 3.23 mm.
Using the milling cutter 99394038 (1), clean the injector seat - Glow plug protrusion: 3.78 mm.
of any deposits.

540665 VALVE SPRINGS ROCKER ARMS — TAPPETS

62386
Before assembly, check the flexibility of the valve springs with

the tool 99305047. Compare the load and elastic
deformation data with those of the new springs given in the
following figures. 75461
COMPLETE ROCKER ARM ASSEMBLY

Figure 169 The rocker arm assembly is composed of the rocker arm (1),
hydraulic tappet (3), made integral with each other by the clip
(2).
Figure 171
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST

VALVE SPRINGS
Height Under a load of

mm kg 75942
H 54 Free
H1 45 P 243 ±12
H2 35 P1 533 ±24 CROSS-SECTION OF THE HYDRAULIC TAPPET
A = 32.44 ±0.3, end of stroke
B = 31.30, working position
C = 29.75 ±0.25, start of stroke

Figure 172
75462
MAIN DATA HYDRAULIC TAPPETS — SEATS
Checks Figure 174

The sliding surface of the tappets must have no scoring/dents;
replace them if they do.
Using a micrometer, measure the diameter of the tappets
and, using a bore meter, measure the diameter of the seats
in the cylinder head; the difference in the measurements will
give the assembly clearance.
ASSEMBLING CYLINDER HEADS

Figure 173
75587
Position the springs (8) and plates (7) on the cylinder head
(5).
Fit the part (4) of tool 99360260 onto the cylinder head (5)
and secure it with the screws (3).
Fit the part (2) of tool 99360260 onto part (4), screw down
the nut (1) so that by compressing the springs (8) it is possible
to insert the retaining cotters (6); then unscrew the nut (1)
checking that the cotters (6) have settled in correctly.
75463
Lubricate the stem of the valves (1) and insert them into the
associated valve guides (4) according to the position marked
during removal. Using tool SP.2264 (2), mount the oil seals
(3) on the valve guides (4).

108323 75466
Only engines with intake distributing shaft con tapered shank.

Using the extractor 99340028 (2) extract the toothed pulley
Fit the thermostat casing (2) with a new seal and tighten the (1) driving the camshaft.
fixing screws (3) to the prescribed torque.
Fit temperature sensor (1) into place and tighten it to the Figure 178
prescribed torque.
Mount the temperature sensors (1 and 2) and, using the
wrench SP.2263 (3), tighten them to the prescribed torque.
540650 Overhead
Overhead removal
Figure 176
75467
Using four self-tapping screws (2), apply the tool SP. 2325 (3)
to the seal (1) and with the extractor (5 and 6) remove the
seal (1) from the overhead (4).
NOTE The screws (2) must be screwed down so they get

positioned at the dimension shown in the figure.
Figure 179
75465
Position the overhead (2) together with the pins 99360614

(1) on the mounting SP. 2271.
Stop rotation the toothed pulley.
Take out the screw (4) with the washer (5) beneath fastening
the toothed pulley (3).
75468
Remove the circlip (1) and take off the cover (2) together
with the seal (3).

Figure 180 5412 TIMING SYSTEM

Figure 183
75469
Take out the screws (1) and remove the rear cover (2)
together with its gasket.
Figure 181 75472
1. Camshaft on intake side — 2. Hydraulic tightener —

3. Camshaft on exhaust side — 4. MORSE chain —
5. Rocker arms — 6. Hydraulic reacting tappet —
7. Valve assembly.
Description
The timing system is the type with a twin camshaft in the head
and four valves per cylinder with hydraulic tappets.
Motion is transmitted by the crankshaft, via a toothed belt,
to the gear keyed onto the intake valve drive shaft. The drive
transmission of the exhaust valve drive shaft takes place via
a MORSE-type chain kept under tension by a hydraulic
tightener.
75470 The toothed belt, moreover, drives the water pump and the
high-pressure pump CP3 and is kept at the right tension by
Insert a suitable pin (2) in the hole (⇒) of the chain drive (3). an automatic tightener roller.
Take out the screws (4) and (6) with their washers (5) for The four valves move by the action of the “free” rocker arms
fixing gears to the camshafts. (with no supporting shaft).
Take out the screws (7) and remove the chain drive (3) from The rocker arms, one per valve, are always in contact with
the overhead (1). the corresponding cam and are kept in this position by a
hydraulic reacting tappet, thereby eliminating the need for
periodical adjustment.
75471
Turn over the overhead (1) and, taking care not to damage 75473
the seats, extract the camshafts (2) and (3) from it.
TIMING SYSTEM DIAGRAM

541210 Camshaft 541211 Checking cam lift and pin alignment

Checks
The surfaces of the shaft supporting pins and of the cams Figure 186
must be finely honed; if there is any sign of meshing or
scoring, replace the shaft.
Figure 185
75475
75474
Set the shaft (1) on tailstocks and, using a dial gauge on the
Using a micrometer (1), measure the diameter of the pins (2) middle mounting, check that the alignment error is no greater
of the camshaft and, using a bore meter, measure the than 0.04 mm; replace the shaft if it is. In addition, check the
diameter of the supporting seats in the overhead. cam lift: it must be as prescribed; replace the shaft if it is any
The difference between these two measurements gives the different.
existing clearance.
The nominal assembly clearance is 0.037 ÷ 0.088 mm.
Figure 187
75476
MAIN SPECIFICATIONS, FULL-SECTION DISTRIBUTING SHAFT SEATS AND PINS

1. Intake valve camshaft seats — 2. Exhaust valve camshaft seats — 3. Intake valve camshaft — 4. Exhaust valve camshaft.

Figure 188
108199
MAIN SPECIFICATIONS, HOLLOW-SECTION DISTRIBUTING SHAFT SEATS AND PINS

1. Intake valve camshaft seats — 2. Exhaust valve camshaft seats — 3. Exhaust valve camshaft — 4. Intake valve camshaft.

Assembling overhead
75471 75479
Lubricate the supporting pins of the shafts (2 and 3) and fit Fit the chain drive (2) on the camshafts and secure it to the
them in the overhead (1). overhead (1) tightening the screws (8) to the prescribed
torque.
NOTE In this operation, take care not to damage the Screw down the screws (4) and (7) with the washers (5) and
overhead supporting seats. (6) and tighten them as follows:
- Tighten the screw (7) to a torque of 50 Nm.
Figure 190 - Close further with an angle of 60°.
- Take out the pin (5).
- Tighten the screw (4) to a torque of 50 Nm.
- Close further with an angle of 60°.
NOTE Use the goniometer 99395216 for the angle

closing.
75477
Position the overhead (1) and secure it on the mounting Figure 193
SP.2271 (2).
Position the camshafts (4 and 5) so as to be able to insert the
pins 99360614 (3) into their radial holes through the
threaded holes of the overhead.
Figure 191
75469
75478 Fit on the rear cover (2) with a new gasket and tighten the
Compress the tightener so as to be able to insert a suitable fixing screws (1) to the prescribed torque.
pin (2) into the hole (→) of the chain drive (1).

Figure 194
NOTE The toothed pulley (1, Figure 196) for the intake
shaft with full-section tapered shank is not locked
on the shaft since it must be able to turn when
fitting and tensioning the timing belt. For the same
reason, keep the tools 99360608 (4, Figure 196)
and 99360614 (3, Figure 190) fitted.
Figure 197
75468
Fit a new seal (3) on the cover (2) and fit this in the overhead.
Fit on the seal (1).
Figure 195
75281
Fit the oil pressure control valve (1) in the crankcase.

Fit on the plug (2) with the seal (3) and tighten it to the
prescribed torque.
540442 Assembling front seal ring
75481
Figure 198
Lubricate the shank of the camshaft.
Using the keying device 99374458 (3), fit the seal (2) in the
overhead (1).
Figure 196
75483
Fit the centring tool 99396037 (2) onto the shank of the
crankshaft.
Mount the oil vacuum pump assembly (1) with a new gasket
and tighten the screws (1-15) according to the following
procedures:
- Tighten the screws from no. 1 to no. 6 to a torque of 5
75482 ±1 Nm while checking that the tool 99360037 (2) turns
freely.
Fit the toothed pulley (1) Only for the intake shaft with
full-section front tapered shank, so as to align the pulley hole - Tighten the screws from no. 7 to no. 15 to a torque of
with the overhead hole and fit tool 99360608 (4) into the 10 ±1 Nm.
holes themselves. Screw down the screw (3) together with - Tighten the screws from no. 1 to no. 6 to a torque of 10
the washer (2) without tightening fully. ±1 Nm.
- After checking that tool 99360037 (2) turns freely,
remove it.

108188
75484
Lubricate the shank of the crankshaft. Mount the speed sensor (1) with a fresh gasket and tighten
the fixing screw (2) to the prescribed torque (if applicable).
Screw down part (3) of tool 99346254 in the crankshaft and
place the seal (2) on the part (3). Fit on the compressor mounting (3) and tighten the fixing
screws (4) to the prescribed torque.
Key part (5) of tool 99346254 onto part (3), screw down the
nut (4) until the seal (2) gets into position in the seat of the
oil vacuum pump assembly (1).
Figure 202
Take out the tool 99346254 (3, 4 and 5).
Figure 200
75279
Mount the air-conditioner compressor (1) (if applicable) and

tighten its fixing (2) screws to the prescribed torque.
75485 Figure 203
Turn the crankshaft so as to be able to insert tool 99360615

(5) into the hole in the crank of the crankshaft, through the
hole in the oil vacuum pump assembly (1), to block crankshaft
rotation.
Mount the gear (2), screw down the screw (3) together with
the spacer (4) and tighten it to the prescribed torque.
NOTE Do not remove the tool 99360615 (5) as it will be

needed for fitting the timing drive belt.
75486
Mount the oil pressure transmitter (3) with a fresh gasket.

Mount the heat exchanger (1) with a fresh seal and tighten
the coupling (2) to the prescribed torque.

108187
Lubricate the seal of the oil filter (1) with engine oil.
Using tool 99360076 (2), tighten the oil filter to the 75490
prescribed torque. Fit the high-pressure pump (2) onto the flange of the water
pump (1) and tighten the fixing screws (3) to the prescribed
torque.
Figure 205
Figure 208
75488
75271
Thoroughly clean the mating surface (à) of the water pump
(1) and position fresh seals (2 and 3) on it. Fit the driving gear (1) onto the shaft of the high-pressure
pump and block rotation of this shaft by applying tool
SP.2263 (2) as illustrated in the figure. Tighten the nut (3) to
the prescribed torque and remove the tool (2).
Figure 206
75489
Mount the water pump (1) and tighten the fixing screws (2)
to the prescribed torque.

Refitting cylinder head

75491
Check that tool 99360619 (2) inserted in the hole (→) of the 75493
oil vacuum pump assembly (1) blocks crankshaft rotation.
Mount the cylinder head (1).
This condition is necessary for setting up the timing system
and to prevent the valves interfering with the pistons. Screw down the fixing screws (3) and tighten them, in three
successive stages, following the order and methods shown in
the following figure.
Figure 210
NOTE The angle closure is done with tool 99395216 (2).
Figure 212
75492
Check that the mating surfaces of the cylinder head and

Keep the cylinder head gasket clean. 75494
Position the cylinder head gasket (1) of the thickness
determined under the heading “checking piston protrusion” Diagram of the tightening sequence for the cylinder head
with the lettering ”TOP” facing the cylinder head. fixing screws:
• screws 1-2-3-4-5-6 to a torque of 100 ±5 Nm;
NOTE It is essential to keep the gasket sealed in its package • screws 7-8-9-10 to a torque of 50 ±2.5 Nm.
until just before assembly. - 2nd phase: angle closing
• screws 1-2-3-4-5-6 90° ±5°;
• screws 7-8-9-10 60° ±3°.
• screws 1-2-3-4-5-6 90° ±5°;
• screws 7-8-9-10 60° ±3°.
A = flywheel side.

75495
Thoroughly clean the hydraulic tappets (2), lubricate them and

fit them in the cylinder head (3), positioning the rocker arms (1) 85844a
on the valves correctly.
Fit on the gasket (5). X = Direction of movement of the tightener —
Insert the two tools SP. 2264 (4) into the electro-injector seats Y = Direction of rotation of the key.
Turn the automatic tightener (1) clockwise, positioning it as
for subsequent centring of the overhead on the cylinder head. shown in frame A.
Turn the timing belt (10) as shown in the figure observing the
Figure 214 precautions below.
NOTE If the engine has run for a period equivalent to ≥
25,000 km, the toothed belt must be replaced with
a fresh one, no matter what its state of wear.
Do not bend the timing belt. Arrows indicating the direction

of assembly of the timing belt on the engine are shown on
the back of the belt. The arrows must correspond to the
direction of rotation of the belt and the notches must
coincide with those on the pulley (7) and the gear (12).
108328
Mount the overhead (1) together with the tools 99360614 NOTE Only for the intake valve distributing shaft with
(3) for the timing and tighten the fixing screws (2) to the full-section tapered shank.
prescribed torque. If required to fit the timing belt (10) on the pulley
(7), remove tool 99360608 (8) and turn the pulley
Take out the tools SP. 2264 (4). (7) clockwise by no more than half a pulley tooth.
Camshaft drive
Figure 215
On completing assembly, adjust the toothed pulley (7) to put
the section X of the belt under tension and tighten the screw
(9) to a torque of 90 Nm
Keeping the screw (2) stationary and using a suitable wrench
on the hexagon of the plate (3) of the tightener, turn it
anticlockwise to cover the reference hole (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 ± 4 Nm.
Tighten screw (9) to the torque values below:
- screw (9) securing pulley (7) to the distributing shaft with
full-section tapered shank: 90 Nm;
- screw (9) securing pulley (7) to the distributing shaft with
hollow-section cylindrical shank: 130 Nm.
75497 Remove the tools 99360614 (6) and 99360615 (11) for the
Mount the fixed tightener (1) and tighten the fixing screw (2) timing.
to the prescribed torque. Turn the engine in its direction of rotation by 8 turns to be
able to put the tools (6) and (11) back in to do the timing.
Mount the automatic tightener (4) without fully tightening In these conditions, the notches of the timing belt (10) must
the fixing screw (3), max. closing torque 5 Nm. coincide with those of the pulley (7) and the gear (12).

NOTE Do not turn the engine in the opposite direction; Figure 219
if, on turning the engine, you pass the point for
inserting the tools (6) and (11), turn the engine
clockwise by another two turns.
See frame C: Figure 216, holding the tightener plate (3)

stationary with the wrench inserted in its hexagon, loosen the
fixing screw (2). Keeping the fixing screw (2) stationary, turn
the plate (3) clockwise until its reference mark (4) coincides
with the reference hole (5) of the fixed portion 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 of tool 99360615 (1) engagement into the drive
shaft is reached. When this point is exceeded, the drive shaft
shall be rotated by two more turns. Verify, under the above 108166
conditions, that reference hole (5) is found within index (4)
as represented in box C; otherwise, the aforesaid operations Fit on the mounting (1) together with the electromagnetic
shall be repeated. coupling (4) and tighten the fixing screws (2 and 3) to the
After assembly, the belt (10) tension measured using tool prescribed torque.
99395849 must be as follows in the following points: X1 =
212 ± 12 Hz -X1 = 178 ± 10 Hz.
Figure 220
Figure 217
75251
75499
Remove the tools (6 and 11, Figure 216). Mount the oil level sensor (1).
Screw the plug (1) into the oil-vacuum pump mounting (2) Fit on the power steering (2) pump mounting (4) and tighten
and the plugs on the holes of the overhead. the fixing screws (3) to the prescribed torque.
Figure 218
Figure 221
75500
Mount the timing cover (1) and tighten the screws (2) to the
prescribed torque. 108165
Mount the damper pulley (3) and tighten the screws (4) to Position the alternator (2) on the mounting (5) and secure
the prescribed torque. it with the bottom screws (3 and 4) and the bolt.

75501
Mount the fixed tightener (2) and tighten the fixing screw (1).
Mount the automatic tightener (3) and tighten the screw (4) 75503
to the prescribed torque. Fit a new seal (3) on the electro-injector (1) and mount this
in the overhead (2).
Figure 223
Figure 226
75248
108326
Using a wrench on the automatic tightener (2), mount the
drive belt (1), taking care to position its ribs correctly in the Mount the brackets (3) fastening the electro-injectors (1)
respective races of the pulleys. and screw down the screws (2) without locking them.
Mount the hydraulic accumulator (4) and tighten the fixing
screws to the prescribed torque.
Figure 224
Figure 227
90155
Fit the flexible belt (3) equipped with tool 99360191 (2) on 108327
the pulley (4) and apply the tool on the pulley (1).
Fit the drive ring (5) on the flexible belt (3) and fasten the ring Screw down pressure sensor (2) onto hydraulic accumulator
on the compressor support. (1) and tighten it to 70 + 5 Nm.
Turn the drive shaft clockwise until the belt fits perfectly on
the pulley (1).

108329
Connect the fuel pipes (2) to the electro-injectors (1) and to

the hydraulic accumulator (3). 108331
Tighten the screws (4) fixing the electro-injector brackets to
the prescribed torque. Mount the intake manifold (1) with a new gasket and, using
a torque wrench, tighten the fixing screws (2) to the
NOTE Whenever they get removed, the fuel pipes must prescribed torque.
be replaced with new ones. Fit air pressure/temperature sensor (3) into place, then
tighten the fastening screw to the prescribed torque.
Figure 229
Figure 232
108330
Using the wrench (4) of the 99317915 series and the torque
wrench 99389829 (3), tighten the fuel pipe fittings (1) and (2)
108332
Figure 230 Fit throttle valve assembly (1), together with a new gasket,
onto inlet manifold (3).
Screw down screws (2), then tighten them to the prescribed
torque.
Fit pipe (5), together with a new gasket, onto throttle valve
assembly (1).
Screw down fastening nuts (4) by a few turns, so that pipe
(5) can still be moved.
75508
Mount the glow plugs (1) and, using the box-type wrench SP.
2275 (2) and torque wrench 99389819 (3), tighten them to
a torque of 8 ÷ 10 Nm.

108334
108176
Connect fuel pipe (3) to high-pressure pump (1) pipe union.
Connect, with coupling (1) equipped with new gaskets, pipe Secure the pipe by means of clamp (2).
(5) to high-pressure pump (2). Fit a new rubber top (5) onto pipe (4), then secure the latter
Fit low-pressure pipe (5) onto bracket (3), then tighten screw to inlet manifold (8) by means of bracket (6) and tighten
(4) to the prescribed torque. screw (7) to the prescribed torque.
Figure 236
Figure 234
108173
Fit coolant pipe (2) into the engine base.

Screw down screw (1), then tighten it to the prescribed
torque.
Fit oil dipstick pipe (4), together with a new seal ring, into the
108333
engine base.
Screw down pipe (2 and 4) fastening nut (3) to the inlet
Connect the fuel pipe (4) to the hydraulic accumulator (7)
manifold, then tighten it to the prescribed torque.
and to the high-pressure pump (5).
With wrench (2) of series 99317915 and dynamometric
wrench 99389829 (1), tighten pipe fittings (3 and 6) at
prescribed torque.
NOTE Whenever they get removed, the fuel pipes (4)

must be replaced with new ones.

Figure 237 Connect oil pipe (4) to turboblower (5) and to the coupling
on the cylinder head, and tighten the fasteners to the
prescribed torque.
Figure 240
108189
Press the clips (3) in the direction shown by the arrow and
connect the fuel recovery pipe fittings (1) to the
Figure 238
108182
Fit pipe union (1), together with a new seal ring, into place,
then screw down screw (2) then tighten it to the prescribed
torque.
Screw down screws (3) securing elbow (4) to bracket (5),
then tighten them to the prescribed torque.
Figure 241
108184
Connect exhaust manifold (1), together with a new gasket

and complete with elbow (3) and pipe (2), to the cylinder
head again. Fit spacers (4) into place, screw down nuts (5),
then tighten them to the prescribed torque.
Figure 239
108335
Fit heat exchanger (5), together with EGR valve (6), back into
place, by proceeding as follows:
- position (by placing a new gasket in between) heat
exchanger (5) onto pipe (4), then screw down screws
(3) securing to bracket (2) by a few turns;
- position a new gasket onto elbow (8), then screw down
screws (7) securing EGR valve (6) to elbow (8);
- tighten nuts (4) and screws (3 and 7) to the prescribed
108183
torque.
Connect turboblower (5), together with a new gasket, to
exhaust manifold (1) again. Screw down nuts (2) then tighten
them to the prescribed torque.
NOTE Before fitting the turbocharger on the engine, it is

necessary to fill the central body with engine
lubricating oil.

108167
Fit coalescence filter (1) into place, screw down screws (2),
108336 then tighten them to the prescribed torque.
Connect pipe (3) to coalescence filter (1), screw down nut
Connect the coolant pipes (by securing them with the new (4), then tighten it to the prescribed torque.
clamps): Connect pipe (5) to pipe union (7), then secure it with a new
clamp (6).
- (3), to heat exchanger (1) pipe union and EGR valve (5);
- (2), to heat exchanger (1) and pipe union (7);
- (6), to pipe union (7) and EGR valve (5);
- (4), to heat exchanger (1) pipe union.
Figure 243
108168
Fit oil filling pipe union (3), together with a new seal ring,
screw down screws (4), then tighten them to the prescribed
torque.
Fit bracket (1) into place, screw down screws (2), then
tighten them to the prescribed torque.

Figure 245
108163
Fit the following items (if any) into place:

Figure 246
- cooling fan to electromagnetic joint;
- engine cable with ducts (13) available by disconnecting
it from:
- electric injectors (3);
- preheating plugs (5);
- inlet manifold air pressure/temperature sensor (12);
- high-pressure pump pressure regulator (10);
- phase sensor (4);
- thermostat coolant temperature sensor (9);
- rpm sensor (8); 108162
- high pressure pump pressure regulator (10);

- temperature sensor (7); Complete engine assembly.
- deadening hood (2) if included; Fit on the left and right engine mountings (3) and tighten the
fixing screws to the prescribed torque.
- plug (1);
Connect the oil pipe (2) to the turbocharger (1) and to the
- the engine with lubricating oil of the prescribed grade crankcase and tighten the fixing screws and the coupling of
and amount. the oil pipe (2) to the prescribed torque.
Fit the swing bar to the engine lifting hooks, then secure the
swing bar to the hoist and take the engine off rotary stand
(6). Take off brackets 99361038 (9).

5450 LUBRICATION Figure 247

General
The engine is lubricated by forced circulation performed by the

following parts:
- An oil gear pump is incorporated in an assembly that also
includes the vacuum pump (GPOD).
- A pressure control valve incorporated in the crankcase.
- A Modine-type heat exchanger with built-in safety valve.
- A double filtration oil filter with built-in safety valve.
Operation (see Figure 247).
Engine oil is drawn up from the sump by the oil pump (3)
via the suction strainer (2) and delivered under pressure to
the heat exchanger (5) where it is cooled.
The oil continues through the oil filter (6) and goes to
lubricate the relevant parts through ducts or pipes.
At the end of the lubrication cycle, the oil returns to the
sump by gravity. The oil filter can be excluded by the safety
valve built into it if it gets clogged. The heat exchanger is
also excluded by a safety valve if it gets clogged.
In addition, the lubrication oil supplies the hydraulic
automatic tightener (7) of the camshaft drive (8).
Oil under pressure
Oil in freefall
Coolant
Breather on pressure control valve
To the oil pressure sensor
108337


OIL VACUUM PUMP ASSEMBLY (GPOD) Characteristic data

transmission ratio 1.15
displacement 16.2 cm3
Figure 248 pumping diameter 49.5 mm
number of teeth 7
height 11
oil pump minimum speed 862 rpm
oil pump max. speed 4485 rpm
oil pump over-revs 5247 rpm
oil pump forced over-revs 6279 rpm
speed 2500 rpm
torque 2.1 Nm
power draw (calc.) 550 W
Oil temperature: 100°C — closed recirculation —

max. outlet pressure 5 bars
engine speed rpm
capacity (l/min)
(oil pump speed — rpm)
750 (862) 12
3900 (4485) 68
Vacuum pump
The vacuum pump (2, SENZA CODICE), with radial blades,
is also incorporated in the GPOD (1, Figure 249). It is driven
directly by the oil pump.
transmission ratio 3.25
75517 displacement 86 cm3
DIAGRAM OF GPOD ASSEMBLY ON ENGINE volume to drain 4.5 litres
volume to drain with EGR 9 litres
1. Vacuum pump — 2. Oil pump — 3. Crankshaft — chamber diameter 65 mm
A. Vacuum pump oil supply hole. rotor diameter 50 mm
Clearance between the crankshaft gear teeth and the oil cam 7.5 mm
pump drive gear 0.003 ÷ 0.2 mm. number of blades 3
The assembly must not be overhauled; in the event of height 34 mm
defective operation, it must be replaced. vacuum pump minimum speed 994 rpm
vacuum pump max. speed 5168 rpm
vacuum pump over-revs 6046 rpm
503010 Oil pump vacuum pump forced over-revs 7235 rpm
Figure 249 theoretical flow rate at minimum (air) 85.5 l/min
actual flow rate at minimum (air) —
at atmospheric pressure 46 l/min
Theoretical speed at max. speed — (air) 444.4 l/min
Actual flow rate at max. speed — (air)
at atmospheric pressure 60 l/min
measured power draw (maximum)
speed 2500 rpm
torque 2.1 Nm
power draw (calc.) 550 W
Oil temperature: 100°C — engine speed 750 rpm

(pump speed 994 rpm)
tank vacuum
0.5 0.8
(litres) (bar)
4.5 4.5 12.5
5.6 time ((sec)) 6.0 16.5
75516
9 9.0 24.0
The oil pump (3) is a gear pump driven directly by the
crankshaft.

543475 Oil pressure control valve 543070 Oil filter

75520
CROSS-SECTION OF OIL PRESSURE CONTROL

VALVE MOUNTED IN CRANKCASE 108539
Valve removed from crankcase L = 51.75 mm.
Valve fitted in crankcase L = 50.75 mm.
Oil filter with single filtration with built-in by-pass valve —
Start of opening 4 bar L = 49.5
opening pressure 2.5 ± 0.3 bar.
maximum opening 4.6 bar L = 44.
543110 Modine heat exchanger
Figure 251
Figure 254
75521
PARTS COMPRISING THE OIL PRESSURE

CONTROL VALVE
1. Split ring — 2. Washer — 3. Spring — 4. Valve —
5. Valve casing.
75524
Figure 252
Thoroughly clean the heat exchanger (1).

Always change the seals (2 and 4).
Built-in safety valve (3).
Opening pressure 0.82 - 1.03 bar
No. of heat exchanger elements:

- 6 (96/116 HP engine)
- 8 (136 HP engine).
75522
MAIN DATA OF THE OIL PRESSURE CONTROL

VALVE SPRING

540480 Oil vapour recirculation system Figure 255

Description
The oil vapours formed in the sump while the engine is
running, passing through the overhead cover, are channelled
into the separator / condenser filter known as the blow-by.
The filter is structured in two sections:
- The first one with a labyrinth, where most of the vapours
are condensed and return to the sump through an
umbrella outlet valve.
- The second one includes a coalescence filter that
condenses the remaining vapours that return to the
sump through another umbrella valve.
The portion of vapour that has not condensed is sent, via a
MANN-HUMMEL valve, to the intake duct and burnt during
normal engine operation.
NOTE The blow-by filter cannot be taken apart and must

therefore be replaced entirely.
75525
OIL VAPOUR RECIRCULATION DIAGRAM
1. MANN-HUMMEL valve — 2. Umbrella valves — 3. Blow-by filter — A. Labyrinth — B. Intake oil
vapour recovery flow — C. Oil return flow into sump — D. Flow of oil vapours from the sump —
E. Flow of oil vapours from the overhead — F. Coalescence filter.


5432 COOLING Figure 256

Description
The engine cooling system is the type with forced circulation
in a closed circuit. It comprises the following parts:
- An expansion tank whose plug has two valves
incorporated in it: an outlet and an inlet, which govern
the pressure of the system.
- A coolant level sensor at the base of the expansion tank.
- Only 136 HP, pressure switch (3), of normally closed
type (calibrated at 0.4 bar, absolute pressure 1.4 bar),
located on expansion tank and connected to EDC
central unit, protects engine against overheating caused
by cooling system failure. Where coolant temperature
exceeds 100 ˚C and contemporarily the pressure inside
expansion tank and it becomes lower than 0.4 bar, EDC
central unit reduces engine performance by changing
fuel flow rate (De-rating) until engine goes off.
- An engine cooling module to dissipate the heat taken
from the engine by the coolant with a heat exchanger
for the intercooler.
- A heat exchanger to cool the lubricating oil.
- A heat exchanger to cool the exhaust gases (engines
with EGR).
- A centrifugal water pump incorporated in the crankcase.
- An electric fan comprising an electromagnetic coupling
on whose shaft a hub turns idle that is fitted with an
axially mobile metal plate on which is mounted the
impeller.
- A 3-way thermostat governing the circulation of the
coolant.
Operation
The water pump driven by a poly-V belt by the crankshaft
sends coolant into the crankcase and with a greater head into
the cylinder head.
When the coolant temperature reaches and exceeds the
working temperature, it causes the thermostat to open and
the fluid is channelled from here to the radiator and cooled
by the fan.
The pressure in the system due to the change in temperature
is governed by the outlet (2) and inlet (1) valves incorporated
in the expansion tank filler plug (detail A).
The outlet valve (2) has a twofold function:
- to keep the system slightly pressurized so as to raise the
boiling point of the coolant;
- to discharge into the atmosphere the excess pressure
produced in case of high coolant temperatures.
The function of the inlet valve (1) is to permit transferring the
coolant from the expansion tank to the radiator when a
lower pressure is created in the system due to the reduction
in volume of the coolant as a result of its temperature
lowering.
Outlet valve opening 1 ± 0.1 kg/cm2.
Inlet valve opening 0.005 — 0.02 kg/cm2.
108200


543212 Electromagnetic pulley The water pump (3) cannot be overhauled. In case of coolant
Figure 257 leaking from the seal or damage, it must be replaced. The
water pump casing (1) is also used as a mounting for the
high-pressure pump. The seals (3 and 4) must always be
replaced.
Figure 259
75527
CROSS-SECTION OF THE ELECTROMAGNETIC JOINT

75529
Characteristics
Transmissible torque at 20°C with clutch run in 45 Nm LONGITUDINAL CROSS-SECTION OF THE
Voltage 12 Volts WATER PUMP
Power input 26 W 1. Pump casing — 2. Pump drive shaft together with
The electric fan control relay is activated or deactivated bearing — 3. Seal — 4. Impeller.
according to the temperatures of: the engine coolant, the fuel
supercharging air and the pressure of the air conditioner fluid 543250 Thermostat
(if present).
Coolant temperature Figure 260
(if the sensor is not defective)
For 96/116 HP engines:
- it activates at > 96°C and deactivates at < 84°C.
For 136 HP engines:
- it activates at > 102°C and deactivates at < 90°C.
Turbocharging air temperature
It activates at > 75°C and deactivates at < 65°C.
Fuel temperatures
(if the coolant temperature sensor is acknowledged to be
defective by the EDC control unit)
With climate control system
With pressure in the system
it turns on 18.5 ± 0.98 bar
it turns off 14.58 ± 0.98 bar
543210 Water pump
Figure 258
75530
The by-pass thermostat (1) needs no adjustment.

If there is any doubt about its operation, replace it.
The thermostat casing is fitted with the thermometric
switch/transmitter and water temperature sensor.
A. — A1 Start of stroke at 78°C ±2°C.
B. Valve (1) stroke at 94°C = 7 mm.
B1 Valve (2) stroke 94°C, 6.4 mm
The stroke of 7 mm less than 60”.
75528

TURBOCHARGING
Figure 261
HOT AIR AT ATMOSPHERIC TEMPERATURE
HOT COMPRESSED AIR
COLD COMPRESSED AIR
EXHAUST GAS
COLD EXHAUST GAS
108201
TURBOCHARGING DIAGRAM
Description
The turbocharging system comprises an air filter, The function of the turbocharger is to use the energy of the
turbocharger and intercooler. engine’s exhaust gas to send pressurized air to the cylinders.
The air filter is the dry type comprising a filtering cartridge to The intercooler comprises a radiator included in the engine
be periodically replaced. coolant radiator and its function is to lower the temperature
of the air leaving the turbocharger to send it to the cylinders.

542410 Turbocharger (KKK K03-2074-CCB 5.88 type)

Figure 262
75532
A. THROTTLE VALVE SHUT B. THROTTLE VALVE OPEN
Figure 263
75533
It is basically composed of: - an overpressure relief valve fitted on the turbine casing.
- a central casing housing a shaft supported by bushings at Its function is to choke the exhaust gas outlet (detail B),
whose opposite ends are fitted the turbine wheel and sending a portion of the exhaust gas straight into the
the compressor rotor; exhaust pipe when the turbocharging pressure
downstream from the turbocharger reaches the setting.
- a turbine casing and a compressor casing mounted on
the end of the central body;

REPAIRS
Figure 265
NOTE On finding irregular engine operation due to the
turbocharging system, it is first expedient to
perform the checks on the turbocharger, check the
efficiency of the seals and the fixing of the couplings,
additionally checking there is no clogging in the
intake sleeves, air filter or radiators. If the
turbocharger damage is due to a lack of lubrication,
check that the oil circulation pipes are not burst or
clogged, in which case replace them or eliminate
the trouble.
88623
Rest the tip of the dial gauge (1) with a magnetic base on the
end of the tie rod (2) and zero it. Using the device 99367121
(3), introduce compressed air into the valve casing (4) at the
prescribed pressure and make sure this value stays constant
throughout the check; replace the valve if it doesn’t. In the
above conditions, the tie rod must have made the prescribed
542418 Pressure relief valve travel.
Checking pressure relief valve
NOTE Before fitting the turbocharger on the engine, it is

Figure 264 necessary to fill the central body with engine
lubricating oil.
88622
Cover the air, exhaust gas and lubricating oil inlets and
outlets. Thoroughly clean the outside of the turbocharger
using anticorrosive and antioxidant fluid. Disconnect the pipe
(2) from the union of the pressure relief valve (1) and fit on
it the pipe of the device 99367121 (3, Figure 265).

542410 GARRET GT 17 variable Figure 267

geometry turbosupercharger
(engine F1A E0481 H - 136 HP)
General
The variable geometry turbosupercharger consists of the
following:
- centrifugal supercharger (1);
- turbine (2);
- set of mobile blades (3);
- mobile blade control pneumatic actuator (4), vacuum
controlled by proportional solenoid valve controlled by
EDC 16 ECU.
Variable geometry enables:
- to increase the speed of the exhaust gases running into
the turbine at low engine rpm;
- to decrease the speed of the exhaust gases running into
the turbine at high engine rpm. 82871
To obtain the max. engine volumetric efficiency also at low
rpm (with on-load engine).
Operation at low engine rpm Operation at high engine rpm

62870 62872
1. TURBINE - 2. MOBILE BLADES - 3. PNEUMATIC ACTUATOR - 4. REVOLVING RING

When engine is running at low speed, the exhaust gases The ECU, through the actuator control solenoid valve,
show weak kinetic energy; under these conditions a modulates the vacuum acting on the diaphragm, so actuator
traditional turbine shall rotate slowly, thus providing a limited (3) controls through the tie rod, the gradual opening of the
booster pressure. mobile blades (2) until reaching the max. open position.
In the variable geometry turbine (1), the mobile blades (2) are Blade through-sections results larger thus producing a speed
set to max. closed position and the small through-sections decrease in exhaust gas flow through the turbine (1) with
between the blades increase the inlet gas speed. Higher inlet speeds equal to or lower than those of the low rpm
speeds involve higher tip speeds of the turbine and therefore condition.
of the turbosupercharger. Turbine (1) speed is therefore adjusted to a proper value
Engine speed increase results in a gradual increase of exhaust enabling suitable engine operation at high speeds.
gas kinetic energy, and also in turbine (1) speed and booster
pressure increase.

Proportional solenoid valve controlling Actuator

turbocharger actuator
Figure 271
Figure 269
62875
SECTION ON THE ACTUATOR

62876
The solenoid valve modulates the low pressure controlling

the turbocharger actuator, taken from the air circuit of the The actuator diaphragm, connected to the control rod, is
servo brake, according to the information exchanged governed by the low pressure on the top of the actuator.
between the electronic control unit and the sensors: engine The low pressure modulated by the proportional solenoid
speed, throttle pedal position and pressure/temperature valve varies the movement of the diaphragm and, as a result,
fitted on the intake manifold. of the rod governing the turbine’s mobile blades.
As a result, the actuator varies the opening of the blades of
the turbocharger that adjust the flow of exhaust gases.
Figure 270
62869
TURBOCHARGING FUNCTIONAL DIAGRAM

1. Variable geometry turbocharger - 2. Pneumatic actuator - 3. Proportional solenoid valve - 4. Air filter -
5. EDC 16 control unit - 6. Servo brake - 7. Vacuum device - 8. High-pressure pump.

REPAIRS
Operate the vacuum pump and check whether the tie rod
542451 Checking and adjusting the actuator (3) stroke values correspond to the vacuum values shown in
the following table:
- vacuum 0 mm Hg Fully open valve
NOTE NOT ALLOWED ARE: - vacuum 0.2 bar Valve stroke 2 ÷ 4 mm
- any replacement or regulation of the - vacuum 0.64 bar Valve stroke 10.5 ÷ 12.5 mm
actuator, since the calibration of such
component is made in an optimal way
for each turbocharger and is
guaranteed for the turbocharger;
Where a different value is found, replace turbocharger.
- any operation on nut (5) and ring nut
(4), since such operation does not
change engine supply characteristics
but may impair engine reliability and NOTE During the check the vacuum value shall not fall,
duration. otherwise the actuator shall be replaced.
Ring nut (4) is sealed with antitempering
yellow paint.
In case of engines under guarantee, each
above specified intervention and/or
alteration to paint applied on ring nut (4)
causes the lapse of the guarantee.
Figure 272
62873
Cover air, exhaust gas and lubricant inlets and outlets.

Clean the turbosupercharger outside accurately using
anticorrosive and antioxidant fluid and check the actuator
(6).
Clamp the turbosupercharger in a vice.
Apply vacuometer 99367121 (1) pipe to actuator (6) hose.
Apply the magnetic base gauge (2) to exhaust gas inlet flange
in the turbine.
Set gauge (2) feeler pin on tie rod (3) end and set gauge (2)
to zero.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM (Exhaust gas recirculation)
Figure 273
112219
a. Brake booster vacuum circuit - b. EGR modulated vacuum circuit. - c. VGT actuator modulated negative pressure circuit
1. Electronic central unit - 2. Throttle valve assembly - 3. Negative pressure take-off - 4 Water temperature sensor - 5. Engine
rpm sensor - 6. E.G.R. pneumatic valve - 7. Flow meter - 8. Intake air filter - 9. EGR modulating solenoid valve -
10. VGT actuator modulating solenoid valve (if present) - 11. Negative pressure additional tank (only vehicles with 136 HP
engine) - 12. Negative pressure power-assisted brake- 13. Negative pressure tank.
EGR system operation

The E.D.C. electronic control unit E.D.C. processes the During the engine operating phases not requiring gas
information from the atmospheric pressure sensor, water circulation (e.g. particulate filter regeneration, start-up,
temperature sensor, engine revs sensor and accelerator engine cold, idle running, load demands, vehicle running at
pedal potentiometer. It drives, according to ways and high altitudes), the control unit control signal to the
procedures properly programmed within its own memory, modulating solenoid valve will be cancelled. The solenoid
both the modulating solenoid valve and the throttle valve by valve will close the connection between the servo brake
means of a PWM signal. vacuum circuit and the E.G.R. one, and will simultaneously
The modulating solenoid valve will, every time is it driver by resume the atmospheric pressure within the E.G.R. circuit.
the E.D.C. control unit 16, communicate the servo brake
vacuum circuit with the E.G.R. one. A vacuum value will be
obtained within the EGR circuit, depending on the control
signal.
Such vacuum will act on the E.G.R. pneumatic valve
membrane, by withdrawing and lifting the shutter that
normally obstructs the passage of the exhaust gas towards
the intake.
Thus, the exhaust gas, passing through the heat exchanger
where it is cooled, will be conveyed into the throttle valve
assembly chamber where it will be mixed with the air from
the intercooler and made to flow out into the inlet manifold.
If the vehicle is equipped with the D.P.F. catalyst, the EDC
control unit 16 will simultaneously adapt the flow rate of fuel
to be injected into the cylinders, depending on the amount
of circulated exhaust gas.

Main system components 772652 Air flow rate meter (flow meter)
540744 E.G.R. valve Figure 276

Figure 274
105060
1. Connector - 2. Flow meter body - 3. Recirculated oil

vapours air inlet grid - 4. Power supply - 5. Earth - 6. Inlet
air temperature sensor - 7. Flow rate output signal.
108204
E.G.R. valve is mounted on heat exchanger end. The flow meter is a heated film type flow meter and is placed
To ensure higher efficiency and longer durability to the valve, between turbocharger and intercooler.
the valve is cooled by engine coolant from heat exchanger. Inside the flow meter, sucked in air temperature sensor is
built in.
Recirculated gas quantity regulation is through a mushroom

valve, pneumatically driven under under-pressure; the NOTE The air flow meter body bears an arrow which
under-pressure, through calibrated section fitting, is taken
from the tube connecting the vacuum unit to power-assisted indicates the air flow and, therefore, the correct
brake. assembling of the meter on the vehicle.
Driving under-pressure modulated by the solenoid valve and
overcoming the force exerted by counteracting spring (1), Operation
will lift membrane (2), connected to cut-off unit (3), which
moves upwards and enables the recirculation of burnt out Operation principle is based on a heated membrane put in
gasses towards inlet manifold. between a measurement channel through which inlet air
entering the engine is flowing.
540746 Modulator solenoid valve The heated film membrane is kept at constant temperature
(about 120 °C, higher than incoming air temperature) by
Figure 275 heating resistance.
The air mass which runs through measurement channel
tends to take out heat from the membrane; therefore, to
keep the membrane at constant temperature, the current
must run through the resistance.
Absorbed current is proportional to air mass flowing to
engine; the current is measured by a Wheatstone bridge and
signal obtained is sent to the electronic central unit.
If the vehicle is equipped with the DPF catalyst, the control
unit program will feature a function capable of correcting the
flow rate meter deviation in time. During vehicle deceleration
with pedal released (overrun), the central unit performs
some checks determining a number of flow rate meter
reading rectification factors (self-adapting process).
Therefore, replacing flow rate meter involves the
self-rectifying process.
Where the central unit is replaced, flow rate meter
112333 rectification coefficients (ZFC) stored in old central unit have
to be copied down and entered into new central unit. Where
Modulator solenoid valve is an integrating part in E.G.R. it is not possible, they must be reset and self-learning process
system and power-assisted brake under-pressure tubes.
It is a proportional solenoid valve modulating E.G.R. valve must be started.
driving under-pressure depending on PWM signal generated
by EDC 16 central unit.

540760 Throttle valve assembly

Figure 277 When the engine is switched off, the throttle valve will close
in order to reduce engine noise during this phase.
540730 Heat exchanger
Figure 278
105061
1. Throttle valve - 2. Electrical actuator

A. Air / exhaust gas mixing chamber
Throttle valve (normally open) assembly, mounted on inlet
manifold, has the task to regulate the flow rate of air, 108205
incoming from the intercooler, to be mixed to exhaust gasses
recirculated by E.G.R. valve according to programmed Heat exchanger, mounted between turbocharger and
percentage. throttle valve assembly, has the task to lower exhaust gas
Throttle valve is driven by an electrical actuator driven by a temperature in order to reduce gas volume.
PWM signal from EDC 16 central unit. It consists of a body that incorporates a number of
In case of throttle valve lock, the central unit reduces engine corrugated pipes. The circulated exhaust gas flowing through
performance to prevent the engine from being damaged. the pipes are cooled by the engine coolant flowing inside the
body
Figure 279
108202
Cold air
Hot exhaust gasses
Air from intercooler
Engine coolant
Cooled exhaust gasses
Engine coolant
Hot exhaust gasses Exhaust gas - air mixture
EXHAUST GAS COOLING SCHEME
A. Air from intercooler - B. Cooled exhaust gasses - C. Intake exhaust gas mixture - D. Coolant to heater - E. Coolant -
F. E.G.R. valve exhaust gasses - G. Coolant incoming from cylinder head -

EXHAUST POLLUTANT REDUCTION SYSTEM WITH DPF CATALYST (ON REQUEST)
Figure 280
Exhaust gasses
Recirculation cooled exhaust gasses
Recirculation oil vapours
Under-pressure tube
108363
1. E.G.R. valve - 2. E.G.R. heat exchanger - 3. Air pressure/temperature sensor - 4. Engine revs sensor - 5. Vacuum pump
coupling - 6. Modulating solenoid valve - 7. VGT actuator modulating solenoid valve (136 HP engine) - 8. Auxiliary vacuum
tank for vehicles equipped with 136 HP engine - 9. Air filter - 10. Air flow meter) - 11. VGT actuator - 12. Differential
pressure sensor (delta p) - 13. Incoming exhaust gas temperature sensor - 14. Outgoing exhaust gas temperature sensor -
15. DPF catalytic silencer - 16. Vacuum tank - 17. EDC control unit 16 - 18. Engine coolant temperature sensor - 19. Servo
brake - 20. Throttle valve assembly.
General
To keep the exhaust emission levels of pollutants such as nitric oxides (NOx), hydrocarbons (HC) and particulate (PM) within
the limits established by the Euro 4 standard, the engine is equipped with an EGR system combined, on request, to the DPF
catalytic silencer for post-treatment of the aforesaid polluting substances.

507130 D.P.F. (Diesel Particulate Filter) CATALYST

Figure 281
105064
D.P.F. CATALYST VIEW

1. Exhaust gas inlet- 2. Exhaust gas temperature sensor connection - 3. Catalyst module - 4. Particulate filter -
5. Exhaust gas outlet - 6. Pipes connecting pressure sensor to catalyst - 7. Differential pressure ( ∆p) sensor
Description
D.P.F. catalyst is made up of an oxidiser catalyst and a If filter interior is kept at a temperature higher than 530 ºC
particulate filter. and oxygen percentage is higher than 8% (oxygen being
Oxidiser catalyst (3) is an exhaust gas post-treatment device. produced by the decomposition of nitrogen oxide NO2),
Active substances, contained in the catalyst, oxidise, at 250 then some combustion reactions, boosted by the catalyst put
°C÷450 °C temperature, carbon oxide (CO) and before the filter, burn particulate particles (regeneration), so
hydrocarbons (HC), turning them into carbon dioxide (CO2) keeping the filter clean.
and steam (H2O). Conversely, if its temperature is lower, the filter will get
Catalyst module is made up of a ceramic structure clogged, with bad effects on the back pressure to the exhaust
impregnated with platinum, as platinum is a catalysing gas generated.
substance in oxidation reactions. Exhaust gasses heat the In this case, to regenerate the filter, temperature of exhaust
catalyst, so triggering the conversion of pollutants into inert gasses is artificially raised (up to 630 ºC) by fuel post-injection.
compounds. A differential pressure sensor (7), connected to D.P.F.
Particulate filter (4), connected to the catalyst, has a double catalyst, as it detects a pressure difference between inlet and
task: retaining particulate particles (PM) depositing between outlet, sends a (feed-back) signal to the central unit to warn
the pores of the ceramic structure of which the filter is made about particulate filter possible clogging.
up and working as a particulate particles combustion
chamber when the filter is being clogged.

PARTICULATE FILTER REGENERATION SYSTEM

Figure 282
105065
1. E.G.R. valve - 2. Exhaust valve - 3. Differential pressure sensor - 4. Inlet exhaust gas temperature sensor -
5. Outlet exhaust gas temperature sensor - 6. D.P.F. catalysed silencer - 7. E.D.C. 16 central unit -
8. Piston - 9. Inlet valve - 10. Electrical injector - 11. Throttle valve
A. Post-injection - B. Exhaust gasses heated by post-injection - C. Catalyst - D. Particulate filter -
E. Purified exhaust gasses
Operation
Particulate filter regeneration is managed by engine E.D.C. 16 Exhaust gasses, so heated enter into the silencer, where,
central unit. The central unit, based on the temperature of passing through the catalyst, the pollutants they are
exhaust gasses detected by sensors (5 and 4) and particulate composed of (nitrogen oxides) are reduced or transformed
filter clogging grade detected by differential pressure sensor into inert substances (carbon dioxide - steam), then pass into
(3), when exhaust valve (2) is closing at about 1º÷3º from particulate filter where the regeneration process takes place:
T.D.C., causes electrical injectors (8) to inject small quantities exhaust gas high temperature causes the combustion of
of fuel into the cylinders. The combustion of this fuel particulate particles accumulated in the filter.
increases the temperature of flowing gasses. Particulate filter regeneration is realised when following
At the same time, the central unit shuts out: conditions are present:
- Throttle valve (11), to prevent, at opening start, air from - catalyst inlet exhaust gas temperature >230 ºC with the
entering through inlet valve (9), as air would cool help from post-injection;
exhaust gasses; - exhaust gas temperature in particulate filter >530 ºC with
- E.G.R. valve (1), to prevent recirculated oil vapours and presence of free oxygen having a percentage >8%;
gasses produced by post-injection from being sucked - minimum time of permanence in above conditions >10’.
into the cylinders.

Forced regeneration Refilling engine oil

In many cases of doubts about particulate filter cleanness During vehicle use, the central unit counts post-injected fuel
actual conditions and/or of impossibility to regenerate it quantity in order to activate and maintain particulate filter
owing to very particular engine/vehicle running conditions regeneration.
(persistent idling, very slow speeds and very frequent stops), A small quantity of this fuel, which is injected into the
a safety forced regeneration has to be performed. cylinders after combustion has already taken place and
Independently of all parameters activating the regeneration, remains partially unburnt, leaks out through pistons spring
the engine is taken to run without load to a point where rings into oil sump, accumulating to lubrication oil. Although
exhaust gasses have a temperature (>230 ºC) such as to a part of it, evaporating, will be burnt in the engine through
activate the reaction in the Oxicat in presence of recirculation system, its remaining part can degrade oil
post-injection. characteristics, impairing its functionality.
The only limit to this operation is the presence in the filter Quantity of accumulated fuel may increase in case of catalyst
of a particulate quantity that is in excess, being anyhow or engine inefficiency, and vehicle use in conditions of low
calculated by the central unit and set as a condition to temperature and/or small amounts of miles covered.
regeneration startup. The central unit counts the amounts of post-injections and
consequently determines the quantity of fuel accumulated in
engine oil, and warns about refilling needed.
If, after refilling engine oil, the function is not reset, the central
unit will keep on counting fuel accumulation increase even
with new oil, with consequent engine oil refilling warning.

Print 603.93.281
FUEL SUPPLY
Figure 283
HIGH-PRESSURE ELECTRONIC
INJECTION SYSTEM (MS 6.3 - EDC 16)
General
Common Rail MS6.3 is a high-pressure electronic injection
system for fast diesel engines with direct injection.
Its main features comprise:
- high injection pressures available (1600 bar);
- these pressures can be modulated between 250 bar up
to the maximum operating pressure of 1600 bar,
irrespective of the speed of rotation and engine load;
- capacity to operate at very high speeds (up to 6000
rpm);
- injection control precision (injection duration and
advance);
- lower consumption;
- lower emissions.
The main functions of the system are basically as follows:
- checking fuel temperature;
- checking engine coolant temperature;
- checking amount of fuel injected;
- checking idling speed;
- cutting off fuel in release phase;
- checking cylinder balancing when idling;
- checking anti-sawing;
- checking smokiness at exhaust on acceleration;
- checking exhaust gas recirculation (E.G.R.);
- checking top speed limit;
- checking glow plugs;
- checking activation of air-conditioning system (if any);
- checking auxiliary fuel pump;
- checking position of cylinders;
- checking main and pilot injection advance;
- checking closed cycle of injection pressure;
- checking turbocharging pressure;
- self-diagnosis;
- connection with immobilizer unit;
- checking maximum torque limitation.
The system makes pre-injection (pilot injection) possible
before the TDC with the advantage of decreasing the
derivative of the pressure in the combustion chamber,
lowering the noise level of combustion, which is typical of
direct injection engines.
The control unit checks the amount of fuel injected,
adjusting the line pressure and injection times.
The information the control unit processes to regulate the
amount of fuel to be injected comprises:
- engine speed;
- coolant temperature;
- turbocharging pressure; high pressure 108203
- air temperature; low pressure
- intake air quantity;
HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM COMPONENTS LAYOUT
- battery voltage;
- diesel pressure; 1. Timing phase sensor - 2. Electric injectors - 3. Preheating plug - 4. Coolant temperature sensor - 5. Electromagnetic fan - 6. E.G.R. valve modulator - 7. Engine revs sensor - 8. Compressor (if any) -
- position of throttle pedal. 9. High-pressure pump - 10. Connector for fuel temperature sensor, heater and fuel filter clogging sensor (on request) - 11. Pressure regulator - 12. Fuel filter - 13. Fuel tank - 14. Fuel gauge with built-in electric
fuel pump - 15. Control unit with atmospheric pressure sensor - 16. Battery - 17. Accelerator pedal sensor - 18. Clutch pedal sensors - 19. Brake pedal sensors - 20. Low-pressure fuel pipes - 21. Throttle valve
assembly - 22. Hydraulic accumulator (rail) air pressure/temperature sensor - 23. Air pressure/temperature sensor - 24. Hydraulic accumulator - 25. Engine revs counter - 26. Display - 27. Tachograph.


SYSTEM OPERATION Checking regular engine rotation (anti-sawing)

Self-diagnosis — BLINK CODE It ensures regular engine rotation at a constant rate while
The control unit self-diagnosis system checks the signals from increasing revs.
the sensors, comparing them with the admitted limits (see The control unit processes the signals received from the
relative heading): sensors and determines the amount of fuel to be injected via:
- the pressure regulator;
Immobilizer recognition - the electro-injector opening time.
When the control unit receives the signal of the key on ”MAR”
it communicates with the immobilizer control unit to enable Checking smokiness at exhaust on
starting. acceleration
With heavy acceleration, on the basis of the signals received
Checking fuel temperature from the air introduction meter and engine speed sensor, the
control unit determines the optimum amount of fuel to inject:
With the fuel temperature greater than 75°C, detected by the
sensor on the fuel filter, the control unit operates the pressure - it operates the pressure regulator;
regulator to decrease the line pressure (injection times are not - it varies the electro-injector injection time.
changed). If the temperature exceeds 90°C, the power is
reduced to 60%. Checking exhaust gas recirculation (E.G.R.)
Depending on the engine load and the signal from the
Checking engine coolant temperature accelerator pedal sensor, the control unit limits the amount of
The control unit, depending on the temperature: air taken in, actuating partial suction of the exhaust gases.
- of the engine coolant, turbocharging air and fuel, operates Checking top speed limit
the electromagnetic fan (Baruffaldi) and switches on the
coolant temperature warning light. Depending on the number of revs, the control unit actuates
two action strategies:
Checking quantity of fuel injected - at 4250 rpm it cuts off the fuel, decreasing the
According to the signals from the sensors and the mapped electro-injector opening time;
values, the control unit: - over 5000 rpm it deactivates the electro-injectors.
- operates the pressure regulator;
Checking regular rotation on acceleration
- varies the ”pilot” injection time to 2200 rpm;
- varies the ”main” injection time. Regular progression is assured in all conditions by the control
of the pressure regulator and the electro-injector opening
Checking idling adjustment time.
The control unit processes the signals from the various sensors
and regulates the amount of fuel injected: Checking glow plug control unit
- it operates the pressure regulator; The injection control unit, in the phase of:
- it varies the injection times of the electro-injectors. - starting
Within certain thresholds the speed takes account of the - after-starting
battery voltage. times operation of the glow plugs according to the engine
temperature.
Fuel cut-off in release phase
In the phase of releasing the throttle pedal the control unit Checking activation of air-conditioning system
actuates the following logic elements: The control unit operates the air-conditioning compressor:
- it cuts off supply to the electro-injectors; - switching it on/off when the relative switch is pressed;
- it partially reactivates supply to the electro-injectors - momentarily turning it off (approximately 6 sec.) if the
before reaching idling speed; engine coolant reaches the set temperature.
- it operates the fuel pressure regulator.
Checking fuel pump
Checking cylinder balancing on idling Irrespective of the speed, the control unit:
According to the signals received from the sensors, the control - supplies the auxiliary fuel pump with the key on MAR;
unit controls the regularity of the torque at idling speed: - cuts off auxiliary pump supply if the engine is not started
- it varies the amount of fuel injected into the single up within a few seconds.
electro-injectors (injection time).

Checking diesel warming Correcting flow rate to avoid noise, smoke or

It times operation of diesel warming in relation to ambient overloading
temperature. The behaviour that could lead to this kind of trouble is well
known.
Checking cylinder position The designer has therefore included special instructions in the
During each turn of the engine, the control unit recognizes control unit to avoid it.
which cylinder is in the power stroke and operates the
injection sequence for the appropriate cylinder. De-rating
In the event of the engine overheating, injection is modified,
Checking pilot and main injection timing decreasing the delivery to a varying degree, in proportion to
According to the signals from the various sensors, including the the temperature reached by the coolant.
absolute pressure sensor built into the control unit, the control
unit determines the optimum point of injection according to Injection timing electronic test
internal mapping.
The advance (start of delivery, expressed in degrees) may be
different from one injection to the next, also differentiated
Checking injection pressure closed cycle from one cylinder to another. It is calculated, similarly to the
Depending on the engine load, determined by processing the delivery, in relation to the engine load (accelerator position,
signals from the various sensors, the control unit operates the engine speed and air introduced).
regulator to obtain optimum line pressure. The advance is appropriately corrected:
- in phases of acceleration;
Fuel supply - according to the water temperature.
The fuel supply is calculated in relation to: And also to obtain:
- accelerator pedal position - lower emissions, noise and overloading;
- engine speed - better vehicle acceleration.
- quantity of air introduced. An extremely high advance is set on starting, depending on the
The outcome may be corrected in relation to: water temperature.
- the water temperature. Feedback from the start of delivery is supplied by the change
in impedance of the injector solenoid valve.
Or to avoid:
- noise Speed governor
- smoke
The electronic speed governor has both features of
- overloading governors:
- overheating
- idling and top speed
- turbine over-revving.
- all speeds
The delivery can be modified in the case of:
It is stable in ranges where conventional, mechanical governors
- action of external devices (ABS), ABD, EDB are imprecise.
- serious trouble decreasing the load or stopping the
engine. Engine starting
After determining the mass of air introduced by measuring its During the first few turns of the engine, the timing and cylinder
volume and temperature, the control unit calculates the no. 1 recognition signals (flywheel sensor and camshaft sensor)
corresponding mass of fuel to inject into the relevant cylinder are synchronized.
(mg per delivery) also taking into account the temperature of The accelerator pedal signal is ignored on starting. Starting
the diesel. delivery is set only according to water temperature, by a
The mass of fuel calculated in this way is first converted into special map.
volume (mm3 per delivery) and then into degrees of throw, When the control unit detects such speed and acceleration of
or duration of injection. the flywheel as to be able to consider the engine started up
and no longer driven by the starter motor, it re-enables the
Correcting flow rate according to water accelerator pedal.
temperature
A cold engine meets with greater resistance during operation:
friction is high, the oil is still very viscous, and the various
clearances are not yet optimized.
In addition, the injected fuel tends to condense on the metal
surfaces that are still cold.
The fuel supply for a cold engine is therefore greater than for
a warm one.

Cold starting Cut-off

If even just one of the three temperature sensors (water, air This function cuts off fuel delivery when the vehicle is
or diesel) records a temperature lower than 10°C, pre-post decelerating (accelerator pedal released).
heating is activated.
When the key makes contact the pre-heating indicator light Cylinder balancing
comes on and stays on for a length of time that varies in
relation to the temperature (while the glow plugs in the Individual cylinder balancing contributes to increasing comfort
cylinder head heat the air), then flashes. It is now possible to and handling.
start up the engine. This function permits individual, customized control over the
When the motor is running this indicator light goes out, while delivery of fuel and the start of delivery for each cylinder, even
the glow plugs continue to be powered for a certain length of differently from one cylinder to another, to compensate for
time (variable) for post-heating. the hydraulic tolerances of the injector.
If, with the indicator light flashing, the engine is not started up The differences in flow (delivery specifications) between the
within 20-25 seconds (inattention time), the operation is various injectors cannot be evaluated directly by the control
cancelled so as not to run down the batteries pointlessly. unit. This information is supplied by Modus reading the bar
The pre-heating curve is also variable in relation to the battery code of each injector at the time of assembly.
voltage.
Synchronization search
Warm starting
If there is no signal from the camshaft sensor, the control unit
If the reference temperatures all exceed 10°C, when the key is anyhow able to recognize the cylinders into which the fuel
makes contact the indicator light comes on for approximately is to be injected.
2 sec., for a short test, and then goes out. It is now possible to If this occurs when the engine is already running, the
start up the engine. combustion sequence has already been acquired, so the
control unit continues with the sequence on which it has
Run up already been synchronized.
When the key makes contact, the control unit transfers the If this occurs when the machine is at a standstill, the control
information stored in memory when the engine was last unit energizes a single solenoid valve. Within at most 2 turns
stopped into the main memory (see After Run) and makes a of the crankshaft, injection will take place in that cylinder, so
diagnosis of the system. the control unit just needs to get synchronized on the firing
sequence and to start up the engine.
After run
Whenever the engine is switched off with the key, the control
unit stays powered for a few seconds by the main relay.
This makes it possible for the microprocessor to transfer some
data from the main memory (volatile) to a non-volatile
memory, which can be erased and written over (EEPROM),
so as to make it available at the next start up (see Run Up).
These data basically consist of:
- various settings (engine idling adjustment, etc.);
- settings of some components;
- fault memory.
The process lasts a few seconds, typically from 2 to 7
(depending on the amount of data to save), after which the
ECU sends a command to the main relay and makes it
disconnect from the battery.
NOTE It is extremely important for this procedure not to

be broken off, for example by switching off the
engine with the battery cut-out, or by disconnecting
the battery cut-out before 10 seconds have passed
since switching off the engine.
If this happens, the functioning of the system is
ensured, but repeated interruptions may damage
the control unit.


OPERATION Figure 284

In this injection system, the pressure regulator, located
upstream from the high-pressure pump, governs the flow of
fuel needed in the low-pressure system. Afterwards, the
high-pressure pump correctly supplies the hydraulic
accumulator.
This solution, pressurizing solely the necessary fuel, improves
the energy efficiency and limits heating the fuel in the system.
The relief valve fitted on the high-pressure pump has the
function of keeping the pressure, at the pressure regulator
inlet, constant at 5 bars; irrespective of the efficiency of the fuel
filter and of the system upstream. The action of the relief valve
causes an increase in the flow of fuel in the high-pressure pump
cooling circuit.
The high-pressure pump continually keeps the fuel at the
working pressure, irrespective of the timing and the cylinder
that is to receive the injection and accumulates it in a duct
common to all the electro-injectors.
At the electro-injector inlet, there is therefore always fuel at
the injection pressure calculated by the electronic control unit.
When the solenoid valve of an electro-injector is energized by
the electronic control unit, fuel taken straight from the
hydraulic accumulator gets injected into the relevant cylinder.
The hydraulic system is made out of a low-pressure fuel
recirculation circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipes:
- ;pipe connecting the high-pressure pump outlet to the
hydraulic accumulator (rail);
- hydraulic accumulator (rail);
- pipes feeding the electric injectors from the hydraulic
accumulator.
The low-pressure circuit is composed of the following pipes:
- fuel intake pipe from the tank to the filter;
- pipe assembly made up of the following:
- feed pipe from the fuel filter to the high-pressure pump;
- fuel return pipe from the high-pressure pump to the tank;
- fuel exhaust pipe from the injectors to the fuel return pipe
to the tank.
According to the high performance of this hydraulic system,
for reasons of safety it is necessary to:
- avoid connecting high-pressure pipe fittings with
approximate tightening;
- avoid disconnecting the high-pressure pipes with the
engine running (NEVER try bleeding, which is both
pointless and dangerous).
The integrity of the low-pressure circuit is also essential for the
system to work properly; it is therefore necessary to avoid all
manipulation and modifications and act only in the event of
leakage. high pressure
low pressure
NOTE The pipes connected to the fuel filter support to the 108338
low-pressure pipe assembly are of the
quick-connect type. FUEL RECIRCULATION AND SUPPLY SYSTEM DIAGRAM
Before fitting them, make sure the couplings and the 1. CP1 H high-pressure pump - 2. Pressure regulator - 3. Heated fuel filter with water separator - 4. Fuel delivery pipe to the filter - 5. Fuel return pipe to the tank - 6. Low-pressure pipe assembly - 7.
associated fittings on the mounting are clean.
High-pressure delivery pipe to the hydraulic accumulator - 8. Pressure sensor - 9. Hydraulic accumulator - 10. Return pipe from the electric injectors to the low-pressure pipe assembly - 11.
High-pressure pipe between the hydraulic accumulator and the electric injectors - 12. Electric injectors.


Figure 285
109124
FUNCTIONAL DIAGRAM OF HYDRAULIC SYSTEM

1. High-pressure pump - 2. High-pressure delivery pipe - 3. Electric injector return pipe - 4. Electric injectors - 5. Common rail -
6. Fuel pressure sensor - 7. Filter with water separator - 8. Fuel electric pump non-return valve - 9. Injector return line
pressure-relief valve - 10. Tank - 11. Fuel electric pump - 12. Fuel electric pump intake filter - 13. Fuel electric pump
overpressure valve - 14. Pressure-relief valve - 15. Proportional pressure-relief valve.
Relative pressures within the circuit:
a. 4.15 bar <p< 5.35 bar

b. 3.5 bar <p< 5.0 bar
c. p < 0.8 bar
d. 0.3 bar <p< 0.8 bar

HYDRAULIC SYSTEM 773010 Fuel pump

The hydraulic system is composed of:
The fuel electric pump is of the volumetric, low-pressure type.
- tank It is built into the fuel level indicator located in the fuel tank
- electronic fuel pump;
- fuel filter;
- high-pressure feed pump;
- pressure regulator;
- manifold (rail);
- electric injectors;
- low-pressure feed pipe assembly;
- high-pressure pipes.
Figure 286
109073
FUEL ELECTRIC PUMP ASSEMBLY SECTION

1. Return - 2. Connector - 3. Delivery - 4. Float - 5. Level sensor (+) - 6. Level sensor (-) - 7. Pump (-) - 8. Pump (+) - A.
Return line - B. Delivery line - C. Level sensor - D. Prefilter - E. Jet pump.
Electric connector (2), located in the upper portion of the assembly, features the pins both for the electric pump and the level
sensor.
During the installation, the assembly shall not be stressed with axial loads of more than 67 N and torque of more than 3 Nm.
The maximum fastening torque on the gasket shall be 60 Nm.
Figure 287
109123

542011 Fuel filter “UFIfilters”

Figure 288
112723
1. Fuel filter support- 2. Diesel oil outlet - 3. Diesel oil inlet - 4. Diesel oil filter - 5. Drain screw - 6. Electronic unit - 7. Fastener -
8. 12-way connector - 9. Screw securing Diesel oil filter: H-G-B, water present sensor; - H-C, clogging sensor (if foreseen); -
D-E, NTC temperature sensor; - F-A, heater.
Fuel filter (4) is made up of a filtering cartridge with water Normally open contact type.
separator, inside which electronic unit (6) is housed. Operation differential pressure delta p: 0.8 bar
Water accumulation capacity is equal to 140 cm3.
NTC temperature sensor
Electronic unit (6) includes water present sensor, (optional)
30 ˚C = 26.114 ohm ± 9.7%
filter clogging sensor and temperature sensor.
0˚C = 5.896 ohm ± 7.3%
Water present sensor
+25 ˚C = 2.057 ohm ± 5.6% +0,05
Water present sensor detects water present in the filter
+60 ˚C = 596 ohm ± 3.8% -0,5
starting from 110 cm3 volume present. Water present sensor
+100 ˚C = 186 ohm ± .2.0%
provides values of:
+110 ˚C = 144 ohm ± 2.4%
- low voltage in presence of water; Temperature range: -40˚C to +130˚C
- high voltage in absence of water.
Heater
Characteristics Nominal voltage 12 V
12V nominal voltage (8V minimum -16V maximum Maximum allowed voltage 30 V
Absorbed current: Nominal power 250 W
- lower than 15 mA in rest conditions; Tightening torques
- lower than 150 mA in alarm conditions (including load). 9. Screw securing filter 1.5 + 0.5 Nm
Voltage on load: 4. Water draining or air bleeding screw 1.5 + 0.5 Nm
- in rest conditions: higher than 11.8 V;
- in alarm conditions: lower than 3.9 V.
At key-on operation, the sensor makes a self-test issuing 2.5
second duration sound signal.

542011 Fuel filter “Filtrauto”

Figure 289
112721
1. Body - 2. Gasket - 3. Cover bottom - 4. Drain screw gasket - 5. Customer reference - 6. Diesel oil outlet - 7. Diesel oil inlet -
8. Air drain screw - 9. Supplier code - 10. Air bleeding or water draining screw - 11. Lower bottom - 12. Inner pipe - 13.
Filtering paper - 14. Upper bottom - 15. Heating earth - 16. NTC1 - 17. NTC2 - 18. Clogging sensor (if foreseen) - 19. Water
sensor - 20. Heating - 21. Feed - 22. GND
The fuel filter consists of an internal filtering-paper cartridge
(13) and is equipped with a water separator. Fuel pipes
The maximum water storage capacity of the filter is 150 cm3. Figure 290
The water sensor detects the presence of water in the filter
starting from an existing volume of 70 cm3.
This sensor is located in the lower part of the filter.
The temperature, water and clogging (if any) sensors are
interfaced with the electronic circuit (11) located inside in the
upper portion of the assembly.
When the diesel fuel temperature is lower than a limit value,
the electric resistor will come into operation by properly
heating the diesel fuel before the latter is conveyed to the
high-pressure pump.
Clogging sensor (if any) features:
- differential working pressure: 0.7 to 0.85 bar
Tightening torques
5. Cover 35±5 Nm
112218
12. Air/water drain screw 1±0.2 Nm
NTC and heating features 1. High-pressure pump supply pipe quick-coupling fitting —
- rated voltage 13.5 V 2. Supply pipe quick-coupling fitting — 3. — Fuel filter
- max. permitted voltage 30 V mounting.
- rated output 250 W at 185 l/h, T = - 10˚C
- temperature range -30 to 120˚C
NOTE Due to the very high pressure existing within this hydraulic system, the following precautions shall be taken for safety
reasons:
- avoid connecting the high-pressure pipe fittings by means of makeshift fasteners: tighten them to the specified
torque;
- avoid disconnecting the high-pressure pipes when the engine is running (DO NOT make any attempt at draining:
this is absolutely useless and dangerous
To ensure correct operation of the system, it is essential that the low-pressure circuit is intact. Therefore, any modification
or attempt at tampering shall be avoided, and corrective actions shall be taken immediately in case of leaks.
In the event that fuel pipes (1-2-3) are disconnected from support (1), make sure, when reattaching the pipes, that their
respective fittings are fully clean.
Such precautions shall be taken to avoid detective sealing, with resulting fuel leaks.

775010 High-pressure pump CPH1

Figure 291
109125
1. Low-pressure feed line - 2. Shaft with cam - 3. 3-lobe element - 4. Pressure regulator - 5. High-pressure line non-return valve -
6. Delivery line - 7. Low/high-pressure line non-return valve.
Pump with 3 radial pumping elements controlled via a gear by

the timing belt; it needs no timing. NOTE The high-pressure pump cannot be overhauled;
The pump is lubricated and cooled by the fuel. therefore, the fastening screws shall not be removed
or tampered with. The only operation that can be
carried out is the replacement of the drive gear and
pressure regulator.

771034 Pressure control valve Replacing pressure regulator

The fuel pressure regulator is mounted on the low-pressure
circuit of the CP3 pump. The pressure regulator modulates Figure 294
the amount of fuel sent to the high-pressure circuit according
to the commands received directly from the engine control
unit. The pressure regulator is mainly composed of the
following components:
- connector
- casing
- solenoid
- pre-load spring
- shutter cylinder.
When there is no signal, the pressure regulator is normally
open, therefore with the pump providing maximum delivery.
The engine control unit, via the PWM (Pulse Width
Modulation) signal, modulates the change in fuel flow rate in
the high-pressure circuit by partially closing or opening the 108347
sections of passage of the fuel in the low-pressure circuit.
Operation Accurately clean high pressure pump.
Take off screws (2) and unthread pressure regulator (3) from
Figure 292 high pressure pump.
Figure 295
75574
1. Solenoid — 2. Magnetic core — 3. Shutter cylinder — 108348

4. Fuel inlet — 5. Fuel outlet.
When the engine control unit governs the pressure regulator Accurately clean the seat (→) of pressure regulator and the
(via PWM signal), the solenoid (1) is energized that, in its turn, connection surface (→) of the regulator.
generates the movement of the magnetic core (2). The shift
of the core causes the shutter cylinder (3) to move axially,
choking the flow of fuel. NOTE For cleaning, do not use a tool which could damage
the surfaces and pay attention that impurities are
not introduced into channels.
Figure 293
Figure 296
75575
1. Solenoid — 2. Magnetic core — 3. Pre-load spring —

4. Shutter cylinder.
When the solenoid (1) is not energized, the magnetic core is
pushed into the rest position by the pre-load spring (3). In this 88408
condition, the shutter cylinder (4) is in such a position as to Mount new seal rings (1 and 2) on pressure regulator (3) and
offer the fuel the greatest section of passage. lubricate the rings with vaseline.

Figure 297 774510 Hydraulic accumulator (rail)
Figure 299
108349
Mount pressure regulator (1) on high pressure pump (2).

108387
The hydraulic accumulator is mounted on aspiration side

NOTE Mounting operation must be performed keeping cylinder head.
the regulator perpendicular to connection plane Its task is to damp pressure oscillations caused:
without angling it, in order not to damage seal rings
(1-2, Figure 296). - the operation of the high-pressure pump;
- the opening of the electro-injectors.
Fuel pressure sensor (2) is fitted on hydraulic accumulator (1).
Figure 298 Small valves (throttle valves) or control bushes (3), with ∅ =
0.85 mm, have been fitted to the fuel delivery couplings, which
control the fuel pressure waves generated by the
high-pressure pump. Their function is to protect the electric
injectors by reducing their wear in time.
Fuel pressure sensor (2) may affect the accuracy of the injector
minimum flow rate correction, since the minimum flow rate
depends both on the injection time and the actual pressure of
the hydraulic accumulator.
In case of replacement, the EDC control unit 16 correction
coefficients (ZFC) shall be set to zero.
The correction coefficients can be set to zero by means of the
IVECO MODUS - E.A.SY. - IT 2000 diagnosis instruments, by
programming the control unit again and performing the sensor
108350 given by the diagnosis instruments.
Screw up screws (1) and tighten them at 6 ÷ 7 Nm (0.6 ÷ 0.7
kgm) torque.
NOTE Where pressure regulator is replaced on the engine

mounted on the vehicle, it is needed, after
replacement, to check that there are no fuel leaks
after an engine working period.

775010 ELECTRO-INJECTORS Operation

Electro-injector operation can be broken down into three
Figure 300 phases:
- ”rest position”
Coil (4) is de-energised, and shutter (6) is in closing position
and prevents fuel from being introduced into the cylinder, Fc
> Fa (Fc: caused by fuel pressure acting on control area (7) of
rod (1); Fa: caused by line pressure acting on pressure
chamber (8).
- ”start of injection”
The coil (4) is energized and causes the shutter (6) to rise.
75588
The fuel of the control volume (9) flows off towards the return
The electro-injectors have high-pressure supply (up to 1600 manifold (10) causing a drop in pressure in the control area
bar) and recirculation at atmospheric pressure, necessary for (7).
the diesel used to operate the pilot valve. At the same time, line pressure through feed duct (12) applies
The temperature of the diesel put back into circulation by the a force Fa > Fc in pressure chamber (8) lifting peg (2), with fuel
electro-injector can get very high (approximately 120°C). being consequently introduced into cylinders.
The head of the electro-injector has a fitting for the electrical - ”end of injection”
connector. The coil (4) is de-energized and makes the shutter (6) return
They are mounted on the cylinder head and operated by the to its closed position. This recreates such a balance in the
injection control unit. forces as to make the pin (2) return to its closed position and
consequently end injection.
The electro-injector can be divided into two parts (see
Figure 301):
- actuator/jet composed of pressure rod (1), pin (2) and
nozzle (3);
- control solenoid valve composed of coil (4) and pilot 755010 Replacing an electrical injector
valve (5).
Figure 302
Figure 301
Fc
105066
1. IMA Matrix code- 2. Bosch spare part no.-

6. Series no. - 7. Production date
Electrical injectors are not assigned any more to classes Min
(01) - Med (02) - Max (03); therefore, flow rate deviations
from design values are detected, during final check step, by the
manufacturer on each single injector and printed with I.M.A.
(Injector Menge Abgleichung) [Injector Quantity Offset] code
on injector magnet.
At engine production plant, I.M.A. code is read on line from
Fa an automatic reading station, converted into bar code, printed
on engine identification label and applied on the engine itself.
At vehicles production plant, at line end, E.D.C. 16 central unit
is programmed automatically reading the engine identification
50704 label.
1 Pressure rod — 2 Pin — 3 Nozzle — 4 Coil — 5 Pilot valve —
6 Ball shutter — 7 Control area — 8. Pressure chamber —
9 Control volume — 10 Low-pressure fuel return —
11 Control pipe — 12 Supply pipe — 13 Electrical
connection — 14 High-pressure fuel inlet fitting — 15 Spring.

llllk
Figure 303 The correction coefficients (ZCF) can be set to zero by means
of the IVECO: MODUS - E.A.SY. - IT 2000 diagnosis
instruments, by programming the control unit again and
performing the sensor replacement procedure indicated by
the diagnosis instrument itself.
ELECTRIC/ELECTRONIC COMPONENTS
766161 Electronic control unit EDC 16
k
Figure 304
85711
Conversion table of OCR The control unit is a ”flash EPROM” and so it can be
characters into ARIAL characters 105067 reprogrammed from outside without changing the hardware.
At assistance, code written in clear has to be used (3, Figure 31) It processes the signals from the sensors by applying software
for central unit replacement and reprogramming procedures. algorithms and controls the actuators (especially the
In the table there is shown the conversion of OCR characters into electro-injectors and pressure regulator).
Arial characters. The control unit records, in the memory non-labile area, the
When electrical injectors mounted on the vehicle must be information on the engine parameters originally set or
replaced, meet following warnings: acquired during engine operation.
- where electrical injectors are dismounted and do not The injection control unit has the absolute pressure sensor
need to be replaced, their mounting position has to be built in to further improve the control of the injection system.
noted down in order to remount them later in the same The control unit is mounted on the left-hand side of the engine
position; this is done to avoid to reprogram the central bay and is connected to the vehicle’s wiring harness by two
unit; connectors:
- after replacing one or more injectors, the central unit has — 60-pin connector A for the components on the engine
to be reprogrammed; — 94-pin connector K for the components on the vehicle
- before mounting a new electrical injector, note down IMA In addition to handling the operation of the system described
code printed on the injector, because the code is difficult
to read after the injector has been mounted; under the relevant heading, the electronic control unit is
- where the central unit is replaced, reprogram the new interfaced with the other electronic systems on the vehicles
central unit with the IMA codes of the electrical injectors such as ABS — EBD cruise control, speed limiting device,
mounted on the engine and copy down the rectification immobilizer (IVECO CODE), EGR and glow plugs.
coefficients (ZFC) of replaced central unit; where it is not On the vehicles equipped with D.P.F. catalyst, the control unit
possible, they must be reset and self-learning process also controls the catalyst regeneration system. In this case,
must be started up again. after any of the operations below is carried out:
During engine running, EDC 16 central unit performs some - replacing one or several injectors;
checks on electrical injectors minimum flow rate. - replace all injectors;
In certain conditions (overrun: vehicle deceleration with pedal - replace flow rate meter (flow meter);
released) an increasing (very small) fuel quantity starting from - rreplacing the hydraulic accumulator (common rail)
zero is injected and its effect on engine rotation smoothness
is observed. pressure sensor;
Injection start threshold is detected and stored by the central - replace E.D.C. 16 central unit;
unit. - refill engine oil;
This self-learning process is carried out on each single cylinder. - replace D.P.F. catalyst;
Therefore, replacing an electrical injector involves the need of - replace filter differential pressure ( ∆p) sensor;
reprogramming the central unit by entering the IMA codes of - replace components relevant to emissions;
new electrical injectors and resetting the rectification factors
(ZFC) of the cylinder considered. - necessarily perform a forced regeneration;
Replacing all electrical injectors extends the need of resetting the following operations shall be carried out by using the
to all the rectification coefficients (ZFC) of each single IVECO diagnosis instrument:: MODUS - E.A.SY. - IT 2000;
electrical injector. then the procedure to replace affected component has to be
carried out, following below indications provided by diagnosis
tools:

761917 Glow plug electronic control unit SENSORS

764266 Engine speed sensor
Figure 305 It is an inductive type sensor and is positioned on the phonic
wheel mounted on engine shaft front end.
It generates signals obtained from magnetic flux lines which
close through phonic wheel teeth. Teeth number: 58.
The electronic control unit uses this signal to measure the
speed of rotation of the engine, its angular position and to
operate the electronic rev counter.
If this signal fails the rev counter will not work.
764264 Camshaft timing sensor

It is a Hall effect type sensor positioned on camshaft pulley.
It generates signals obtained from lines of magnetic flux that
close through a notch in the pulley.
The signal generated by this sensor is used by the electronic
control unit as a redundant signal to measure the different
engine speeds.
75578
The engine control unit, in the phase of:

- starting
- after-starting Figure 307
Section A-A
times the operation of the glow plug control unit according to
the engine temperature.
Glow plugs drive is through glow plugs pre-heating central unit
depending on engine temperature under close control of
engine control central unit.
The pre-heating control unit contains an “intelligent”
contactor that sends feedback to the control unit that is thus
informed about any fault with the pre-heating control unit or
shorting to earth of the glow plugs.
761915 Glow plugs

Figure 306
75579
CONTROL VALUES 75514
With a constant supply voltage of 11 V: SENSOR ASSEMBLING DIAGRAM

- max. current drawn 18 A The sensor gap is:
- in 5 sec. 11 ±1.5 A
- 1 ±0.5 mm, between the camshaft pulley (2) and timing
- in 30 sec. 6 ±0.9 A sensor (1).
- temperature after 7 sec. 850°C
- 1 mm, between the phonic wheel (4) and speed sensor
- tightening torque 8-10 Nm (3).

772655 Air temperature and pressure sensor 772641 Clutch pedal position sensor
Positioned on the intake manifold, it measures the pressure of Mounted on the pedal board, it provides the control unit with
the turbocharging air introduced into the intake manifold. a positive signal when the clutch is engaged (pedal released).
This value, together with that of the air temperature sensor, Every time the clutch is disengaged to change gear, the control
makes it possible for the electronic control unit to calculate the unit fails to receive this signal and deactivates the Cruise
exact quantity of air introduced into the cylinders so as to Control function.
operate the injectors adjusting the fuel delivery, limiting
harmful emissions, improving consumption and performance. 772642 Brake pedal position sensor
The sensor contains an electronic temperature correction
circuit to optimize the pressure measurement in relation to the There are two of these sensors mounted on the pedal board.
temperature of the intake air. With the brake pedal released, they provide the control unit
with a positive signal that is used to detect brake operation so
772656 Fuel temperature sensor as to deactivate the Cruise Control function and stop delivery
of fuel.
Integrated in the fuel filter, it measures the fuel temperature In addition, a sensor switches on the brake lights.
and transmits it to the electronic control unit.
When the fuel temperature is too high (ambient temperature 764261 Vehicle speed sensor
condition, engine at full load and tank in reserve), correct
lubrication of the high-pressure pump is no longer assured. On This sensor, mounted on the gearbox by the drive output
the basis of the values received, the control unit determines the shaft, transmits the vehicle speed signal, through the electronic
density and volume of the fuel, correcting the delivery limiting tachograph, to the control unit.
engine performance.
540743 Differential pressure sensor - delta p
774511 Fuel pressure sensor (Dp)
This is mounted in the middle of the hydraulic accumulator This sensor detects the difference between the pressure (Dp)
(rail) and it has the task of providing feedback for the injection of the incoming exhaust gas and the pressure of the gas flowing
control unit to: out of the D.P.F. catalyst.
The measured value indicates the extent of particulate (PM)
- adjust injection pressure particle accumulation or clogging in the D.P.F. filter.
- adjust the duration of injection. This value will, through a proper signal (feed-back), be
processed by the EDC control unit 16, which will cause
post-injection so as to increase the exhaust gas temperature
(630˚-650˚C) and also cause the particulate particles
accumulated in the D.P.F. filter to be burned.
NOTE In case of replacement, the control unit shall be

programmed again by means of the IVECO
MODUS - E.A.SY. - IT 2000 diagnosis instrument, by NOTE In case of replacement, the control unit shall be
performing the replacement procedure indicated programmed again by means of the IVECO
by the diagnosis instrument itself. MODUS - E.A.SY. - IT 2000 diagnosis instrument, by
performing the replacement procedure indicated
by the diagnosis instrument itself.
766161 Atmospheric pressure sensor
This is integrated in the electronic control unit. It provides a
criterion of correction for the measurement of the air flow Exhaust gas temperature sensor
rate and to calculate the reference air flow rate to check the The D.P.F. catalyst includes two temperature sensors located
EGR. at the D.P.F. catalyst inlet and outlet, respectively.
The temperature values are processed by the control unit to
764254 Engine coolant temperature sensor determine post-combustion, in order to increase the exhaust
gas temperature needed to burn the particulate particles.
This provides the control unit with an index of the thermal
status of the engine in order to determine corrections for the
fuel delivery, injection pressure, EGR injection advance when
starting cold (if mounted) and warm-up.
505910 Throttle pedal position sensor

The accelerator pedal position sensor provides the control
unit with a voltage value in proportion to the angle of
operation of the pedal determining fuel delivery.

ACTUATORS
The injection system comprises three classes of actuators
interlocked with the electronic control unit:
- electro-injectors (see relevant heading);
- regulators (see relevant headings) requiring PWM control
(Pulse Width Modulation):
• for pressure
• EGR (see respective chapter)
• turbocharger with variable geometry (if mounted);
- actuators with continuous ON/OFF signal to:
• engage electromagnetic coupling for radiator cooling
fan;
• turn on/off air-conditioner compressor (if mounted);
• Cruise Control;
• starter heater control;
• fuel filter heating;
• electric supply pump.
NOTE All the power controls are made with relays located
in the cab.
PWM (Pulse Width Modulation) controls

A PWM control has an active and an inactive state that
alternate within a constant set length of time. During the active
state the actuator control circuit is closed, which is thus
powered with the control voltage; whereas, during the
inactive state the circuit is open.
The duration of the two states may be varied with the
condition that the sum of the two times is equal to the length
of the modulation delivery.
The duration of the active state determines the duty-cycle,
which is normally expressed as a percentage of the total time.
Therefore, if the duration of the two active and passive states
are the same, the duty-cycle is equal to 50%.
For reasons of diagnostics, the duty-cycle is limited between
1% and 99%; the control resolution is equal to 0.005%
(1/20000 of the time).
The time length has been chosen taking account of the
dynamic actuator response specifications.
Too low a carrier frequency could cause oscillations in the
actuator, while too high a frequency would decrease control
resolution.
The E.G.R. and variable geometry turbocharger (if mounted)
are controlled through a vacuum modulating valve.

DAILY EURO 4 F1C ENGINE 157
F1C engine
Page
MAIN OPERATIONS ON ENGINE MOUNTED ON

VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
- Service procedures to be performed after replacing
high-pressure feeding system and/or exhaust gas
post-treatment system components . . . . . . . . . 162
POWER UNIT REMOVAL/REFITTING . . . . . . . . 163
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
- Checks and tests . . . . . . . . . . . . . . . . . . . . . . . 167
- Power steering system air bleed . . . . . . . . . . . . 167
REPLACING AIR-CONDITIONING COMPRESSOR
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 168
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
POWER STEERING PUMP-ALTERNATOR BELT
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 168
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
REPLACING THE WATER PUMP . . . . . . . . . . . . 168
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
REPLACING THE HIGH-PRESSURE PUMP . . . . 169
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
REPLACING THE POWER STEERING PUMP . . 170
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
REPLACING THE DRIVE SHAFT SEAL RING AND
THE FRONT COVER GASKET . . . . . . . . . . . . 170
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
REPLACING THE VACUUM PUMP OIL PUMP
ASSEMBLY (GPOD) . . . . . . . . . . . . . . . . . . . . 172
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
REPLACING THE DRIVE SHAFT REAR SEAL RING 173
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
REPLACING ELECTRO-INJECTORS . . . . . . . . . . 174
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

158 F1C ENGINE DAILY EURO 4
Page Page
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 - Measuring main journals and crank pins . . . . . . 233
REMOVAL/REFITTING THE CYLINDER HEAD . 175 - Checking crankshaft . . . . . . . . . . . . . . . . . . . . . 234
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 - Replacing timing control gear . . . . . . . . . . . . . . 236
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 236
EGR HEAT EXCHANGER REMOVAL - REFITTING 179 - Assembling main bearings . . . . . . . . . . . . . . . . . 236
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 - Measuring main journal assembly clearance . . . 236
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 - Checking crankshaft end float . . . . . . . . . . . . . . 237
- Checks and tests . . . . . . . . . . . . . . . . . . . . . . . 180 - Assembling rear seal . . . . . . . . . . . . . . . . . . . . . 238
EGR HEAT EXCHANGER REMOVAL - REFITTING 180 ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . 239

- Replacing bearing supporting gearbox input shaft 239
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
CONNECTING ROD — PISTON ASSEMBLY . . . 239
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
- Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
- Checks and tests . . . . . . . . . . . . . . . . . . . . . . . 181
- Measuring piston diameter . . . . . . . . . . . . . . . . 240
BURNT GAS EXHAUST SYSTEM . . . . . . . . . . . . 182
- Piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY
COMPONENTS (SYSTEMS EQUIPPED WITH D.P.F. - Conditions for correct pin-piston coupling . . . . 241
CATALYST) . . . . . . . . . . . . . . . . . . . . . . . . . . 183
- Exhaust silencer removal . . . . . . . . . . . . . . . . . 183 - Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
- D.P.F. catalyst removal . . . . . . . . . . . . . . . . . . . 183 - Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 242
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
- Replacing D.P.F. catalyst . . . . . . . . . . . . . . . . . . 184 - Checking connecting rods . . . . . . . . . . . . . . . . 242
- Replacing differential sensor (delta-p) . . . . . . . . 184 - Checking torsion . . . . . . . . . . . . . . . . . . . . . . . 243
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . 185 - Checking bending . . . . . . . . . . . . . . . . . . . . . . . 243
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 - Assembling connecting rod-piston assembly . . . 243

- Checking for connecting rod — piston distortion 244
ENGINE IDENTIFICATION CODE . . . . . . . . . . . 189
- Assembly piston rings . . . . . . . . . . . . . . . . . . . . 244
CHARACTERISTIC CURVES . . . . . . . . . . . . . . . . 195
- Assembly connection rod-piston assembly in the
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 197 cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
ASSEMBLY DATA — CLEARANCES . . . . . . . . . . 200 - Measuring crankpin assembly clearance . . . . . . 244
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 - Checking piston protrusion . . . . . . . . . . . . . . . 245
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . . 211 CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . 246
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . 218 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
OVERHAULING ENGINE F1C . . . . . . . . . . . . . . 221 - Disassembly the camshaft . . . . . . . . . . . . . . . . 246
DISASSEMBLING THE ENGINE AT THE BENCH 221 - Checking cylinder head seal . . . . . . . . . . . . . . . 247
- Checking cylinder head mating surface . . . . . . . 247
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 232
- Removing deposits, refacing and checking valves 247
- Checks and measurements . . . . . . . . . . . . . . . . 232
- Checking clearance between valve stem and valve
- Checking head mating surface on cylinder block 233 guide and centring valves . . . . . . . . . . . . . . . . . 248
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 233 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
- Replacing valve guide . . . . . . . . . . . . . . . . . . . . 248

Page Page
- Boring valve guides . . . . . . . . . . . . . . . . . . . . . . 248

- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 279
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
- Recutting and replacing valve seats . . . . . . . . . . 249
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . 280
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 250
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
ROCKER ARMS — TAPPETS . . . . . . . . . . . . . . . . 250
- Turbocharger type MITSUBISHI TD 4 HL-13T - 6 281
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
ASSEMBLING CYLINDER HEADS . . . . . . . . . . . 251
- Pressure relief valve . . . . . . . . . . . . . . . . . . . . . 282
- Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
- Pressure-relief valve check . . . . . . . . . . . . . . . . 282
- Overhead removal . . . . . . . . . . . . . . . . . . . . . . 252
- GARRET GT 2260 V variable
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 253 geometry turbosupercharger . . . . . . . . . . . . . . 283
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 - Operation at low engine rpm . . . . . . . . . . . . . . 283
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 - Operation at high engine rpm . . . . . . . . . . . . . 283
- Checking cam lift and pin alignment . . . . . . . . . 254 - Proportional solenoid valve controlling turbocharger
actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
- Assembling overhead . . . . . . . . . . . . . . . . . . . . 256
- Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
AUXILIARY ORGAN CONTROLS . . . . . . . . . . . 256
- Cynder head refitting . . . . . . . . . . . . . . . . . . . . 258 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
TIMING SYSTEM CONTROL . . . . . . . . . . . . . . . 259 - Checking and adjusting the actuator . . . . . . . . . 285
- Replacement of alternator free wheel . . . . . . . 264 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 286
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 271 - Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 - Main system components . . . . . . . . . . . . . . . . . 287
OIL PUMP/DEPRESSOR UNIT . . . . . . . . . . . . . . 273 - E.G.R. valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 - Modulator solenoid valve . . . . . . . . . . . . . . . . . 287
- Characteristic data . . . . . . . . . . . . . . . . . . . . . . 273 - Air flow rate meter (flow meter) . . . . . . . . . . . 287
- Vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . 274 - Throttle valve assembly . . . . . . . . . . . . . . . . . . 288
- Oil pressure adjusting valve . . . . . . . . . . . . . . . 274 - Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 288
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 EXHAUST SYSTEM REMOVAL-REFITTING . . . . 289
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
- Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 D.P.F. (DIESEL PARTICULATE FILTER) CATALYST 290
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 275 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 SYSTEM TO REDUCE POLLUTANTS AT EXHAUST 291
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
- Oil vapour recirculation (Blow-by) . . . . . . . . . . 277 - Forced regeneration . . . . . . . . . . . . . . . . . . . . . 292
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 - Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . 292
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM
(MS 6.3 - EDC 16) . . . . . . . . . . . . . . . . . . . . . 293
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
- Electromagnetic pulley . . . . . . . . . . . . . . . . . . . 279 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Page Page
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . 295

- Self-diagnosis — BLINK CODE . . . . . . . . . . . . . 295 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 298
- Immobilizer recognition . . . . . . . . . . . . . . . . . . 295 - Fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
- Checking fuel temperature . . . . . . . . . . . . . . . . 295 FEED SYSTEM AND FUEL RECIRCULATION . . 299
- Checking engine coolant temperature . . . . . . . 295 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 301
- Checking quantity of fuel injected . . . . . . . . . . . 295 - Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

- Checking idling adjustment . . . . . . . . . . . . . . . . 295 - ”Filtrauto” fuel filter . . . . . . . . . . . . . . . . . . . . . 302
- Fuel cut-off in release phase . . . . . . . . . . . . . . . 295 - ”UFIfilters” fuel filter . . . . . . . . . . . . . . . . . . . . . 303
- Checking cylinder balancing on idling . . . . . . . . 295 - CP3.2 high-pressure pump . . . . . . . . . . . . . . . . 304
- Checking regular engine rotation (anti-sawing) . 295 - Pressure regulator . . . . . . . . . . . . . . . . . . . . . . 305
- Checking smokiness at exhaust on acceleration 295 - Replacing pressure regulator . . . . . . . . . . . . . . . 305
- Checking exhaust gas recirculation (E.G.R.) . . . 295 - Hydraulic accumulator (rail) . . . . . . . . . . . . . . . 306
- Checking top speed limit . . . . . . . . . . . . . . . . . 295 ELECTRO-INJECTORS . . . . . . . . . . . . . . . . . . . . 307
- Checking regular rotation on acceleration . . . . 295 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
- Checking glow plug control unit . . . . . . . . . . . . 295 - Replacing an electrical injector . . . . . . . . . . . . . 307
- Checking activation of air-conditioning system . 295 ELECTRIC/ELECTRONIC COMPONENTS . . . . . 308
- Checking fuel pump . . . . . . . . . . . . . . . . . . . . . 295 - Electronic control unit EDC 16 . . . . . . . . . . . . 308
- Checking diesel warming . . . . . . . . . . . . . . . . . 296 - Glow plug electronic control unit . . . . . . . . . . . 309
- Checking cylinder position . . . . . . . . . . . . . . . . 296 - Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
- Checking pilot and main injection timing . . . . . 296 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
- Checking injection pressure closed cycle . . . . . 296 - Engine speed sensor . . . . . . . . . . . . . . . . . . . . . 309
- Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 - Camshaft timing sensor . . . . . . . . . . . . . . . . . . 309
- Correcting flow rate according to water temperature 296 - Air temperature and pressure sensor . . . . . . . . 310
- Correcting flow rate to avoid noise, smoke or - Fuel temperature sensor . . . . . . . . . . . . . . . . . 310
overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
- Fuel pressure sensor . . . . . . . . . . . . . . . . . . . . . 310
- De-rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
- Atmospheric pressure sensor . . . . . . . . . . . . . . 310
- Injection timing electronic test . . . . . . . . . . . . . 296
- Engine coolant temperature sensor . . . . . . . . . 310
- Speed governor . . . . . . . . . . . . . . . . . . . . . . . . 296
- Throttle pedal position sensor . . . . . . . . . . . . . 310
- Engine starting . . . . . . . . . . . . . . . . . . . . . . . . . 296
- Clutch pedal position sensor . . . . . . . . . . . . . . 310
- Cold starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
- Brake pedal position sensor . . . . . . . . . . . . . . . 310
- Warm starting . . . . . . . . . . . . . . . . . . . . . . . . . 297
- Vehicle speed sensor . . . . . . . . . . . . . . . . . . . . 310
- Run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
- Differential pressure sensor - delta p (Dp) . . . . 310
- After run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
- Exhaust gas temperature sensor . . . . . . . . . . . . 310
- Cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
- Cylinder balancing . . . . . . . . . . . . . . . . . . . . . . 297
- PWM (Pulse Width Modulation) controls . . . . 311
- Synchronization search . . . . . . . . . . . . . . . . . . . 297
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

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 diagnosis
equipment and print out the results.
- Replacement of the MS6.3 or EDC 16control unit must be authorized by the Help Desk. Replacing operation
requires 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 CP3 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 in
cardboard boxes. They must therefore be protected against moisture and unpacked just prior to assembly.
- The greatest care must be taken over the cleanliness of parts, making sure that when handling or assembling
(starting with straightforward filter and pre-filter replacement) no dirt of foreign bodies can get inside. For this
reason, 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 drain
manifold) must be fully inserted. To drive them out, press on the tabs at the base of the connectors.
Electro-injector
None of the couplings/unions/nuts on the injector body may be handled. It is neither necessary nor permitted to
dismantle the nozzle body or the electromagnet.
If working on the high-pressure pipe, the hexagon on the injector side must be kept stationary with a wrench.
Before working on pipes, make sure the injector is stationary in its seat on the cylinder head.
When assembling/disassembling the injector drain, the retaining spring must not be removed from its seat in the injector:
pushing the spring towards the engine and applying a vertical force on the connector frees the recirculation. When
assembling, rest the recirculation connector in its seat and apply a vertical force while keeping the retaining spring
pressed in the direction of the engine. Fitting in has to be easy.
Replacing one or more electrical injectors requires central unit programming as described in specific section.
CP3 High-pressure pump

If working on the high-pressure pipe, the hexagon on the pump side must be kept stationary with a wrench.
Before working on the high-pressure pipe, make sure the pump is secured in its seat.
High-pressure pipes
Each high-pressure pipe must be replaced after disassembly operations.
The couplings must be tightened or loosened with the injectors, hydraulic accumulator (rail) and high-pressure pump
well secured and taking care to keep the hexagon on the component side stationary, space permitting.
Hydraulic accumulator (rail) and accessories

The pressure sensor can be assembled five consecutive times; after that, it must be replaced. They must be lubricated
with a thin layer of oil before being mounted.. Replacing the sensor requires central unit programming as described in
specific section.

Service procedures to be performed after

replacing high-pressure feeding system and/or
exhaust gas post-treatment system
components
For engine correct operation, E.D.C. 16 central unit stores,
into memory non volatile area, information relating to engine
parameters originally set or acquired during operation.
Consequently, whenever a component of high pressure feed
system and/or of the post-treating system for below listed
exhaust gasses, the central unit has to be reprogrammed by
IVECO diagnosis tool: MODUS - E.A.SY. - IT 2000; then the
procedure to replace affected component has to be carried
out, following below indications provided by diagnosis tools:
- replace injector;
- replace all injectors;
- replace flow rate meter (flow meter);
- replace hydraulic accumulator (common rail);
- replace E.D.C. 16 central unit;
- refill engine oil;
- replace D.P.F. catalyst;
- replace filter differential pressure ( ∆p) sensor;
- replace components relevant to emissions;
- necessarily perform a forced regeneration;
- replace central unit.

540110 POWER UNIT REMOVAL/REFITTING

Figure 1
Removal
Place the vehicle on the pit or auto lift.

Lift the engine hood (26), undo the fastening screws (27) and
then remove the hood; remove supporting rod (28).
Disconnect negative cable (4) and positive cable (11) from
battery (10), then remove the latter from the engine
compartment.
Disconnect electric connections (5, 7, 8 and 9) and engine
cable (6) from the EDC control unit, then release the engine
cable from the straps securing the same to the cab.
Unhook cable (1) 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).
NOTE Do not change the assembly position of headlamp

insert (13) threaded bush (14, detail D).

crosspiece (33).
bumper (17).
Remove expansion tank (3) cap (2).
Act as follows, from under the vehicle (see figure 4):
- undo fastening screws (12 and 13), then remove lower
side guards (14);
- undo fastening screws (16), then remove lower central
guard (26).
Apply a tube (16) to radiator pipe union (detail C), then
unscrew cap (15) and drain the coolant into a suitable
container.
NOTE If the vehicle is equipped with a cab air-conditioning

unit, proceed as follows:
- fit the unit 99309146 pipes to connections (23),
then blow the gas off the air-conditioning unit as
described in the respective charter of the
”Bodywork and chassis” section;
- disconnect electric connection (29) from the
drying filter pressure switch;
- disconnect pipes (20) from air-conditioner
compressor (21);
- remove nuts (25), then disconnect pipes (22)
from expansion valve connection (24).
NOTE Seal the air-conditioning unit pipes and their

respective mounts, to prevent moisture and
impurities from penetrating into the system.
108628

Remove nuts (4), then place remote-control switch/fuse Figure 2

holder (3) aside.
turboblower.
throttle valve assembly.

turboblower and, therefore, damage to the latter.
Disconnect or remove the coolant pipes:

- (15), from the thermostat;
- (16), from the engine oil heat exchanger;
- (19), from pipe (18);
- (20), from radiator (17).
Remove screws (13) securing radiator (17) to the supports.

Disconnect electric connection (12).
Release remote-control switch supporting bracket (14) from
the left side.
Remove radiator/heat exchanger assembly (17) together with
the condenser-drying filter and pipes (if any).
Remove oil filling cap (1) and remove sound-proofing cover
(5).
Loosen the straps, then disconnect coolant vent pipes (2)
from expansion tank (8).
Disconnect tank (8) pressure sensor (7) electric connection.
Remove tank (8) fastening nuts (10), then remove the tank
from the wall.
Disconnect electric connection (9) of the level sensor placed
under tank (8).
Loosen the straps, then disconnect coolant pipe (6) located
below tank (8).
Disconnect electric connection (11) from the throttle valve
assembly actuator.
Disconnect expansion tank (8) pipe (28) and cab heater pipe
(29) from water pump pipe (25).
Loosen the straps, then disconnect coolant vent pipes (33)
from EGR valve (31) and (27) from the cylinder head.
Loosen the strap, then disconnect coolant pipe (32) and
vacuum pipe (30) from EGR valve (31).
Loosen the strap, then disconnect pipe (26) from air pipe (22).
Disconnect electric connection (24) from air flow meter (23).
Loosen the straps, then disconnect air pipe (22) complete
with air flow meter (23) from the turboblower and air filter
(21).

turboblower and, therefore, damage to the latter. 108629

Disconnect vacuum pipe (2) from variable geometry Figure 3

turboblower actuator (1) (if any).
Cut the straps securing the cables to the engine, then
disconnect the electric connections from the VGT solenoid
valve (13, if any), alternator (15), oil level sensor (16).
Remove the screw and take ground cable (9) off.
Remove the nuts, then take cables off starting motor (7).
Disconnect servo brake vacuum pipe (8) from pipe union
(12).
Disconnect delivery pipe (5) and return pipe (6) from the
low-pressure fuel pipes.
Place a container under the power steering pump to recover
the system oil, then detach oil return and delivery pipes (11
and 10).
Loosen the fastening strap, then remove power steering tank
(4) from the support.
Apply tool 99360543 (3) onto the engine brackets to take the
engine off its compartment and secure it to the hoist.
108630

Act from under the vehicle to disconnect jointed heads (17) Figure 4
from:
- lever shift control cables (16);
- selection cable (max. pull-out load: 250 N - max. pull-in load:
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 and
disconnect the speed indicator control cable.
Disconnect electric connection (4) or (28 - for vehicles
equipped with automatic transmission) from the reversing
light switch.
NOTE Vehicles equipped with automatic transmission:

disconnect gearbox-chassis cable connector (27)
from control unit.
Disconnect exhaust pipe (8) from the turboblower outlet

pipe.
Vehicles equipped with D.P.F. catalyst: remove the fastening
screws, then take exhaust pipe (8) supporting bracket (10) off
gearbox unit (9).
Disconnect vacuum pipe (25) from VGT actuator (24 - only
176 HP engines).
Put a supporting jack under the gearbox unit.
Remove the bracket supporting the gearbox to the rear
crosspiece by acting on the four screws (5).
Undo fastening screws (10), then remove gearbox unit
supporting crosspiece (11) complete with its
gearbox/supporting bracket.
Remove nuts (15) securing elastic supports (14) to the chassis.
Remove bolts (3) securing propeller shaft (2) to the gearbox
unit; if necessary, remove screws (6) securing elastic support
(7) to the chassis and properly secure propeller shaft to the
chassis.
Remove the jack from under the gearbox.
Lift the power unit and remove it from the engine
compartment.
NOTE The power unit shall be removed from the engine

compartment with the greatest care, so as not avoid
damaging the parts left on the vehicle, especially the
steering box oil pipes.
When removing the gearbox unit from the engine, remove

the fastening screws and detach the starting motor.
Remove the fastening screws and take the gearbox unit off the
engine.
NOTE As regards the vehicles equipped with automatic

transmission, carefully carry out the operations
described in the charter of the ”Gearbox unit” section. 108631

Refitting
NOTE When positioning the engine in the engine bay,
take special care not to damage the top pipe of the
To refit the engine assembly, carry out the operations power steering and the soundproof-heatproof
described for removal in reverse order, following these cladding of the engine bay.
instructions: Once positioned, meticulously check that the top
pipe of the power steering is sound.
- Before refitting the gearbox to the engine, it is necessary Before using it again, check that the power steering
to remove the pressure plate bearing from the oil and coolant contain no impurities. If they do,
diaphragm spring by opening out the retaining circlip. filter with suitable mesh filters. For any topping up,
Fit the pressure plate bearing on the sleeve of the drive refer to the REPLENISHING FLUIDS table in the
input shaft cover, connecting it to the clutch release “GENERAL” section.
lever. Spread the gearbox input shaft with Molikote
molybdenum disulphide grease.
As regards the 6 S 400 O.D. gearbox units, proceed as
follows.
Engage a gear to let the main shaft turn, rotating the
propeller shaft connecting flange. Push the gearbox fully
in so that the pressure plate bearing couples with the
diaphragm spring correctly.
As regards the 6 S 400 O.D. gearbox units, follow the Checks and tests
procedures described in the specific chapter.
- Pay special attention to the operations needed to install Start up the engine, leave it running just a little faster
the engine assembly in the engine bay. than idling speed and wait for the coolant
temperature to reach the value for opening the
- Check the conditions of the coolant pipes or sleeves and thermostat, then check that:
of the air ducts. Replace them if they show any sign of
deterioration.
- Check the flexible mountings of the assemblies: engine - No water leaks from the connecting sleeves of the
and gearbox. Replace them if they show any sign of engine cooling and cab heating circuit pipes; tighten the
deterioration. collars if necessary.
- Check that the exhaust pipe members have not - No oil leaks from between the cover and cylinder head,
deteriorated and are not about to deteriorate. If this is oil sump and crankcase, oil filter and its seat, heat
so, replace them along with the flexible parts for securing exchanger and crankcase or from between the various
them. pipes of the lubricating circuit.
- Tighten the screws or nuts to the required torque. - No fuel leaks from injection pump and injector lines.
Tighten fittings if necessary.
- Meticulously check the state of the vacuum pipe. It must - Check the indicator and warning lights on the instrument
show no sign of cracking, cutting, scoring or of being panel and the devices disconnected on removing the
crushed. Replace it if there is any doubt at all about its engine all work properly.
soundness. When mounting it, make sure the pipe does
not come into contact with sharp metal parts or corners
or with any particularly hot parts. In addition, after
assembly, the pipe must have no bends or constrictions,
its radius of curvature should be broad and it must be
secured to the vacuum pump fitting with a suitable
clamp.
- Make sure that fuel pipes rapid engagement fittings are
accurately clean, and result to have been fully inserted 501430 Power steering system air
and not going to be disconnected after their being bleed
connected to relating engagement unions.
- Fill the cooling system with coolant. Check the level of oil in the tank and top it up if necessary.
Lift the vehicle at the front, start up the engine and let it idle
- Fill the hydraulic power steering circuit and bleed the air for some time.
as described under the relevant heading. Check there is no oil leakage from the hydraulic circuit and
- Check the level of oil in the engine and gearbox. check the level in the tank.
Slowly turn the steering wheel in both directions of steering
- Recharge the air-conditioning system (if any), as so that the air in the hydraulic system comes out.
described in the relevant chapter in the “Bodywork and Check the level of oil in the tank again and top up if necessary.
chassis” section.
- Check, if necessary, the headlamp orientation.

543910 REPLACING AIR-CONDITIONING 543210 REPLACING THE WATER PUMP

COMPRESSOR DRIVE BELT
Removal
Disassembly
Figure 5 Figure 7
102201 102202
Place the vehicle in a pit or on an auto lift.
Remove, from under the vehicle, the central sound-proofing
guard. Remove elastic belt (4) from pulleys (1 and 5).
Drain the cooling fluid, and then remove both the front
cross-member and the radiator, as described in the “Power
unit detachment/re-attachment” chapter.
Assembly Take the fan off the electro-magnetic joint.
Apply wedge 99360161 (2) with elastic belt (4) to Remove electric connection (3) from the engine cable.
pulley (1), then place the elastic belt onto roller (3) Stop rotation of electro-magnetic joint (6), then remove nut
and pulley (5), taking care to place the pulley ribs in (8).
the corresponding races of pulleys (1 and 5).
Rotate the drive shaft counterclockwise (→) until belt (4) is NOTE Unscrew nut (8) in a clockwise direction, since the
correctly coupled with pulley (1). nut thread goes leftwards.
Take off hub (6) and pulley (5).

543910 POWER STEERING PUMP-ALTER- Cut the strap (→), remove electric cable (3) retaining strap
NATOR BELT REPLACEMENT fastening screw (1), remove nuts (2), then take
Disassembly electro-magnet (4) off water pump (7).
Remove the fastening screws, and then take off water pump
Figure 6 (7).
Refitting
of detachment operations. In particular, tighten the
screws and nuts to the specified torque values.
88330 After re-attachment has been completed, fill the
Disassemble the compressor drive belt, if there is one, as engine cooling system, start the engine and check for
described under the relevant heading. cooling fluid leaks.
Slacken off the tension of the belt (1) using a specific wrench
on the automatic tightener (2) and remove the belt.
Assembly
Mount the drive belt (1) taking care to position its
ribs correctly in the respective races of the pulleys.
Release the automatic tightener (2). Turn the
crankshaft by one turn to settle the belt.
Mount the compressor drive belt, if there is one, and adjust
the tension as described under the relevant heading.
Fit the middle soundproofing guard back on.

771010 REPLACING THE HIGH-PRESSURE PUMP

Removal
Figure 8
108635
Remove cap (2), then take cover (1) off the cylinder head. Refitting
Loosen the straps, then disconnect air pipe (3) from the inlet
manifold and the heat exchanger.
Use tool 99360076 to take oil filter (4) off the heat Re-attachment is carried out by reversing the order
exchanger. of detachment operations. In particular, comply with
Remove the electric connection from pressure regulator the following instructions:
(13). - replace the seal rings, gaskets, high-pressure pipe
Remove connections (8 and 10), then disconnect and oil filter with new parts;
low-pressure pipes (11) from high-pressure pump (9).
Remove pipe (5) retaining bracket (7) fastening screw (6), - lubricate, prior to assembling, seal ring (17) with
then disconnect the retaining bracket from hydraulic engine oil;
accumulator (14) and high-pressure pump (9). - tighten the screws, nuts, fittings and oil filter to
Remove screws (18) and spacers (19), then remove the specified torque value;
high-pressure pump (9) from support (15). Remove joint
(16). - check the engine oil level; top up, if necessary.

501450 REPLACING THE POWER STEE- 540440 REPLACING THE DRIVE SHAFT
RING PUMP SEAL RING AND THE FRONT
COVER GASKET
Removal
Removal
Figure 9
Figure 11
102204
102206
Remove oil filling plug (1) from oil tank (2).
Remove, from under the engine compartment, the central Proceed as follows, by operating as described in the “Power
sound-proofing guard. unit detachment/re-attachment” chapter:
Place a container under power steering pump (6) to recover
the oil from the system, and then remove fittings (3 and 8) - drain the engine cooling fluid;
and disconnect oil pipes (4 and 7) from power steering pump - remove the front cross-member;
(6). - remove the radiator.
Remove fan (1) from the electro-magnetic joint.
Figure 10 Take off the air-conditioning compressor drive belt (if any)
as well as the water pump-alternator drive belt, as described
in the relevant chapters.
Figure 12
102205
Remove screws (6) and take power steering pump (5) off
support (4). Remove joint (2) from drive arbor (3).
Refitting
102207
of detachment operations. In particular, take care of
the following: Use tool 99360190 (3) to stop drive shaft rotation, then
- replace seal ring (1) with a new part, and remove screw (2) and take off damper pulley (1).
lubricate the same with engine oil prior to
assembling; Apply tool 99340059 (6) as shown in the figure to remove
- replace the oil pipe gaskets (as above); seal ring (5) from cover (4).
- tighten the nuts, screws and fittings to the
specified torque values.
After re-attachment has been completed, fill the
hydraulic power steering circuit and bleed the air as
described under the relevant heading.

Figure 13 Figure 15
102209
Remove screw (11), and then take off dipstick pipe (4). 102215
Loosen strap (3), remove screw (2), then take pipe (1) off Thoroughly clean cover (1) seal ring seat.
cover (5). Screw down part (2) of tool 99346258 into the drive shaft
Remove screws (6), and then take off cover (5). Remove shank.
snap ring (8). Take out centrifugal filter (7). Lubricate the drive shaft shank and the outside of part (2),
then couple the new seal ring (3) with part (2).
Place part (4) onto part (2), screw down nut (5) until seal ring
NOTE Both centrifugal filter (7) and cover seal ring (5) (3) is fully assembled to cover (1).
must be replaced every time they are dismounted.
Remove screws (9), and then take off front cover (10).
Refitting
Figure 14 Figure 16
102216
102214
Mount cover (1) with a new gasket. Screw down screws (2) Fit cover (1) centring tool 99396030 (3) into the centrifugal
without tightening them up. filter seat, then tighten screws (2) to the specified torque.
Remove tools 99346258 (4) and 99396039 (3).

Figure 17 503010 REPLACING THE VACUUM PUMP

OIL PUMP ASSEMBLY (GPOD)
Removal
Remove the front cover, as described in the “Replacing the

drive shaft seal ring and the front cover gasket” chapter.
Figure 18
1
102217
Fit a new centrifugal filter (1).

Fit a new snap ring (2).
Fit cover (3), and then tighten screws (4) to the specified
torque.
3 4
NOTE Both centrifugal filter (1) and cover (3) seal ring
must be replaced every time they are dismounted. 102218
Remove screws (3), and then take off vacuum pump oil pump
Re-attachment is carried out by reversing the order of assembly (2).
detachment operations. In particular, tighten the screws and Remove connecting joint (1) from gear (4).
nuts to the specified torque values.
After re-attachment has been completed, fill the engine
cooling system, check the engine oil level (top up, if
necessary), start the engine and check for cooling fluid leaks.
Refitting
Position connecting joint (1) into gear (4).
Fit vacuum pump oil pump assembly (2) by placing
a new gasket in between.
Tighten screws (3) to the specified torque.
of detachment operations. In particular, tighten the
screws and nuts to the specified torque values.
After re-attachment has been completed, fill the
engine cooling system, start the engine and check for
cooling fluid leaks.

540640 REPLACING THE DRIVE SHAFT Refitting

REAR SEAL RING
Removal Figure 21
This operation involves:

- detaching/re-attaching the drive shafts (see
relevant section 505620);
- detaching/re-attaching the gear shift (see
relevant section 530210;
- detaching/re-attaching the clutch (see relevant
section 505210).
Figure 19
102221
Thoroughly clean the seal ring seat.

Lubricate the drive shaft rear shank with engine oil.
Apply part (2) of tool 99346259 to the drive shaft rear shank,
then secure it with screws (5) and couple the new seal ring
(3) with the same.
Place part (1) onto part (2), screw down nut (4) until seal ring
(3) is fully assembled to the base.
102219
Stop flywheel (1) rotation by means of tool 99360306 (4). Figure 22

Remove screws (2), and then take off engine flywheel (1).
Figure 20
102222
Fit engine flywheel (1), then tighten screws (4).

Apply tool 99360351 (3) to the base in order to stop engine
flywheel (1) rotation.
Tighten engine flywheel (1) fastening screws (4) in two
separate steps:
- step 1: tighten to 30 Nm by means of a torque wrench;
- step 2: tighten to 90° angle lock.
NOTE Angle lock is performed by means of tool

99395216 (2).
102220
Apply tool 99340060 (2) to rear seal ring (1), then take the Disassemble tool 99360351 (3).Then fit the clutch, gear shift
latter out of the engine base. and drive shaft back into position, as described in the relevant
sections.

775010 REPLACING ELECTRO-INJECTORS

Figure 23
102223
Removal Refitting
Disconnect the following electric connections: (4), from the Thoroughly clean the electric injector seat, taking care not to
pressure sensor, and (2), from the level sensors, both of them introduce foreign bodies into the cylinder liners.
located on expansion tank (1). Fit a new gasket (18) onto electric injector (16), and then fit
Remove nuts (3) securing expansion tank (1) to the wall, the latter into the overhead.
then put the expansion tank aside.
Re-attachment is carried out by reversing the order of
Remove plug (6), and then take off sound-proofing cover (5).
detachment operations. In particular, comply with the
Disconnect electric connections (7) from electric injectors
following instructions:
(16) and (9) from fuel pressure sensor (8).
Press clips (15) in the direction shown by the arrow, then - fuel pipes must be replaced with new parts every time they
disconnect fuel recovery pipe (14) fittings from electric are disassembled;
injectors (16).
Disconnect fuel pipes (11) from electric injectors (16) and - tighten the nuts, screws and fittings to the specified torque
values;
hydraulic accumulator (10).
Remove screws (12) and brackets (13) securing electric - to tighten the fuel pipe fittings, use a wrench of the
injectors (16) to the cylinder head. 99317915 series as well as torque wrench 99389829.
Use tool 99342153 (17) to take electric injectors (16) off the
overhead.

540610 REMOVAL/REFITTING THE CYLINDER HEAD

Figure 24
108636
Remove bracket (11) securing the low-pressure pipe

Removal assembly to the inlet manifold.
Remove screw (6), then take coolant pipe (8) fastening strap
(5) off the cylinder head.
Proceed as follows, by operating as described in the “Power Remove air conveyor (3) from the overhead, from
unit detachment/re-attachment” chapter: turboblower (4).
- drain the cooling fluid;
- remove the front cross-member; Disconnect oil pipe (7) from the connection on the cylinder
- remove the expansion tank. head.
Cut the straps securing the cables to the engine, then Remove nuts (2), then remove turboblower (4) from
disconnect the electric connections below: exhaust manifold.
- (12) thermostat;
- (17) preheating plugs;
- (20) pressure sensor;
- (21) electric injectors; NOTE Properly plug the turbocharger air outlet/inlet, to
- (1) electromagnetic joint; prevent foreign bodies from penetrating
- (22) phase sensor; accidentally into the turbocharger (and, therefore,
- (9) pressure regulator; damaging the same).
- (15) air temperature sensor;
- (23) throttle valve assembly actuator.
Remove the electric injectors as described in the respective Remove the fan from the electro-magnetic joint.
charter. Remove screw (14), then take fuel pipe (16) off
high-pressure pump (10) and hydraulic accumulator (18). Take off the air-conditioning compressor drive belt (if any)
Remove the fastening screws, then take off hydraulic as well as the water pump-alternator drive belt, as described
accumulator (18). in the relevant chapters.
Use tool 99360076 to remove oil filter (3) from the heat
exchanger. Remove the front cover, as described in the “Replacing the
seal ring and the front cover gasket” chapter”.

Figure 25
102225
Remove the screws, and then take upper cover (2) off Remove screws (18), then take off overhead (19) complete
overhead (19). with pins 99360614 (13).
Remove plugs (20) from overhead (19).
Rotate the drive shaft clockwise, so that pins 99360614 (13) NOTE Pins 99360614, applied in order to avoid modifying
can be inserted, through the holes of plugs (20), into the timing after the toothed chain has been
corresponding holes of the drive shafts, and pin 99360615 (5) disassembled, must be removed from the overhead
can be inserted into the drive shaft through the base unit only when the latter has been disassembled.
hole.
Remove the overhead gasket.
Remove upper chain stretcher (1). Remove the tappets and put them apart carefully.
Remove pin (4), then take off upper shoe (3). Remove the pre-heating spark plugs by means of tool
Remove both screw (17) and washer (16), and then 99355041.
disassemble gear (15). Remove the cylinder head fastening screws, and then take
Remove both screw (10) and washer (11), then disassemble the head off the base unit.
gear (12) and chain (14). Remove the cylinder head gasket.
Remove both plug (6) and screws (7 and 8), then disassemble
fixed upper shoe (9).

Refitting Figure 27
Unless otherwise specified, re-attachment is carried out by

reversing the order of detachment operations. In particular,
comply with the following instructions:
Verify the conditions listed below, which refer to the tools
used for valve timing:
- tool 99360614 (6, SENZA CODICE) must be inserted
into the overhead;
- tool 99360615 (11, SENZA CODICE) must be inserted
into the base unit.
Verify that the junction planes of the cylinder head and the
base unit are clean.
Do not soil the cylinder head gasket.
Place the cylinder head gasket with the “TOP” writing facing 102226
the head itself. Thoroughly clean hydraulic tappets (2), then lubricate and fit
them to cylinder head (3), by correctly positioning rocker
NOTE The gasket must strictly be kept sealed in its own arms (1) on the valves.
package and be unwrapped soon before being
Fit gasket (5).
fitted. Insert the two tools Sp. 2264 (4) into the electric injector
Fit the cylinder head, insert the screws and tighten up in three seats for subsequent overhead centring on the cylinder head.
subsequent steps, by following the sequence and indications Figure 28
shown in the next figure.
NOTE Angle lock is carried out by means of tool

99395216.
Figure 26
102273
Fit overhead (1) complete with tools 99360614 (3) for valve
timing, then tighten fastening screws (2) to the specified
torque.
Remove tools Sp. 2264 (4).
Figure 29
88355
Cylinder head fastening screw tightening sequence:

- step 1: preliminary tightening by means of a torque
wrench:
• tighten screws 1-2-3-4-5-6 to 130 Nm;
• tighten screws 7-8-9-10 to 65 Nm.
- step 2: angle locking:
• tighten screws 1-2-3-4-5-6 to 90º;
• tighten screws 7-8-9-10 to 90º.
- step 3: angle locking: 88270
• tighten screws 1-2-3-4-5-6 to 90º; Fit fixed upper shoe (1). Tighten screws (2 and 3) to the
• tighten screws 7-8-9-10 to 60º. specified torque.
- Tighten screws A to 25 Nm. Fit plug (4) together with a new basket, then tighten it to the
specified torque.

Figure 32
NOTE All the camshaft drive components (fixed and
moving pads, timing gears, chain nuts and timing 1
control chains) shall be replaced even though the
anomaly affects only one of the above-mentioned
items. 2
Figure 30
3
102231
Check the conditions of moving pads (1 and 3): if they are

worn, they shall be replaced together with the other
camshaft drive components.
Position moving shoes (1 and 3), then secure them to the
base unit with pin (2) by tightening the latter to the specified
torque
102229
Place chain (1) on gear (5) and on gear (2).

Fit the gear in such a way that when it is inserted onto the
dowel bolt of the intake valve distributing shaft, slots A will
be positioned as shown in the figure.
Figure 33
NOTE The chain (1) branch included between the two

gears must be subjected to tension.
Screw down fastening screw (4) with washer (3) without

tightening up.
Figure 31
102127
NOTE Chain stretcher (1) cannot be re-used for any

reason after it has been disassembled. Moreover, in
the event that piston (1) has been unintentionally
made to escape from chain stretcher (2), the latter
must be replaced.
Chain stretcher reconditioning is not permitted.
Screw down hydraulic chain stretcher (2), then tighten it to

the specified torque.
88359 Insert, through the opening on the overhead, a suitable
screwdriver, then press on moving shoe (4) fin (3) until chain
Place chain (1) on gear (2), then fit the latter onto the exhaust stretcher (2) piston (1) is pushed to its end of stroke.
valve distributing shaft. Release moving shoe (4), and make sure that piston (1)
Screw down fastening screw (4) with washer (3) without causes, by escaping from its seat, chain (5) to be subjected
tightening up. to tension.

Figure 34 Re-attachment is carried out by reversing the order of

detachment operations. In particular, comply with the
following instructions:
- replace the seal rings, gaskets, safety snap rings and
high-pressure pipes with new parts;
- lubricate the seal rings with engine oil prior to assembling;
- tighten the screws, nuts and pipe fittings to the specified
torque values;
- check the engine oil level; top up, if necessary;
- fill the engine cooling system, start the engine, and check
for cooling fluid leaks.
88372
Tighten the screw securing gear (1) to the intake valve

distributing shaft to the specified torque.
540730 EGR HEAT EXCHANGER RE-
MOVAL - REFITTING
Removal
Figure 35
Figure 36
88373
Make sure that chain (3) is subjected to tension in the length

included between gear (2) and gear (4).
Tighten the screw securing gear (2) to the exhaust valve
distributing shaft to the specified torque. 105027
Remove tools 99360614 (1) and 99360615 (5, Figure 25).
Remove plug (4) from expansion tank (3).
Arrange special container under the radiator, remove plug
located on radiator right side and drain engine coolant.
Remove oil filling plug (1) and take off sound deadening cover
(2).
Disconnect electrical connection (6) from pressure switch.
Loosen clamps and disconnect coolant vent tube (5).
Remove securing screws and disconnect tank (3) from wall.
Disconnect electrical connection (7) from the level sensor
placed under tank (3).
Loosen clamps and disconnect coolant tube (8) placed under
tank (3).

Figure 37 Refitting
removal observing following warnings:
- replace gaskets (2 and 3) and the straps with
new parts.
- tighten the screws to the specified torque
value.
Checks and tests

Start up the engine, let it run at rpm’s just a little
over idling and wait for coolant temperature to
reach the value for opening the temperature
switch, then check for no water leaks existing from
cooling circuits tubes.
112331
Loosen the straps, then disconnect coolant pipes (1 and 2)

and vacuum pipe (4) from EGR valve (3).
540730 EGR HEAT EXCHANGER RE-
Figure 38 MOVAL - REFITTING
Removal
Figure 40
108632

from EGR valve (6). Loosen screw (7) of strap (8) joining EGR
valve (6) to pipe (9). Remove screws (4), then take heat
exchanger (1), complete with EGR valve (6), off the
overhead.
Figure 39
105027
Remove plug (4) from expansion tank (3).

Arrange special container under the radiator, remove plug
located on radiator right side and drain engine coolant.
Remove oil filling plug (1) and take off sound deadening cover
(2).
Disconnect electrical connection (6) from pressure switch.
Loosen clamps and disconnect coolant vent tube (5).
Remove securing screws and disconnect tank (3) from wall.
Disconnect electrical connection (7) from the level sensor
placed under tank (3).
Loosen clamps and disconnect coolant tube (8) placed under
108633 tank (3).
Place the heat exchanger/valve assembly onto a work bench,
then remove EGR valve (4) fastening screws and take EGR
valve (4) off heat exchanger (1).

Figure 41 Refitting
removal observing following warnings:
- replace gaskets (2 and 3) and the straps with
new parts.
- tighten the screws to the specified torque
value.
Checks and tests

Start up the engine, let it run at rpm’s just a little
over idling and wait for coolant temperature to
reach the value for opening the temperature
switch, then check for no water leaks existing from
cooling circuits tubes.
112331

and vacuum pipe (4) from EGR valve (3).
Figure 42
108634
Loosen screw (5) of strap (6) joining EGR valve (4) to pipe
(7).
Remove screws (1), then take EGR valve (4) off the heat
exchanger.

BURNT GAS EXHAUST SYSTEM

The exhaust system is made up of three components:
A. system length with hose;

B. catalyst with particulate filter (DPF);
C. silencer.
The exhaust system is manufactured by Arvin Meritor (ArM).
Figure 43
108626

REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY COMPONENTS (SYSTEMS EQUIPPED

WITH D.P.F. CATALYST)
Figure 44
105073
Exhaust silencer removal Refitting

Refitting is carried out by reversing the order of the
detachment operations. Moreover, the following
Place the vehicle on a pit or auto lift. instructions shall be observed:
Carry out the following operations by acting from under the
- check the conditions of the elastic dowels,
vehicle: taking care to replace the defective ones (if any);
- unscrew nuts (2) securing silencer (3) supporting - replace the gaskets with new parts;
bracket (1) to the vehicle chassis; - tighten the nuts and screws to the specified
torque.
- unscrew and remove fastening screws (4) of flanges (5)
connecting exhaust silencer (3) and D.P.F. particulate After the operation has been completed, and in the event
filter (8); that either the D.P.F. catalyst or the differential sensor
- remove exhaust silencer (3). (delta-p) needs replacing, follow the instructions given in the
respective chapters.
D.P.F. catalyst removal
- unscrew and remove the exhaust gas temperature
sensors at the catalyst inlet 16) and outlet (17);
- unscrew to disconnect couplings (6 and 12) securing
rigid pipes (7 and 11) running to the pressure sensor to
D.P.F. catalyst (8);
- properly secure D.P.F. catalyst (8) to the vehicle chassis;
- unscrew nuts (9) securing D.P.F. catalyst (8) filter
supporting bracket (10) to the vehicle chassis;
- unscrew and remove fastening screws (13) of flanges
(15) connecting D.P.F. catalyst (8) filter to the exhaust
gas outlet pipe from turbine (14);
- remove D.P.F. catalyst (8) filter.

507130 Replacing D.P.F. catalyst 540743 Replacing differential sensor

Replacing D.P.F. catalyst needs that all the counters of below (delta-p)
indicated parameters are reset in the central unit, as: Pressure difference between gas pressure at catalyst module
- particulate quantity in new filter is zero, so, if particulate inlet and gas pressure at ceramic walls filter outlet is
quantity is not reset, filter regeneration will start even if it converted into a voltage signal (Vout) by pressure sensor.
is not necessary; During engine running, E.D.C. 16 central unit performs
- quantity of accumulated ashes is zero, so, if ashes counter checks on differential pressure sensor drift and calculates
is not reset, regeneration frequency will be greater than engine compensation and running values, and corrects them.
needed, consequently increasing fuel consumption, and Consequently, after replacing the sensor, it is necessary to
particulate filter thermal fatigue; and, in extreme cases, reset rectification coefficients.
there will be an unnecessary request to refill engine oil; The meters used to evaluate the above-mentioned
- post-injected fuel quantity is zero, so, if post-injected fuel parameters can be reset by means of the IVECO MODUS
counter is not reset, there may be an early request to refill - E.A.SY. - IT 2000 diagnosis instruments, by programming the
engine oil. control unit again and performing the differential sensor
NOTE Where both DPF catalyst is replaced and engine oil

is refilled, resetting post-injected fuel counter is not
necessary.
- regeneration status: regeneration unnecessary, in progress,

interrupted, resumed;
- miles covered and times from last complete regeneration;
- differential pressure (delta-p) sensor drift self-rectification;
- oxidiser catalyst drift; consequently, if catalyst ageing
function is not reset, quantities of unnecessary
post-injections might be present.
The meters used to evaluate the above-mentioned

parameters can be reset by means of the IVECO MODUS
- E.A.SY. - IT 2000 diagnosis instruments, by programming the
control unit again and performing the differential sensor

ENGINE VIEWS
Figure 45
107864

Figure 46 Figure 48
107865
LEFT-HAND SIDE VIEW 107867
FRONT VIEW
Figure 47
107866
REAR VIEW

Figure 49
107868
RIGHT-HAND SIDE VIEW
A. Turbocharger with pressure relief valve (Waste-Gate, ENGINE 136 HP)
Figure 50
107869
TOP VIEW

Print 603.43.671
EMISSIONS
Engines for LD (Light Duty) vehicles
Gas emissions Grade of smoke

Engines comply with Euro4 Gas Emission Regulation Engines comply with grade of smoke limits requested by
(measurement at engine bench according to cycle regulations to have following grade of smoke values at outlet:
ECE15+EUDC), with following limits set by Regulation 98/69
- maximum power (Bosch BSU opacimeter grades) 1.5
- 1999/102/CEI - level B:
- maximum torque (Bosch BSU opacimeter grades) 1.5
- CO (carbon oxide) 0.74 g/kWh
- NOx (nitrogen oxide) 0.39 g/kWh
Sound emissions
- HC (unburnt hydrocarbons) + Maximum average acoustic level, Lpa, of standard
NOx (nitrogen oxide) 0.46 g/kWh configuration engines measured according to ISO Std 3745
- Particulate 0.06 g/kWh (microphones at one metre distance from engine surfaces):
Test fuel: CEC RTF 73 - T90 S = 0.05 %. - at idling . . . . . . . . . (800 rpm) . . . . . . . . . . . . 72 dB A
- at maximum torque . . . . . . . . . . . . . . . . . . . . 84 dB A
- at maximum power (3800 rpm) . . . . . . . . . . 93 dB A.
Engines for HD (Heavy Duty) vehicles
Gas emissions
Grade of smoke
Engines comply with Euro4 Gas Emission Regulation
Engines comply with grade of smoke limits requested by
(measurement at engine bench according to cycles ETC and
ESC/ELR, with following limits set by Regulation 98/69 - regulations to have following grade of smoke values at outlet:
1999/102/CEI - level B: - maximum power (Bosch BSU opacimeter grades) 1.5
- maximum torque (Bosch BSU opacimeter grades) 1.5
Cycle ESC + ELR:
- CO (carbon oxide) . . . . . . . ... . . . . . . . . . . 1.5 g/kWh
- NOx (nitrogen oxide) . . . . . ... . . . . . . . . . . 3.5 g/kWh Sound emissions
- HC (unburnt hydrocarbons) .. . . . . . . . . . 0.46 g/kWh
- Particulate . . . . . . . . . . . . . . ... . . . . . . . . . 0.02 g/kWh Maximum average acoustic level, Lpa, of standard
configuration engines measured according to ISO Std 3745
Cycle ETC: (microphones at one metre distance from engine surfaces):
- CO (carbon oxide) . . . . . . . ... . . . . . . . . . . 1.5 g/kWh - at idling . . . . . . . . . . (800 rpm) . . . . . . . . . . . . 72 dB A
- NOx (nitrogen oxide) . . . . . ... . . . . . . . . . . 3.5 g/kWh - at maximum torque . . . . . . . . . . . . . . . . . . . . . . 84 dB A
- HC (unburnt hydrocarbons) .. . . . . . . . . . . . -- g/kWh - at maximum power . (3800 rpm) . . . . . . . . . . 93 dB A.
- Particulate . . . . . . . . . . . . . . ... . . . . . . . . . 0.03 g/kWh
Test fuel: CEC RTF 73 - T90 S = 0.05 %.

ENGINE IDENTIFICATION CODE
F 1 C E 4 4 8 1 F * C +
Exhaust emiss. level
Homologation power
Duty No.
Supply / injection
Cylinder No.
Engine cycle — cylinder position
Engine
Engine series evolution 0= 4-stroke,

vertical
Engine series
4 = 4 cylind.
6 = 6 cylind.
8 = DI. TCA
1 = Truck
2 = Bus
4 = M.T. vehicles and tractors
6 = Marine
9 = Army
0481 F = 107 kW - (146 CV) 3500 rpm - 350 Nm -(35,6 kgm) 1500÷2800 rpm
0481 H = 129 kW - (176 CV) 3500 rpm - 400 Nm -(40,7 kgm) 1500÷2800 rpm

Figure 51
SELF-ADHESIVE LABEL
Engine variant
Iveco drawing number
— 9 digits
Engine serial number

— 7 digits
GAN — 9 characters
Electro-injector class
107870
Figure 52 CRANKCASE MARKING
107871
EXAMPLE
A = IVECO trademark IVECO
B = IVECO name of engine variant ** F1CE0481F/H * A001
C = Engine serial number 1359862
st
D = 1 digit, main journal no. 1 (engine front)
E = Main bearing selection diameters 12345
F = Barrel selection diameters 1234
st
G = 1 digit, cylinder no. 1 (engine front)
(**) Data obtainable from “XZ” engine ordering number information

Figure 53
108444
LONGITUDINAL SECTION

Figure 54
108445
F1C ENGINE CYLINDER AXIS CROSS SECTION (146 HP)

Figure 55
108446
F1C ENGINE SUPPORT AXIS CROSS SECTION (146 HP)

Figure 56
108447
F1C ENGINE CROSS SECTION (176 HP)

Figure 57
107872
CHARACTERISTIC CURVES OF ENGINE F1C (146 HP)
Max OUTPUT 107 kW 146 HP at 3500 rpm
Max TORQUE 350 Nm 35,6 kgm at 1500 ÷ 2800 rpm

Figure 58
107873
CHARACTERISTIC CURVES OF ENGINE F1C (176 HP)
Max OUTPUT 122 kW 176 HP at 3500 rpm
Max TORQUE 400 Nm 40,7 kgm at 1250 ÷ 3000 rpm

GENERAL SPECIFICATIONS
Type F1CE0481 F F1CE0481 H
Cycle Diesel 4 strokes

Feeding Turbocharged with intercooler
Injection Direct
N. of cylinders 4 on-line
∅
Diameter mm 95,8
Stroke mm 104
+ + +.. = Total displacement cm3 2998
Max. power KW 107 122

(HP) (146) (176)
rpm 3500 3500
Max. power KW
350 250
(HP)
Max. power KW 350 400
(HP) (35,6) (40,7)
rpm 1500 ÷ 2800 1500 ÷ 2800
Engine idling speed,
no load rpm 800 ± 25
Maximum engine
speed, no load rpm 4200 ± 50
Pressure at T.D.C.
*bar 20 ÷ 26
bar Minimum permissible
pressure at T.D.C.
*bar 16
(*) The pressure value is recorded by turning the engine over with the electric starter motor, with oil temperature at 40°- 50°C
and the injection pump in the stop condition.

A
VALVE TIMING
opens before T.D.C. A 24°
closes after B.D.C. B 26°

B
opens before B.D.C. D 70°
closes after T.D.C. C 24°

D
For timing check
-
mm
-
X X
mm
-
Running
-
mm
mm
High pressure electronic fuel feed system BOSCH EDC16

Composed of CP3.2 high-pressure pump, electro-injectors,
FEED
hydraulic accumulator (rail), EDC control unit, pressure and
temperature sensors
Pump arrangement -
With piston n. l at T.D.C.
X
Start of delivery mm -
Injector nozzle type BOSCH CR1 2-2

22
Injection order 1- 3 - 4 - 2
ba
r Release pressure bar 1600

SUPERCHARGING With intercooler

MITSUBISHI
TD 04 - HL - 13T-6 GARRETT GT 2260 V
Turbocharger type variable geometry
with Waste-Gate
Turbocharger shaft radial clearance 0,396 ÷ 0,602 0,086 ÷ 0,117

Turbocharger shaft axial clearance 0,034 ÷ 0,106 0,030 ÷ 0,083
Minimum opening stroke of pressure relief valve mm 1 -
Maximum opening stroke of pressure relief valve mm
5 -
Pressure corresponding to the minimum stroke bar 1,22 ± 0,027 -
Pressure corresponding to the maximum stroke bar 1,38 ± 0,047 -
Actuator setting:
- low pressure 0 . mmHg valve fully open
- low pressure 0,2 bar valve stroke mm - 0,5 ÷ 2,5
- low pressure 0,64 bar valve stroke mm - 9,5 ÷ 11,5
Forced lubrication by means of gear pump, pressure-relief
LUBRICATION
valve and simple-filtering oil filter.
Oil pressure with engine hot
bar (100 ± 5 °C):
at idling speed bar 1,0
at maximum speed bar 5,0
by centrifugal pump, thermostat for adjustment, coolant
COOLING temperature, fan with electromagnetic coupling, radiator,
heat exchanger
Water pump control: by belt
Thermostat: N. I.
starts to open: 79 ºC ± 2 ºC
fully open: 94º C ± 2 ºC
Urania Daily OIL REPLENISHMENT
Urania Turbo LD 5
Total capacity at 1st filling
liters 7,6
kg 6,79
Quantity at periodical
replacements:
- engine sump
liters 6,6
kg 5,81

ASSEMBLY DATA — CLEARANCES
CYLINDER BLOCK AND CRANK MECHANISM COMPONENTS

∅1 Bores for cylinder liners ∅ 1
95,802 ÷ 95,822
Cylinder liners: -
L outside diameter ∅ -
∅2 length L -
Cylinder liners -
crankcase bores -
(negative allowance)
Outside diameter ∅2 -
∅3
Cylinder sleeve -
X
inside diameter ∅3 -
Pistons: supplied as spare parts

∅1 MAHLE
type:
X measuring dimension X 10
outside diameter ∅1 95,705 ÷ 95,715
∅2 pin bore ∅2 36,003 ÷ 36,009
Piston - cylinder sleeve 0,087 ÷ 0,117
Piston diameter ∅1 0,4
X
Pistons protrusion
X 0,3 ÷ 0,6
∅3 Gudgeon pin ∅3 35,990 ÷ 35,996
Gudgeon pin - pin housing 0,07 ÷ 0,019

CYLINDER BLOCK AND CRANK MECHANISM COMPONENTS

Piston type -
X1* 2,200 ÷ 2,230
X1
Piston ring grooves X2 2,050 ÷ 2,070
X2
X3 X3 2,540 ÷ 2,560
* measured on ø of 92.8 mm
S1 2,068 ÷ 2,097
S2 Piston rings S2 1,970 ÷ 1,990
S3 S3 2,470 ÷ 2,490
* measured on ø of mm
0,103 ÷ 0,162
Piston rings - grooves 2 0,060 ÷ 0,100
3 0,050 ÷ 0,090
Piston rings 0,4
X1 Piston ring end gap in cylinder

liners
X2
X1 0,20 ÷ 0,35
X3
X2 0,60 ÷ 0,80
X3 0,30 ÷ 0,60
∅1 Small end bush housing
Ø1 39,460 ÷ 39,490
Big end bearing housing

∅2
Ø2 67,833 ÷ 67,848
Small end bush diameter

∅4 outside ∅4 39,570 ÷ 39,595
∅3 inside ∅3 36,010 ÷ 36,020
Big end bearing shell

S supplied as spare parts S
outside ∅4 1,883 ÷ 1,892
outside ∅4 1,885 ÷ 1,891
Small end bush - housing 0,08 ÷ 0,135
Piston pin - bush 0,014 ÷ 0,030
Piston rings 0,254 - 0,508


X
Measurement X 125
Maximum error
on alignment of
connecting rod axes = 0,09
Main journals ∅1
No. 1-2-3-4 76,182 ÷ 76,208
∅1 ∅2 83,182 ÷ 83,208
No. 5
Crankpins ∅2 64,015 ÷ 64,038
Main bearing shells
S1* 2,165 ÷ 2,174
S1 S 2 Big end bearing shells
- superior S2* 1,883 ÷ 1,892
- inferior 1,885 ÷ 1,891
* supplied as spare parts
Main bearing housings ∅ 3
∅3 No. 1-2-3-4 80,588 ÷ 80.614
No. 5 87,588 ÷ 87,614
Bearing shells -
main journals 0,032 ÷ 0,102
Bearing shells —
crankpins 0,035 ÷ 0.083
Main bearing shells 0,254 - 0,508
Big end bearing shells 0,254 - 0,508
Main journal
for shoulder X1 32,500 ÷ 32,550
X 1
Main bearing housing

for shoulder X2 27,240 ÷ 27,290
X 2
X3
Half thrust washers X3
32,310 ÷ 32,460
Crankshaft shoulder
0,040 ÷ 0,240

CYLINDER HEADS - VALVE GEAR

∅ 1
Valve guide housings in the

cylinder heads ∅1 9,980 ÷ 10,000
∅ 2
∅2 6,023 ÷ 6,038
Valve guide
∅3 10,028 ÷ 10,039
∅ 3
Valve guides and seats on head

0,028 ÷ 0,059
(interference)
Valve guide 0,05 - 0,10 - 0,25
∅ 4 Valves:
∅4 5,985 ÷ 6,000
α 60° ±7,5’
∅4 5,975 ÷ 5,990
α α 60° ±7,5’
Valve stem and its guide 0,023 ÷ 0,053
Seat on head for valve seat:
∅1 34,490 ÷ 34,515
∅ 1
∅1 34,490 ÷ 34,515
Outside diameter of valve seat;

∅ 2 angle of valve seat in cylinder
head:
∅2 34 590 ÷ 34,610
34,590 34 610
α 59,5° ±5’
α ∅2 34,590 ÷ 34,610
α 59,5° ±5’
X 0,375 ÷ 0,525
X Recessing X 0,375 ÷ 0,525
0,075 - 0,12
Between valve
seat and head
0,075 - 0,12
Valve seats -


Valve spring height:
free height H 54
H under a load of:
H1
H 2 N243 ± 12 H1 45
N533 ± 24 H2 35
Injector protrusion X 2,77 ÷ 3,23

X
∅ Seats for tappets on

cylinder head normal ∅ 12,016 ÷ 12,034
Tappet
11,988 ÷ 12,000
∅ normal
∅
Between tappets and seats 0,016 ÷ 0,046

Camshaft pin seats in
cylinder overhead
1⇒7
∅1 48,988 ÷ 49,012
∅ ∅ ∅ ∅2 46 988 ÷ 47,012
46,988 47 012
∅3 35,988 ÷ 36,012
∅ 2
Camshaft supporting pins:
∅1 48,925 ÷ 48,950
∅2 46 925 ÷ 46,950
46,925 46 950
∅1 ∅2 ∅3
∅3 35,925 ÷ 35,950
Between seats and
0,032 ÷ 0,087
supporting pins
Useful cam height
H H
3,622
H
4,328

TOOLS
99305047 Appliance to check spring loads
99317915 Set of six box-type wrenches (14-17-19 mm)
Rotary telescopic stand for overhauling assemblies

99322205 (capacity 700 daN, torque 120 daN/m)
99340059 Extractor for camshaft pulley
99340060 High-pressure pump toothed pulley extractor
99342153 Tool to remove crankshaft front gasket

TOOLS
99346258 Keying device for mounting crankshaft front gasket
99346259 Keying device for mounting crankshaft rear gasket
99358026 Wrench for alternator pulley (free wheel) removal/refitting
99360076 Tool to remove cartridge filters
99360183 Pliers for mounting rings on engine pistons
99360186 Guide for flexible belt

TOOLS
99360187 Retaining tool for hydraulic power steering control shaft
99360190 Damper pulley retaining tool
99360260 Tool for removing and refitting engine valves
99360306 Tool to retain engine flywheel
99360543 Swing bar for engine detachment/re-attachment
99360605 Band to insert standard and oversized pistons into the cylinders

TOOLS
99360614 Tool (2) for camshaft timing
99360615 Tool for crankshaft timing
99361041 Brackets securing engine to rotary stand 99322205
99367121 Manual pump to measure pressure and vacuum
99370415 Dial-gauge base for various measurements (to be used with

99395603)
99389817 Dynamometric wrench (60 ÷ 320 Nm) with 3/4” coupling

TOOLS
99389818 Dynamometric wrench (150-800 Nm) with 3/4” square coupling
99389819 Torque wrench (0-10 Nm) with square 1/4” connection
99389829 9x12 coupling torque wrench (5-60 Nm)
Pair of meters for angular tightening with square 1/2” and 3/4”
99395216 connection
99395363 Complete square to check for connecting rod distortion
99395603 Dial gauge (0-5 mm)

TOOLS
99395687 Bore meter (50 — 178 mm)
Belt tension control device (frequency from 10.0 bis 600 Hz)
99395849
Centring ring for timing gear cover

99396039

EXPERIMENTAL TOOLS
This section shows the working drawings for the experimental tools (S.P.) used in overhauling the engine described in this
section, which may be made by the repair shops.

MOTORI F1A - F1C

MOTORI F1A - F1C

MOTORI F1A - F1C

MOTORI F1A - F1C

MOTORI F1A - F1C

MOTORI F1A - F1C

TIGHTENING TORQUE
TORQUE
PART
Nm kgm
Six-lobe screw (M15x1.5 L 193) for cylinder head internal fastening
First stage: pre-tightening 130 13
Second stage: angle 90º
Third stage: angle 90º
Six-lobe screw (M12x1.5 L 165) for cylinder head side fastening
First stage: pre-tightening 65 6,5
Second stage: angle 90º
Third stage: angle 60º
Six-lobe screw (M8x1.25 L 117/58) for chain compartment side fastening (cylinder head) 25 2,5
R 1/2”bevel threaded cap with socket head 40 4
R 3/8” bevel threaded cap with socket head 29 2,9
M26x1.5 threaded screw tap 50 5
Screw with flange M6x1 for camshaft rear cover fastening 10 1
Screw with flange M6x1 for camshaft shoulder plate fastening 10 1
Socket head screw with flange M8x1.25 L 30/40/77/100 for over-head fastening 25 2,5
M14x1.5 L 10 threaded screw tap 25 2,5
Cap bolt socket screw (M6x1x25) for camshaft drive cover fastening 10 1
Flanged nut (M6x1) for camshaft drive cover fastening 10 1
M12x1.5 L 125 inner fastening screw for lower cylinder block
First stage: pre-tightening 50 ± 5 5 ± 0,5
Second stage: angle 60º ± 2,5º
Third stage: angle 60º ± 2,5º
M8x1.25 L 77.5/40 outer fastening screw for lower cylinder block 26 2,6
Socket head screw with flange M11x1.25x49 for connecting rod cap fastening
Preliminary torque 50 5
Second stage: angle 70°
Socket head screw with flange M12x1.25x52,5 for engine flywheel fastening
Preliminary torque 30 3
Second stage: angle 90°
Six-lobe socket screw (M6x1x15) for securing the phonic wheel to the drive shaft 15 1,5
Connection M10x1 for piston cooling nozzle 25 2,5
Tapered threaded cap with socket head (R 3/8”x10) 40 4
TE flanged screw (M20x1.5x58) for securing the camping pulley to the drive shaft 350 35
Bevel cap R 1/8 x 8 7 0,7
Water draining plug M14x1.5 L10 25 2,5
Pipe union on block for oil return from turbocharger G 3/8” x 12 50 5
Suction rose M6x1 fastening screw 10 1
Socket head nut with flange M8x1.25 for depressor — oil pump unit support fastening 25 2,5
Pin (M12x1.5x35) for oil pump/vacuum pump assembly control 130 13
Male threaded cap (M26x1.5) 40 4
Connection (R 1/4”) for oil delivery to the turboblower 40 4
Socket head screw with flange M8x1.5 L35 for oil sump retaining frame fastening 25 2,5
Threaded cap with O-ring (M22x1.5 L10) 50 ±10 5 ±1
Socket head screw with flange M8x1.25 L60 for depressor - oil pump unit fastening 25 2,5
Flanged, hexagon nut (M8x1.25) for power steering pump support fastening 25 2,5

TORQUE
PART
Nm kgm
TE screw with flange (M10x1.25x60/110) 50 5
TE screw with flange (M8x1.25x16) for blow-by pipe fastening. 28 2,8
Socket head screw with flange M8x1.25 L18 for suction manifold fastening 25 2,5
TE screw with flange (M6x1 L20) for blow-by pipe fastening. 10 1
M14x1.5 L10 cap 25 2,5
Flanged nut M8x1.25 L40 for exhaust manifold fastening 30 3
Flanged nut M8x1.25 for exhaust manifold fastening 25 2,5
Socket cylinder head screw M8x1.25 L65 for Poli-V belt automatic backstand 25 2,5
Flanged screw M10x1.25 L22 for Poli-V belt take-up pulley fastening 40 4
Flanged head M12x1.75 L30 for camshaft gear fastening 110 11
Timing chain tightener fastener M22x1.5x22 50 5
Screw (M10x1.5x12) for timing chain moving pad fastening 40 4
Socket cylinder head screw M8x1.25x30 for fixed skid fastening 25 2.5
Socket cylinder head screw M6x1 L16/20 for skid fastening 10 1
Water temperature/pressure sensor fastener (M12x1.5) 30 3
Socket cylinder head screw M6x1 for water temperature/pressure sensor fastening 10 1
Socket cylinder head screw M6x1 for air temperature/pressure sensor fastening 10 1
Socket cylinder head screw M6x1 for engine rev sensor fastening 10 1
High-pressure injection system
Flanged nut M8x1.25 for high pressure pump support fastening 25 2,5
Hydraulic accumulator fastening screw M8x1.25 L50 28 2,8
High pressure pump fastening screw M8x1.25 L90 25 2,5
Screw M6x1x16 for fastening of fuel delivery pipe anchoring bracket 10 1
Pipe union for fuel delivery pipes to rail and electric injectors:
- M14x1.5 19 ± 2 1,9 ± 0,2
- M12x1.5 25 ± 2 2,5 ± 0,2
Socket cylinder head screw M8x1,25 for fastening of electric injector retaining bracket 28 2,8
Flanged nut M8x1,25 for anchoring bracket support fastening 25 2,5
Pin fastener M12x1.25 for high pressure pump 110 11
Flanged nut (M6x1) for low-pressure fuel pipe fastening 10 1
TE flanged screw (M8x1.25) for pipe supporting bracket fastening 25 2,5
Filler neck M12x1.5 for adjustable pipe union 25 2,5
Filler neck M16x1.5 for adjustable pipe union 40 4
Pipe union for revolving multiple-way connection to the high-pressure pump (M12x1.5) 25 2,5
Nut M8x1.25 for turbocharger fastening 25 2,5
TE flanged screw (M8x1.25) for turboblower exhaust gas outlet pipe fastening 25 2,5
Pipe union M14x1.5 or M12x1.5 for oil delivery pipe to turbocharger 35 3,5
Pipe union M22x1.5 for oil return pipe from turbocharger 45 4,5
Flanged screw M6x1 for fastening of oil return pipe from turbocharger 10 1
Pipe union M14x1.5 for fastening of oil delivery pipe to turbocharger 35 3,5
Threaded union R 1/4” 40 4
TE screw with flange (M8x1.25) for air conveyor bracket fastening 28 2,8
TE screw with flange (M8x1.25) for air conveyor fastening 28 2,8
Socket cylinder head screw M6x1 for V-clamp closing ring 8 0,8
TE screw with flange (M6x1x16) for air pipe fastening 10 1
TE screw with flange (M6x1) for oil filling pipe fastening 10 1
Pre-warming plug M8x1 8 ÷ 11 0,8 ÷ 1,1
Oil filter cartridge M22x1.5 25 2,5
TE screw with flange (M8x1.25x20) for water inlet pipe fastening 25 2,5
TE screw (M8x1.25x30) for heat exchanger fastening 25 2,5

TORQUE
PART
Nm kgm
Pipe union M24x1.5 for oil filter cartridge 80 8
TE flanged screw (M8x1.25x30/40) for heat exchanger inner element fastening 25 2,5
Socket cylinder head screw for water pump fastening:
- M10x1.5x55 50 5
- M8x1.25x45 25 2,5
Flanged screw M8x1.25 for rear cover fastening to cylinder head 25 2,5
Flanged screw M8x1.25 for coolant delivery pipe fastening 25 2,5
Flanged nut M8x1.25 for coolant delivery pipe support bracket fastening 25 2,5
Pipe union M10x1x10 for vapour vent fastening 12 1,2
Flanged screw M8x1.25 for thermostat fastening 25 2,5
Flanged nut M6x1 for electro-magnetic joint fastening 10 1
Nut (M30x1.5) for electromagnetic joint 150 15
Flanged screw M8x1.25 for air conditioner compressor fastening 25 2,5
Flanged screw M8x1.25 L20/130 for air conditioner compressor support fastening 25 2,5
Socket cylinder head screw M8x1.25 for fastening of air conditioner compressor control belt
25 2,5
idler
Socket cylinder head screw M10x1.5 for alternator fastening 50 5
Flanged screw M10x1,25x110 for hydraulic power steering pump fastening 40 4
Flanged screw M12x1,25 securing the power steering pump 50 5
Flanged screw M8x1,25 securing the power steering tank support 25 2,5
Flanged screws M10x1.25 for power take off cover fastening 50 5
Depressor pipe union M14x1.5 35 3.5
Oil level sensor M12x1.25 25 2,5
Thermometric transmitter/switch M16x1.5 (conical) 25 2,5
Oil pressure switch M14x1.5 25 2,5
Power unit suspension
Screw (M8x16) securing the elastic dowel to the gearbox cross-member 23,5±2,5 2,3±0,2
Nut (M12) securing the gearbox cross-member to the chassis 92±9 9,2±0,9
Nut (M12) securing the engine supports to the elastic dowels 49±4 4,9±0,4
Nut (M12) securing the gearbox bracket onto the rear cross-member elastic dowel 49±4 4,9±0,4
Locknut (M10) with flange, securing the engine supports to the chassis 52,5±5,5 5,2±0,5
Screw (M10x30) securing the gearbox support to the gearshift 46,5±4,5 4,6±0,4
* On the threading apply LOCTITE 577

Print 603.43.671/A
OVERHAULING ENGINE F1C

540110 DISASSEMBLING THE ENGINE Fit the brackets 99361041 (11) to the crankcase and use
AT THE BENCH these to secure the engine to the rotary stand 99322205
(12). Drain the oil from the engine by removing the plug from
Figure 59 the oil sump.
If fitted, remove the fan (1) from the electro-magnetic joint
(2).
Remove the items below, if they have not yet been removed
prior to detachment:
- upper sound-proofing cover;
- engine cable complete with raceway (6), by
disconnecting the electric connections of the same
from:
107701 - inlet manifold air pressure/temperature sensor (8);
To fit the engine base with the brackets securing the rotor - revs sensor (4);
to the overhaul bench, disassemble the left and right engine - high-pressure pump pressure regulator (10);
mounts (3), then disconnect oil pipe (2) from turboblower - phase sensor (2);
(1) and engine base connection (4). - thermostat coolant temperature sensor (9).
NOTE Block the turbocharger air/exhaust gas inlets and

outlets to prevent foreign bodies getting inside.
Figure 60
107702

Figure 61 Figure 64
88244
107703
Press the springs (3) in the direction shown by the arrow and Using tool 99342153 (1) extract the electro-injectors (2)
disconnect the fittings of the pipe (1) recovering fuel from the from the overhead (3).
Figure 62 Figure 65
107704 107706
Disconnect the fuel pipes (2) from the electro-injectors (3) Remove the fastening screw (3) of the pipe retaining bracket
and from the hydraulic accumulator (1) (rail). (2). Disconnect the pipe (2) from the hydraulic accumulator
(1) and the high pressure pump (4).
Figure 63 Figure 66
107705 107708
Take out the screws (2) and the brackets (3) fixing the Remove the screws (1) and the hydraulic accumulator (2)
electro-injectors (1) to the cylinder overhead. from the overhead device (3).

Figure 67 Figure 70
107712
107709 Remove screws (5) with spacers (4), then take off high-pressure
Use tool 99360076 (1) to take oil filter (4) off heat exchanger pump (3).
(5). Remove screws (6) with spacers (7), then take off power
Remove screws (2) and (6), then disconnect pipe (3) from steering pump (8).
heat exchanger (5). Remove screws (1), then take off power steering tank support
(2).
Figure 68 Figure 71
107710
107713
Remove the screw (6) and the low pressure pipes (5) from Cut elastic belt (1), if any, due to its being unable to be reused.
the bracket (4). Remove screws (3), then remove air-conditioner
Slacken the pipe unions (1 and 3) and remove the low compressor (4) from support (2).
pressure pipes (5) from the high pressure pump (2).
Figure 69 Figure 72
107711 88252
Remove screws (1), then take heat exchanger (2), with its Remove the screws (4) and take off the support (3).
respective gasket, off the engine base. Remove the screw (1) and the fixed backstand (2).

Figure 73 Figure 76
107714 107717
Remove screws (3), then remove throttle valve assembly (4). Loosen screw (5), then remove strap (6).
Remove the screw (2) and take off the air temperature and Remove screws (1), then take heat exchanger (2), together
pressure sensor (1). with EGR valve (3), off overhead (4) and connecting pipe (7).
Remove the screws (5) and take off the suction manifold (6)
with the relevant gasket.
Figure 74 Figure 77
107715 107718
Using wrench SP.2275 (3), remove the glow plugs (4). Remove screws (2), then take cover (3), together with pipes
(4 and 5), off cylinder head (1).
Figure 75
Figure 78
107716
107719
Remove the retaining straps, then remove coolant pipes (1
and 2). Unscrew connections (2, 4 and 6), then disconnect oil pipe
Remove screw (3) and strap (5), then disconnect coolant (5).
pipe (4) from water pump (6). Remove nuts (2), then take turboblower (3), together with
its respective gasket, off exhaust manifold (1).

Figure 79 Figure 82
88255 107722
Remove the nuts (2), the spacers (1) and take off the exhaust Remove the screw (2), the bolt (4) and pull the alternator (3)
manifold (3) with the relevant gasket from the cylinder head. out of the support (1).
Figure 80 Figure 83
88260
107720
Using the specific wrench on the automatic tightener (2), Remove the screws (1) and take off the support (2) from the
slacken the tension of the belt (1) and remove it. cylinder block.
Figure 81 Figure 84
107721 107723
Take out the screw (2) and remove the automatic tightener Use the suitable wrench to remove the oil level sensor (1).
(1). Remove the fastening screw and the rev sensor (2).

Figure 85 Figure 88
107727
107724
Secure water pump shaft (5) by means of an Allen wrench Remove the screws (3) and the cover (4). Take off the snap
(3) and a special lever. Use a suitable wrench (4) to remove ring (2). Pull out the centrifugal filter (1).
nut (2) securing hub (1) to shaft (5).
NOTE The centrifugal filter (1) and the seal ring of the
NOTE Slacken the nut (2) anticlockwise because its cover (4) must be changed at every removal.
threading is left-handed.
Figure 86 Figure 89
107725
107728
Disassemble hub (5) and pulley (4).
Disconnect electric cable (1) from the retaining clip, then Stop the rotation of the engine flywheel (2) by means of tool
99360306 (1).
remove nuts (2) and take electromagnet (3) off water pump
(6).
Figure 87
Figure 90
107726
Remove screws (1), then take water pump (2) off. 88265
Remove screw (3), then take oil dipstick pipe (4) out of front Remove the screw (2) and the damper pulley (1).
cover (5).

Figure 91 Figure 94
88266
88268
Remove the screws (1) and the distribution cover (2).
Remove the hydraulic chain tightener: top (1) and lower (2).
Remove the pin (4) and disassemble the mobile skid: lower
(5) and top (3).
NOTE Tool 99340059 (4) is used to remove the seal ring
(3) from the cover (2) when the engine is installed NOTE Upper hydraulic chain stretcher (1) is equipped with
on the vehicle. an anti-return device that makes it necessary to
replace the chain stretcher every time it is
disassembled.
Figure 92 Figure 95
107729
Remove the nut (1) and the phase sensor (2). 88269
Remove the nuts (3) and the cover (4). Remove the screw (3), the washer (2) and the gear (1).
Remove the screw (7), the washer (6), the gear (5) and the
chain (4).
Figure 93
Figure 96
88271
88270
Remove the screws (3) and disassemble the depressor/oil
pump unit (2). Remove the cap (4), the screws (2 and 3) and the top fixed
Remove the connection key (1). skid (1).

88275
88272
Remove the screws (2) and the side fixed skid (1). Remove the gear (1) and the chain (3) from the high pressure
Remove the screws (4) and the lower fixed skid (3). pump control shaft (2).
90311 88276
Stop the rotation of the high pressure pump control shaft (1) Remove the high pressure pump control shaft (3).
by inserting the suitable wrench inside it. Remove the nuts (2) and the support (1).
88274 88277
Remove the screw (3) and the stem with the drive gear (2) Stop the rotation of the hydraulic power steering pump
from the high pressure pump control shaft (1). control shaft (2) by inserting tool 99360187 (3) in the shaft
and fastening the tool on the support (1) by means of the
screws (4).

88278 88281
Remove the screw (2) and the gear (1) from the hydraulic Remove the hydraulic tappets (1) with the rocker arms.
power steering control shaft (3). Remove the gasket (2).
88282
88279
Take out the screws (1) and remove the cylinder head (2).
Remove the hydraulic power steering control shaft (3).
Remove the nuts (2) and the support (1).
Figure 108
Figure 105
88283
Remove the cylinder head gasket (1).

88280
NOTE Check the protrusion of the pistons (2) as
Remove the screws (1) and take off the over-head (2) from described under the relevant heading to check the
the cylinder head (3). possibility of facing the crankcase if it has deformed.

Figure 109
NOTE On the same side of the connecting rod and its
associated cap, indicate the number of the cylinder
from which the connecting rod has been removed.
Keep the bearing shells in their respective housings
since, if they are used, they will need to be fitted in
the position found during removal.
88284
Remove the screws (2) and take off the oil sump (1) with its
gasket and frame (3).
88285 107707
Remove the screws (2) and the suction rose (1). Block rotation of the flywheel (1) with tool 99360306 (4).
Take out the screws (2) and remove the engine flywheel (1).
Take out the guard (3).
88738 88287
Take out the screws (2) and remove the connecting rod caps Apply tool 99340060 (2) to the rear O-ring (1) and extract
(3). it from the crankcase.
Extract the pistons (1) from the top of the crankcase.

88288
Remove the screws (2) and take off the oil sump (1) with its
gasket and frame (3).
Figure 115 75290
Take out the couplings (1) and remove the oil jets (2).
NOTE On completing engine removal, it is necessary to

clean the removed parts thoroughly and check
their integrity.
The following pages give the instructions for the
main checks and measurements to make in order
to determine whether the parts can be reused.
88289

Figure 116
87793
With the aid of a hoist and a rope, remove the crankshaft (1).

The central half-bearing (3) is fitted with shoulder half-rings.

REPAIRS
CYLINDER BLOCK Figure 120
Checks and measurements
Figure 118
18837
Once the engine removal is complete, carefully clean the

cylinder block. For the cylinder block transportation use the
87782
suitable rings.
Carefully check that the crankcase has no cracks in it.
Check the state of the plugs. If they are rusty or there is any Figure 121
doubt about their seal, replace them. When fitting the caps
into place, apply Loctite 270 sealant (IVECO NO. 93162429)
to the same. Examine the surfaces of the cylinder liners; they
must show no sign of meshing, scoring, ovalization, taper or
excessive wear. The inside diameter of the cylinder liners is
checked, to ascertain the extent of ovalization, taper and
wear, using the bore meter 99395687 (1) fitted with a dial
gauge previously reset on the ring gauge of the diameter of
the cylinder liner or on a micrometer.
Figure 119
87783
87781
* Surface roughness parameters:
The measurements must be made for each single cylinder at
R1 = 4 ÷ 10 μm
three different heights up the liner and on two planes at right
Rz = 3 ÷ 8 μm
angles to each other: one parallel to the longitudinal axis of
Ra = 0,3 ÷ 0,6 μm
the engine (B) and the perpendicular (A); the greatest wear
W1 < 2 μm
is generally found on this last plane with the first
Permissible surface porosity for machined cylinder
measurement.
(see Figure 121)
On finding ovalization, taper or wear, go ahead and
bore/grind and finish the face of the cylinder liners. The ZONE B1 = Area of greatest mechanical stress,
refacing of the cylinder liners should be done in relation to segment/liner contact: No.2 C
the diameter of the pistons supplied as spare parts oversized non-continuous porosities are 100%
by 0.4 mm of the nominal value and to the prescribed permissible max. 0.5x0.5.
assembly clearance. ZONE B2 = Surface involved in segment rubbing:
No.2 non-contiguous porosities are
C
permissible max. 1x0.8. 100%

Checking head mating surface on cylinder 5408 CRANKSHAFT

block 540810 Measuring main journals and crank
Figure 122 pins
Figure 124
88290 75298
See that the head mating surface, on the cylinder block, has On finding signs of seizure, scoring or excessive ovalization
no deformation. on main journals and crankpins, it is necessary to regrind the
This check can be made, after taking out the grub screws (3), pins. Before grinding the pins (2), measure the shaft pins with
with a surface plate spread with carbon black or with a a micrometer (1) to establish to what diameter it is necessary
calibrated rule (1) and a feeler gauge (2). After ascertaining to decrease the pins.
the areas of deformation, level the bearing surface with a
grinding machine.
NOTE The crankcase can only be surfaced after making NOTE It is advisable to enter the measurements in a table.
sure that, on completing the work, the piston See Figure 123.
protrudes from the cylinder liner by no more than
the prescribed value.
Figure 123 NOMINAL NOMINAL

VALUE VALUE
∅ MIN
∅ MAX
NOMINAL
VALUE
∅ MIN 87784
∅ MAX
TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS
NOTE The main journals and crankpins must always be For undersized crankpins, letter M.
ground to the same undersize class. For undersized main journals, letter B.
The undersizing performed, on the main journals or For undersized crankpins and main journals, letter MB.
crankpins, must be marked by punching on the side The undersize classes are:
of crank arm no. 1. 0.254 — 0.508 mm.

Checking crankshaft
Figure 125
87785
MAIN CRANKSHAFT TOLERANCES
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Circularity ○
SHAPE
Cylindricality
Parallelism
ORIENTATION
Perpendicularity ⊥
POSITION Concentricity or coaxiality
Circular oscillation ↗
OSCILLATION
Total oscillation ↗↗
CLASS OF IMPORTANCE ATTRIBUTED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL E
IMPORTANT ⊕
SECONDARY ⊝
Figure 126 NOTE The checks on the tolerances indicated in the

figures must be made after grinding the crankshaft
pins.
SYMMETRY BETWEEN MAIN JOURNALS AND

CRANKPINS
1. Crankpins
2. Main journals
3. Normal position
After grinding, keep to the following:
- Round off the edges of deburring the holes for
lubrication of the main journals and crankpins.
87786

JOURNAL ON TIMING SYSTEM SIDE JOURNAL ON FLYWHEEL SIDE

87787
87790
INTERMEDIATE JOURNALS NO. 2-4
CRANKPINS
87791
* As far as both values are concerned, for the whole 360°.

87788
INTERMEDIATE JOURNAL NO. 3 NOTE Since, during the 0.254 and 0.508 mm undersizing
on the diameter of the crankpins and main journals,
the rolled portion of the side races of the pins may
get involved, it is necessary to turn the races
Figure 129 keeping to the data given in the figure and to do the
rolling keeping to the following instructions.
Rolling force:
- 1st main journal 925 ±25 daN.
- 2nd — 3rd — 4th — 5th main journal 1850 ±50 daN.
- crankpin 1850 ±50 daN.
- Rolling turns: 3 approach, 12 effective, 3 out.

- Rolling speed: 56 rpm.
- Reduction of the connecting rod pin slot diameter after
rolling: 0.15 ÷ 0.30 mm*.
87789
- Reduction of the journal slots after rolling: 0.15 ÷ 0.30
mm.
MAIN DATA OF MAIN JOURNALS AND CRANKPINS
* Measured with calibrated rollers ∅ 2.5 mm.

Figure 132 Assembling main bearings

Figure 134
87792
Take out the screws (4) and replace the phonic wheel (3). 88345
Screws (4) shall be tightened to 10 + 1 Nm.
NOTE Not having found it necessary to replace the main
Replacing timing control gear bearings, they need to be fitted back on in the same
On finding the timing control gear teeth (1) damaged or sequence and position found upon disassembly.
worn, remove them from the crankshaft (2) using a suitable
extractor.
The main bearings (1) are supplied as spare parts undersized
The new gear is fitted onto the crankshaft by heating it to a on the inside diameter by 0.254 ÷ 0.508 mm.
temperature of 180°C for no longer than 15 minutes.
On completing assembly and after the gear has cooled, it NOTE Do not do any accommodating on the bearings.
must withstand a torque of 150 Nm without slipping.
Thoroughly clean the top main bearing shells (1) and position
them in the crankcase.
NOTE The middle half ring (2) is fitted with thrust washers.
ENGINE ASSEMBLY
The following parts must be replaced with new ones at the 540811 Measuring main journal assembly
time of assembly: retaining rings, seals and gaskets, screws clearance
whose thread is coated with sealant.
Figure 135
Figure 133
90064
Mount the crankshaft (1).
Check the clearance between the crankshaft main journals
75306
and their respective bearings by proceeding as follows:
Fit on the oil spray nozzles (2) and tighten the couplings (1)
to the prescribed torque. - Thoroughly clean the pins.
- Apply a calibrated wire onto the main journals.

88289 75310
Thoroughly clean the bottom main bearing shells (2) and - Remove the bottom crankcase.
mount them in the crankcase base (1).
The clearance between the main bearings and their
associated pins is measured by comparing the length of the
calibrated wire (1), at the point of greatest crushing, with the
Figure 137 graduated scale on the casing containing the calibrated wire.
The numbers on the scale indicate the clearance of the
coupling in millimetres, which must be 0.032 ÷ 0.102 mm.
If the clearance is not as prescribed, replace the bearings and
repeat the check.
α
Checking crankshaft end float
Figure 139
88292
Mount the crankcase base (12). 88293
Tighten the screws in the sequence shown in the figure in The end float is checked by setting a dial gauge (2) with a
three steps: magnetic base on the crankshaft (1) as shown in the figure.
The normal assembly clearance is 0.060 — 0.310 mm.
If you find the clearance to be greater than as required,
- Step 2: closing to an angle of 60°. replace the rear main bearing shells carrying the thrust
- Step 3: closing to an angle of 60°. bearings and repeat the clearance check between the
crankshaft pins and the main bearing shells.
If the end float of the crankshaft does not come within the
prescribed values, it is necessary to grind the crankshaft and
NOTE Use tool 99395216 (11) for the angle closing. accordingly change the main bearing shells.
NOTE The middle main bearing has half thrust washers

integrated in it, so it performs the function of a
Then tighten the outer screws to torque 26 Nm. thrust bearing. It is supplied as a spare part only with
the normal shoulder thickness.

88294
88296
Thoroughly clean the crankcase / crankcase base mating
surface. Then tighten the outer screws (1) to a torque of 26 — 30 Nm.
Apply, on base, sealant LOCTITE 510 IVECO no. 93162432,
as indicated in the scheme. The sealant must result to be
even, not patchy.
540460 Assembling rear seal
NOTE Mount the crankcase base within 10 minutes of Figure 143

applying the sealant.
Figure 141
88297
Carefully clean the seal seat.

Lubricate the rear shank of the crankshaft with engine oil.
Fit part (2) of tool 99346259 onto the rear shank of the
crankshaft; secure it with the screws (3) and key the fresh seal
(1) onto it.
Position part (4) on part (2); screw down the nut (5) to fit
the seal (1) fully inside the crankcase.
88292
Mount the crankcase base (12) and tighten the fixing screws
in three stages, following the sequence shown in the figure:

540850 ENGINE FLYWHEEL

107731
Tighten the screws (2) fixing the engine flywheel (3) in two
steps:
88054
Double-mass engine flywheel, one integral with the drive
shaft and one with the input shaft of the gearbox and in
between a torsion elastic dampening system. NOTE Use tool 99395216 (1) for the angle closing.
The advantages of this type of flywheel compared to the
normal one are:
- Dampening of engine irregularities transmitted to the
gearbox and resulting drive noise reduction; Take off tool 99360351 (4).
- Noise reduction in the cabin as a result of the overall
noise reduction.
Check the clutch disc mating surface, if there are too many 5408 CONNECTING ROD — PISTON
scratches, change the engine flywheel (3). ASSEMBLY
Check conditions of the teeth of crown wheel (1); where
excessive cracking or wear is found, replace engine flywheel.
Figure 147
540852 Replacing bearing supporting gear-

box input shaft
The bearing (2) supporting the gearbox input shaft is
removed and fitted using a general-purpose drift.
Figure 145
75392
PISTON — CONNECTING ROD ASSEMBLY

1. Piston — 2. Piston ring — 3. Pin — 4. Trapezoidal ring —
5. Oil scraper ring — 6. Slotted oil scraper ring with spiral
spring — 7. Connecting rod body — 8. Bearing shells —
9. Connecting rod cap — 10. Cap fixing screws.
107730
Position the metal sheet guard (3) on the cylinder block. Check the pistons. They must show no signs of seizure,
Mount the engine flywheel (1) and screw down the screws (2). scoring, cracking or excessive wear; replace them if they do.
Fit tool 99360351 (4) onto the crankcase to block rotation
of the engine flywheel (1).

Figure 148 540840 Piston

Measuring piston diameter
Figure 151
107732
Using a micrometer (2), measure the diameter of the piston

75393 (1) to determine the assembly clearance. The diameter has
Remove the piston rings (1) from the piston (2) using pliers to be measured at the value shown.
99360183 (3).
NOTE The pistons are supplied as spare parts with the
Figure 149 standard, normal and 0.4mm oversize diameters
together with rings, pin and retaining rings.
Figure 152
75394
Remove the piston (1) from the connecting rod, taking out
the piston ring (2) and extracting the pin (3).
88300
The clearance between the piston and cylinder liner can also
be checked using a feeler gauge (1) as illustrated in the figure.
Figure 150
107733
MAIN DATA FOR MONDIAL PISTON, PINS AND PISTON RINGS
* The value is measured at 1.5 mm from the outer diameter
** The value of the diameter measured is 91.4 mm
X = 0.5

540841 Piston pin

16552
18857
Check the thickness of the piston rings (2) with a micrometer
Measuring the diameter of the piston pin (1) with a (1).
micrometer (2). Figure 157
Conditions for correct pin-piston coupling
Figure 154
88301
Check the clearance between the trapezoidal ring (2) (1st

slot) and the associated slot on the piston with a feeler gauge
(1), proceeding as follows: insert the piston into the cylinder
75397 liner so that the ring (2) comes approximately half way out
Lubricate the pin (1) and its seat on the hubs of the piston of it.
(2) with engine oil. The pin must go into the piston by lightly
Figure 158
pressing with the fingers and must not drop out by gravity.
540842 Piston rings

Figure 155
41104
DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
74947
1. Piston slot — 2. Trapezoidal piston ring —
3. Cylinder liner
The trapezoidal split rings (1st slot) and the oil scraper rings
(2nd slot) have the word TOP etched in them; when fitting Using a feeler gauge (1, SENZA CODICE), check the
them on the piston, the word TOP must be facing upwards. clearance (X) between the ring (2) and the slot (1); this
clearance must have the prescribed value.

Figure 159
NOTE Each connecting rod has its cap marked:
- with a letter: O or X indicating the diameter class of the

big end mounted in production;
- with a number indicating the weight class of the
connecting rod mounted in production.
In addition, it could be stamped with the number of the
cylinder in which it is fitted.
In the event of replacement it is therefore necessary to
number the new connecting rod with the same number as
the one replaced.
The numbering must be done on the opposite side to the
bearing shell retaining slots.
75398
The connecting rods are supplied as spare parts with the
Check the clearance between the piston rings (2) of the 2nd diameter of the big end 67.833 — 67.848 mm marked with the
and 3rd slot and the associated seats on the piston (3) with letter O and the weight class marked with the number 33.
a feeler gauge (1).
It is not permissible to remove material.
Figure 160
540834 Bushing
Check that the bush in the small end has not come loose and
shows no sign of seizure or scoring. If it does, replace the
complete connecting rod.
Checking connecting rods

Figure 162
75399
Check the opening between the ends of the piston rings (2)
inserted in the cylinder liner using a feeler gauge (1).
540830 Connecting rods
Figure 161
61696
87796
Check the alignment of the axes of the connecting rods (1)

MAIN DATA OF THE CONNECTING ROD, BUSHING, with device 99395363 (5), proceeding as follows:
PISTON PIN AND BEARING SHELLS
* Internal diameter to obtain after driving into the small - Fit the connecting rod (1) on the spindle of the tool
end and grinding with a reamer. 99395363 (5) and lock it with the screw (4).
** Dimension cannot be measured in the free state. - Set the spindle (3) on the V-prisms, resting the
*** Thickness of the bearing shell supplied as a spare part. connecting rod (1) on the stop bar (2).

Checking torsion Assembling connecting rod-piston assembly

87797
Etched on the top of the piston are: the type of engine (1),
class selection (2) and supplier (3) as well as the direction of
fitting the piston in the cylinder liner (4). The mark (5) is for
passing the 1st slot insert adhesion test.
61694 Figure 166
Check the torsion of the connecting rod (5) by comparing
two points (A and B) of the pin (3) on the horizontal plane
of the axis of the connecting rod.
Position the mount (1) of the dial gauge (2) so that this
pre-loads by approx. 0.5 mm on the pin (3) at point A and
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side B of the pin (3): the difference between A and
B must be no greater than 0.08 mm.
Checking bending
Figure 164
87798
Connect the piston (1) to the connecting rod (2) together

with its cap so that the piston assembly reference, position
of the connecting rod and of the cap are observed as shown
in the figure.
Figure 167
61695
Check the bending of the connecting rod (5) by comparing

two points C and D of the pin (3) on the vertical plane of the
axis of the connecting rod.
Position the vertical mount (1) of the dial gauge (2) so that
this rests on the pin (3) at point C.
Swing the connecting rod backwards and forwards seeking
the highest position of the pin and in this condition zero the
dial gauge (2).
75394
Shift the spindle with the connecting rod (5) and repeat the
check on the highest point on the opposite side D of the pin Position the piston (1) on the connecting rod, insert the pin
(3). The difference between point C and point D must be no (3) and secure it with the split rings (2).

Checking for connecting rod — piston distortion Assembly connection rod-piston assembly in
Figure 168
the cylinder liner
Figure 170
88302
Lubricate the pistons well, including the piston rings and the
75403
inside of the cylinder liners.
After fitting the connecting rod — piston assembly together, With the aid of the clamp 99360605 (2), fit the connecting
check for distortion with the tool 99395363 (8) as follows: rod — piston assembly (1) in the cylinder liners, checking that:
- Fit the connecting rod (7) together with the piston (3) - The number of each connecting rod corresponds to the
on the spindle (4) of tool 99395363 (8) and lock it with cap mating number.
the screw (5). - The openings of the piston rings are staggered 120° apart.
- Rest the connecting rod (7) on the bar (6). - The pistons are all of the same weight.
- Position the mount (1) of the dial gauge (2) so that this - The symbol punched on the top of the pistons faces the
is positioned at point A of the piston with a pre-load of engine flywheel, or the recess in the skirt of the pistons
0.5 mm and zero the dial gauge (2). tallies with the oil spray nozzles.
- Shift the spindle (4) so as to position the dial gauge (2)
at point B of the piston (3) and check for any deviation. NOTE Not finding it necessary to replace the connecting
rod bearings, you need to fit them back in exactly
the same sequence and position found on
disassembly.
Assembly piston rings
Figure 169 540831 Measuring crankpin assembly
clearance
Figure 171
41097
Fit the piston rings (1) on the piston (2) using the pliers
99360183 (3). To measure the clearance, carry out the following steps:88303
- Thoroughly clean parts (1) and (4) and eliminate all
NOTE The 1st and 2nd slot rings need to be mounted with traces of oil.
the word ”TOP” facing upwards. - Place a length of calibrated wire (3) on the crankshaft
pins (4).

Figure 172 Checking piston protrusion

Figure 173
88326
88327
- Fit the connecting rod caps (3) with the associated At the end of the connecting rod-piston assembly refitting,
bearing shells. check the piston protrusion (2) at the T.D.C. compared to
- Tighten the screws (2) in two steps: the top level of the cylinder block by means of a dial gauge
(1) and relevant base 99370415.
NOTE The difference between the minimum and
NOTE Use tool 99395216 (1) for the angle closing. maximum protrusions of the four pistons must be
= 0.15 mm.
The cylinder head gasket in the set of spare gaskets
needed for complete engine overhaul is supplied
with a single thickness. Clearly, it is supplied
- Remove the cap (3) and determine the existing separately too.
clearance by comparing the width of the calibrated wire
(3, Figure 171) with the graduated scale on the case (2,
Figure 171) that contained the calibrated wire. On
finding a clearance other than as prescribed, replace the
bearing shells and repeat the check. Figure 174
On obtaining the prescribed clearance, lubricate the
connecting rod bearing shells and fit them permanently
by tightening the connecting rod cap fixing screws as
described.
NOTE The connecting rod cap fixing screws must always

be replaced for permanent assembly.
Manually check that the connecting rods slide axially on the

pins of the crankshaft.
88285
Mount the suction strainer (1) together with the pipe.

Screw down the fixing screws (2) and tighten them to the
prescribed torque.

Figure 175 541210 Disassembly the camshaft
Figure 177
75412
88329 Fit part (4) of tool 99360260 onto the cylinder head (5) and
Fit the gasket (4) and the frame (3) onto the oil sump (1). secure it with the screws (3).
Screw down the fixing screws (2) and tighten them to the Fit part (2) of tool 99360260 onto part (4), screw down the
prescribed torque. nut (1) so that on compressing the springs (8) it is possible
Screw down the oil drain plug (5) and tighten it to the to remove the cotters (6). Then take out the plates (7) and
prescribed torque. the springs (8).
Using suitable pliers, remove the oil seal (9).
560610 CYLINDER HEADS Turn the cylinder head over.
Disassembly
Figure 178
Figure 176
88426
88328 The intake (1) and exhaust (2) valves have the same diameter
Apply the support SP. 2271 (5) on the cylinder head and mushroom.
tighten the support in a vice. The central cavity (→) of the mushroom of the intake valve
Remove the brackets (6) for lifting the engine. (1) is distinguished from that of the exhaust valve (2).
Remove the sensors (1 and 2), if needed.
Take out the screws (3) and remove the thermostat casing
(4). NOTE Before removing the valves from the cylinder
heads, number the valves in order to refit them
correctly if they are not changed.
A = intake side — S = exhaust side
Remove the intake (1) and exhaust (2) valves.

Checking cylinder head seal 540662 VALVES

Check the hydraulic seal using a suitable tool. Figure 180
Pump in water heated to approx. 90°C at a pressure of 2 ÷ EXHAUST INTAKE
3 bars. VALVE VALVE
Replace the cup plugs if they are found to leak at oil, using 5,975 5,985
a suitable drift for their removal — assembly. 5,990 6,000
32,3
32,5
NOTE Prior to fitting the caps into place, apply Loctite 270
water-reactive sealant (IVECO NO. 93162429) to
the cap sealing surface. 2,25+07.5’
If there is any leakage from the cylinder head, it must be O 30,8

replaced.
60 +7.5’
87799
Checking cylinder head mating surface
MAIN DATA OF INTAKE AND EXHAUST VALVES
Figure 179 Removing deposits, refacing and checking

valves
Figure 181
88331 18625
The mating surface of the head (1) with the cylinder block Remove the carbon deposits on the valves with a wire brush.
is checked using a rule (2) and a feeler gauge (3). Check that the valves show no signs of seizure, cracking or
The deformation found on the entire length of the cylinder burning.
head must be no greater than 0.20 mm.
For greater values, regrind the cylinder head according to the Figure 182
values and instructions given in the following figure.
The nominal thickness A of the cylinder head is 112 ±0.1 mm;
the maximum permissible removal of metal must not exceed
a thickness of 0.2 mm.
NOTE After regrinding, check the valve recessing and if

necessary regrind the valve seats to make the
prescribed valve recessing. 18882
Use a micrometer (2) to measure the valve stem (1): it must

have the value shown in Figure 132. If necessary, grind the
valve seats by means of the grinding machine 99305018, and
remove as little material as possible.

Checking clearance between valve stem and Figure 185

valve guide and centring valves
Figure 183
88333
Remove the valve guides (2) with the drift SP.2312 (1).
Figure 186
88332
The checks are made using a dial gauge (2) with a magnetic
base, positioned as illustrated. The assembly clearance is
0.033 — 0.063 mm.
Making the valve (1) turn, check that the centring error is no
540667 VALVE GUIDE

Replacing valve guide
88334
Figure 184 Warm up the cylinder head to 80° ÷ 100°C and, by means
of beater SP.2312 (1) fitted with element SP.2311 (2), fit the
new valve guides (3) previously lubricated with engine oil.
Driving force 10 ÷ 25 KN.
If the above mentioned tools are not available, fit the valve
guides by positioning them in the cylinder head according to
the value shown in SENZA CODICE.
Boring valve guides
Figure 187
87800
MAIN DATA OF VALVE GUIDES — SEATS

Valve guide seat inside ∅ 9.980 ÷ 10.000 mm
Valve guide outside ∅ 10.028 ÷ 10.039 mm 88335
* Measurement to be made after driving in the valve guides. After driving in the valve guides (2), regrind them with the
smoother SP.2310 (1).

540661 VALVE SEATS

Recutting and replacing valve seats
Figure 188
87801
INTAKE VALVE EXHAUST VALVE
Check the valve seats. On finding any slight scoring or burns, Mount the valves, block the seat of the electro-injectors and
regrind them with an appropriate tool according to the glow plugs; using a suitable tool, check the seal of the
angles given in Figure 188. valves/seats.
Having to replace them, with the same tool and taking care
not to affect the cylinder head, remove as much material
from the valve seats as possible until, with a punch, it is Figure 190
possible to extract them from the cylinder head.
Heat the cylinder head to 80 ÷ 100°C and, using a suitable
drift, fit in it the new valve seats, previously chilled in liquid
nitrogen.
Using a specific tool, regrind the valve seats according to the
angles given in Figure 188.
Figure 189
88337
Using a dial gauge (1), check that, from the plane of the
cylinder head, the valve recessing (2) and the protrusion of
the injector (3) and of the glow plug have the prescribed
value:
- Valve recessing: 0.375 ÷ 0.525 mm.
88336
- Injector protrusion: 2.77 ÷ 3.23 mm.
Using the milling cutter 99394038 (1), clean the injector seat - Glow plug protrusion: 3.78 mm.
of any deposits.

540665 VALVE SPRINGS ROCKER ARMS — TAPPETS

62386
Before assembly, check the flexibility of the valve springs with

the tool 99305047. Compare the load and elastic
deformation data with those of the new springs given in the
following figures. 75461
COMPLETE ROCKER ARM ASSEMBLY

Figure 192 The rocker arm assembly is composed of the rocker arm (1),
hydraulic tappet (3), made integral with each other by the clip
(2).
Figure 194
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST

VALVE SPRINGS
Height Under a load of

mm kg 75942
H 54 Free
H1 45 P 243 ±12 CROSS-SECTION OF THE HYDRAULIC TAPPET
H2 35 P1 533 ±24 A = 32.44 ±0.3, end of stroke
B = 31.30, working position
C = 29.75 ±0.25, start of stroke

Figure 195
87802
MAIN DATA HYDRAULIC TAPPETS — SEATS
Checks Figure 197

The sliding surface of the tappets must have no scoring/dents;
replace them if they do.
Using a micrometer, measure the diameter of the tappets
and, using a bore meter, measure the diameter of the seats
in the cylinder head; the difference in the measurements will
give the assembly clearance.
ASSEMBLING CYLINDER HEADS
Figure 196
75587
Position the springs (8) and plates (7) on the cylinder head
(5).
Fit the part (4) of tool 99360260 onto the cylinder head (5)
and secure it with the screws (3).
Fit the part (2) of tool 99360260 onto part (4), screw down
the nut (1) so that by compressing the springs (8) it is possible
to insert the retaining cotters (6); then unscrew the nut (1)
checking that the cotters (6) have settled in correctly.
87803
Lubricate the stem of the valves (1) and insert them into the
associated valve guides (4) according to the position marked
during removal. Using tool SP.2264 (2), mount the oil seals
(3) on the valve guides (4).
NOTE The suction valves (5) are different from the

exhaust ones for a slot (→) in the centre of the
valve head.

88340
108441
Remove the nuts (4) and the top skid (3).
Fit the thermostat casing (2) with a new seal and tighten the Remove the screws (1) and the shoulder plate (2).
fixing screws (3) to the prescribed torque.
Fit the temperature sensors (1) and tighten them to the
prescribed torque.
Fit the brackets for lifting the engine and tighten the fixing
screws to the prescribed torque.
Figure 201
540650 Overhead
Overhead removal
Figure 199
88341
Tilt the over-head (1) and take care not to damage the seats,
then take off the camshafts (2 and 3) from the overhead.
88339
Remove the screws (2 and 3) and the covers (1 and 4)

together with the over-head seal rings.

5412 TIMING SYSTEM

NOTE Both chains shall be replaced, even though the
Figure 202
anomaly affects only one chain: in this case, gears
(8-10), pads (7) and belt stretchers (3 and 5) shall
also be replaced (see figure 204).
Hydraulic belt stretcher (5) with anti-return device
shall be replaced every time it is disassembled. In
fact the belt stretcher cannot be assembled back
into place after the piston has come off the
hydraulic belt stretcher housing.
Figure 204
88055
1. Rocker arm - 2. Reaction hydraulic tappet -

3. Valve assembly - 4. Camshaft on exhaust side -
5. Camshaft on suction side - 6. Camshaft control chain.
Description
The timing system is the type with a twin camshaft in the head
and four valves per cylinder with hydraulic tappets.
The control is transmitted by two chains:
- a double chain by 3/8” is set in motion by the driving shaft
and sets the control shafts in motion: oil pump/depressor
— high pressure pump;
- a single chain is set in motion by the high pressure control
shaft gear and sets the camshafts in motion.
The camshaft gears are mutually interchangeable and are
fitted with slots to make it possible for the phase sensor to
detect the phase.
The rocker arms, one for the valve, are kept in contact with
the corresponding cam by an hydraulic tappet, thus
eliminating the need for regular adjustments.
Figure 203
108432
TIMING SYSTEM AND AUXILIARY SYSTEM DIAGRAM

1. Camshaft control gear - 2. Single chain - 3. Hydraulic
chain stretcher with anti-return device - 4. Chain -
HYDRAULIC BELT STRETCHER 5. Hydraulic belt stretcher - 6. Drive gear on driving shaft -
WITH ANTI-RETURN DEVICE 7. Fixed skid - 8. Oil pump/depressor control shaft gear —
A = Max. range: 76.9 ± 0.4 mm Hydraulic power steering pump - 9. Double chain -
B = Piston engaged: 53.6 mm 10. High pressure pump control shaft gear.
C = Min. travel for piston disengagement: 2.3 mm
D = Working travel: 24.5 mm

Figure 205 541211 Checking cam lift and pin alignment
Figure 207
87806
Place the shaft (1) on the parallels and use a centesimal dial
gauge fitted on the central support to check that the
87804 alignment error does not exceed 0.04 mm; otherwise,
change the shaft. Check also the cam lift: it must correspond
to the prescribed value; if different values are detected,
TIMING SYSTEM DIAGRAM change the shaft.
541210 Camshaft
Checks
The surfaces of the shaft supporting pins and of the cams
must be finely honed; if there is any sign of meshing or scoring,
replace the shaft.
Figure 206
75474
Using a micrometer (1), measure the diameter of the pins (2)

of the camshaft and, using a bore meter, measure the
diameter of the supporting seats in the overhead.
The difference between these two measurements gives the
existing clearance.
The nominal assembly clearance is 0.037 ÷ 0.088 mm.

Figure 208
87807
MAIN DATA, CAMSHAFT PINS AND SEATS
1. Intake valve camshaft seats — 2. Exhaust valve camshaft seats — 3. Intake valve camshaft — 4. Exhaust valve camshaft.
NOTE The camshaft (3) of the suction valves can be recognised through the spring cup (4) and the dowel (6).

Assembling overhead
88343 88340
Lubricate the new seal rings (1) with engine oil and fit them Fit the top skid (3) and drive in the nuts (4), then tighten them
on the covers (2). to the prescribed torque.
Fit the covers (2) on the overhead, drive in the fastening Fit the shoulder plate (2) and drive in the screws (1), then
screws (3) and tighten them to the prescribed torque. tighten them to the prescribed torque.
Figure 212
Figure 210
88346
Position the camshafts (3 and 4) so that the pins 99360614

(1) can be inserted in the camshaft slots (2) through the
88344
over-head threaded holes.
Lubricate the support pins of the suction camshafts (2) and
exhaust camshafts (4) and fit them on the overhead (1). AUXILIARY ORGAN CONTROLS
Figure 213
NOTE During this operation do not exchange the

assembly position of the shafts.
The suction camshaft can be recognised (2)
through the dowel (3) on the front side and the
retainer on the rear side.
In addition, take care not to damage the support
seats of the over-head shafts.
88347
Rotate the driving shaft so that the tool 99360615 (1) can be
inserted in the shaft crank hole through the cylinder block
hole, in order to stop the engine in the timing system setting
condition.

88348 88278
Lubricate the seal rings (1 and 2) with engine oil and fit them Fit the gear (1) on the stem (3) of the hydraulic power
on the support (3). steering pump.
Drive in the screw (2) without locking it.
88279 88349
Fit the support (1) and drive in the nuts (2), then tighten them Lubricate the new seal rings (1 and 2) with engine oil and fit
to the prescribed torque. them on the support (3).
Fit the stem (3).
88277 88276
Stop the stem rotation (2) of the hydraulic power steering Fit the support (1), drive in the nuts (2) and tighten them to
pump by inserting in the latter the tool (3) and fastening the the prescribed torque.
tool on the support (1) by means of the screws (4). Fit the control stem (3) of the high pressure pump.

Figure 220 Cynder head refitting
Figure 223
88351
Position the chain (1) on the gears (2, 3 and 5) and fit the gear
88353
(3) on the stem (4) so that the chain (1) in tracts A and B is
tensioned. Check that the mating surfaces of the cylinder head and
Figure 221 Keep the cylinder head gasket clean.
Place the gasket (1) of the cylinder head with the thickness
given in section “Check piston protrusion”, with the “TOP”
sign facing the head.
NOTE It is essential to keep the gasket sealed in its package

until just before assembly.
Figure 224
88274
Fit the stem with the drive gear (2) on the high pressure
pump control stem (1).
Drive in the fastening screw (3).
Figure 222
88354
Mount the cylinder head (2).

Screw down the fixing screws (3) and tighten them, in three
successive stages, following the order and methods shown in
the following figure.
88352
Check the conditions of the fixed skids (1 and 3) and change NOTE The angle closure is done with tool 99395216 (1).
them if worn out.
Fit the skid (1) and drive in the fastening screws (2), then
Fit the skid (3) and drive in the fastening screws (4), then

88355
88357
Diagram of the tightening sequence for the cylinder head Mount the overhead (1) together with the tools 99360614
fixing screws: (3) for the timing and tighten the fixing screws (2) to the
prescribed torque.
Take out the tools SP. 2264 (4).
• screws 1-2-3-4-5-6 to a torque of 130 Nm;
• screws 7-8-9-10 to a torque of 65 Nm.
- 2nd phase: angle closing
• screws 1-2-3-4-5-6 90°;
• screws 7-8-9-10 90°.
• screws 1-2-3-4-5-6 90°;
• screws 7-8-9-10 60°.
- Screws A, to a torque of 25 Nm
TIMING SYSTEM CONTROL
88270
88356
Fit the top fixed skid (1). Drive in the screws (2 and 3) and
Thoroughly clean the hydraulic tappets (2), lubricate them and tighten them to the prescribed torque.
fit them in the cylinder head (3), positioning the rocker arms (1) Fit the rubber cap (4) of the new gasket and tighten it to the
on the valves correctly. prescribed torque.
Fit on the gasket (5).
Insert the two tools SP. 2264 (4) into the electro-injector seats
for subsequent centring of the overhead on the cylinder head.

88360
88358
Check the conditions of the mobile skids (1 and 3), if worn
Position the chain (1) on the gear (5) and gear (2). out change them.
Mount the gear in such a way that fitting on aspiration valve Position the mobile skids (1 and 3) and clamp them on the
timing system shaft dowel makes slots A to result to be cylinder block by the pin (2) and tighten it to the prescribed
positioned as in figure. torque.
Figure 232
NOTE The chain arm (1) between the two gears must be
tensioned.
Drive in the fastening screw (4) with the washer (3) without
tightening it completely.
Figure 230
88361
Drive in the chain hydraulic tightener (1) and lock it to the

prescribed torque.
Figure 233
88359
Position the chain (1) on the gear (2) and fit the latter on the
camshaft of the exhaust valves.
Drive in the fastening screw (4) with the washer (3) without
tightening it completely.
88362
Tighten the fastening screw of the gear (1) on the hydraulic

power steering control stem to the prescribed torque.

90311
Stop the rotation of the high pressure pump control shaft (1)
by inserting the suitable wrench inside it.
88373
Figure 235 Make sure that the chain (3) in the tract between the gear
(2) and gear (4) is tensioned.
Tighten the fastening screw of the gear (2) on the exhaust
valve camshaft to the prescribed torque.
Remove tools 99360614 (1).
Figure 238
102127
NOTE Chain stretcher (1) cannot be re-used for any

reason after it has been disassembled. Moreover, in
the event that piston (1) has been unintentionally made to
escape from chain stretcher (2), the latter must be replaced.
Chain stretcher reconditioning is not permitted. 88370
Make sure that the chain (2) and the tract between the gear
Screw down hydraulic chain stretcher (2), then tighten it to (1) and gear (3) is tensioned.
the specified torque. Tighten the fastening screw of the stem with the drive gear
Insert, through the opening on the overhead, a suitable (1) on the high pressure pump control stem to the prescribed
screwdriver, then press on moving shoe (4) fin (3) until chain torque.
stretcher (2) piston (1) is pushed to its end of stroke.
Release moving shoe (4), and make sure that piston (1) Figure 239
causes, by escaping from its seat, chain (5) to be subjected
to tension.
Figure 236
88374
Fit a new gasket (5) in the cover (2).

Fit the cover (2), drive in the screws (1) and tighten them to
88372
Tighten the fastening screw of the gear (1) on the suction Fit the phase sensor (4).
valve camshaft to the prescribed torque. Drive in the fastening nut (3) and tighten it to the prescribed
torque.

Figure 240 Lubricate the tang of the driving shaft and the element
outside (2) and fit flush the new seal ring on this element (3).
Position the element (4) on element (2), lock the nut (5) until
fitting the seal ring (3) completely in the cover (1).
Figure 243
88375
Position the joint (5) in the gear (6).

Fit the oil pump/depressor unit (4) by inserting a new gasket
(1).
Drive in the screws (2) and tighten them to the prescribed
torque.
Remove tool 99360615 (2).
Figure 241
90156
Mount tool 99396030 (3), for centering cover (1), into

centrifugal filter seat and tighten screws (2) at prescribed
torque. Remove: 99346258 (4) and 99396039 (3) tools.
Figure 244
88376
Fit the cover (1) with a new gasket. Drive in the screws (2)
without tightening them completely.
Figure 242
107727
Fit a new centrifugal filter (1).

Fit a new snap ring (2).
Fit the cover (3), drive in the screws (4) and tighten them to
88377
Clean accurately the seat of the cover seal ring (1).

Drive in the element (2) of tool 99346258 in the driving shaft
tang.

108431
88378 Stop the rotation of water pump shaft (5) by means of an

Allen wrench (3) and a special lever. Screw down hub (1)
Stop the rotation of the engine flywheel (2) by means of tool
fastening nut (2). Use a suitable wrench (4) to tighten nut (2)
99360306 (1).
to the specified torque.
Fit the damper pulley (3). Drive in the screw (4) and tighten
it to the prescribed torque.
NOTE The nut (2) must be driven in anticlockwise (→)
because its threading is left-handed.
Figure 246
Figure 249
88379
Fit the water pump (2) with a new gasket.

Drive in the screws (1) and tighten them to the prescribed 107723
torque.
Drive in the oil level sensor (1) and tighten it to the
prescribed torque.
Figure 247 Fit the rev sensor (2), drive in the fastening screw (3) and
tighten it to the prescribed torque.
Figure 250
107725
Fit the electric magnet (3) of the cooling fan joint on the
water pump (6).
88260
Drive in the nuts (2) and tighten them to the prescribed
torque. Fit the support (2), drive in the screws (1) and tighten them
Secure the electric cable to retaining clip (1). to the prescribed torque.
Fit the pulley (4) and the hub (5).

544017 Replacement of alternator free Figure 253

wheel
Figure 251
88420
Fit the automatic backstand (1), drive in the screw (2) and
tighten it to the prescribed torque.
88419
The free wheel (2) function is to prevent that the engine

idling oscillations bounce back though the control belt on the
alternator (1). Figure 254
If it is necessary to change the free wheel (2), operate as
follows.
Remove the protection cap from the free wheel (2).
Apply tool 99358026 (3 and 4) as illustrated in the figure.
Stop the rotation of the free wheel (2) with the element (3)
and slacken the stem (5) of the alternator (1) with the
element (4).
Fit the new free wheel (2) by reversing the removal
operations. The free wheel (2) must be clamped on the stem
(5) by applying a max torque of 85 Nm.
88330
Figure 252 Operate the automatic backstand (2) with the suitable
wrench, fit the belt (1) and make sure the ribs are positioned
correctly in the respective pulley races.
Figure 255
107722
Fit the alternator (3) on the support (1), lock it with the bolt
(4) and the screw (2) and tighten them to the prescribed
torque.
88255
Fit the exhaust manifold (3) with a new gasket.

Fit the spacers (1), drive in the nuts (2) and tighten them to

107737
Fit rear cover (4) with a new gasket (2) back to cylinder head
88421
(1).
Fit the turbocharger (3) with the relevant gasket on the Screw down fastening screws (3) and tighten them to the
exhaust manifold (1). Drive in the nuts (2) and tighten them specified torque.
Connect the oil pipe (5) to the turbocharger (3) and the
Figure 259
cylinder head, and tighten the pipe unions (4 and 6) to the
prescribed torque.
Figure 257
107738
Fit coolant pipes (1 and 3) to rear cover (2) and heat

exchanger (4), and secure them with new clamps and collars.
107736
Figure 260
Fit heat exchanger (2), together with EGR valve (3), back to
the overhead, then tighten fastening screws (1) to the speci-
fied torque. Connect EGR valve (3) to pipe (6) with a new
collar (4), then tighten fastening screw (5) to the specified
torque.
107739
Connect pipe assembly (3) to water pump (4), then secure

the latter to supporting bracket (1) with screw (2), by
tightening the latter to the specified torque.

88423
107711
Remove the fastening screws (1) and remove tool 99360187
(2). Fit heat exchanger (2), complete with a new gasket, onto the
engine base.
Figure 262 Drive in the screws (1) and tighten them to the prescribed
torque.
Figure 265
107740
Position the joint (2) on the stem (3).
Slightly lubricate the seal ring (1) and fit it on the power
steering pump (5). 107710
Fit the power steering pump on the support (4).
Screw down fastening screws (7) complete with spacers (6) Connect the low pressure pipes (5) with the new gaskets to
the high pressure pump (2) and tighten the pipe unions (1
and tighten them to the specified torque.
and 3) to the prescribed torque.
Figure 263 Drive in the fastening screw (6) of the pipe (5) on the bracket
(4) and tighten it to the prescribed torque.
Figure 266
107741
Lubricate a new seal ring (3) and fit it on the high pressure 107742
pump (4). Lubricate a new seal ring (3), then fit it onto the pipe.
Position the joint (2) on the high pressure pump stem (4). Fit pipe (2) onto heat exchanger (4).
Fit the high pressure pump (4) on the support (1), drive in Screw down screws (1 and 5), then tighten them to the
the screws (5) complete with spacers (6) and tighten them specified torque.

75508
107745
Mount the glow plugs (1) and, using the box-type wrench SP.
2275 (2) and torque wrench 99389819 (3), tighten them to Fit a new seal (3) on the electro-injector (1) and mount this
a torque of 8 ÷ 10 Nm. in the overhead (2).
Figure 268
Figure 271
107743 107705
Fit the suction manifold (1) with a new gasket.

Drive in the screws (2) and tighten them to the prescribed Mount the brackets (3) fastening the electro-injectors (1)
torque. Fit the air temperature and pressure sensor (3). and screw down the screws (2) without locking them.
Drive in the screw (4) and tighten it to the prescribed torque.
Figure 272
Figure 269
107746
107744
Mount the hydraulic accumulator (1) and tighten the fixing
Fit throttle valve assembly (2), together with a new gasket, screws (2) to the prescribed torque.
onto inlet manifold (1). Fit the pressure sensor (3) on the hydraulic accumulator (1)
Screw down fastening screws (3), then tighten them to the and tighten it to the prescribed torque.
specified torque.

107747
107749
Connect the fuel pipes (2) to the electro-injectors (3) and to
the hydraulic accumulator (1). Connect the fuel pipe (3) to the hydraulic accumulator (1)
Tighten the screws (4) fixing the electro-injector brackets (5) and to the high-pressure pump (8).
to the prescribed torque. Tighten the couplings (2 and 5) using a wrench (7) in the
99317915 series and the torque wrench 99389829 (6).
NOTE Whenever they get removed, the fuel pipes must NOTE Whenever they get removed, the fuel pipes (3)
be replaced with new ones. must be replaced with new ones.
Fasten the pipe (3) on the support bracket with the bolt (4)
tightened to the prescribed torque.
107748 107703
Using the wrench (2) of the 99317915 series and the torque Press clamps (3) in the direction shown by the arrow, then
wrench 99389829 (1), tighten the fuel pipe fittings (3) and (4) disconnect the connections of fuel recovery pipe (1) to
to the prescribed torque. electric injectors (2).

Figure 277
NOTE To fit the air-conditioner compressor elastic drive
belt into place, tool 99360191 (2) must be used.
Any other tool or method may cause dangerous
tension to the elastic belt.
Fit the flexible belt (3) equipped with tool 99360191 (2) on
the pulley (4) and apply the tool on the pulley (1).
Turn the drive shaft counterclockwise (⇒) until the belt fits
perfectly on the pulley (1).
107709
NOTE The elastic belt shall be replaced with a new one
Lubricate the seal ring of the oil filter (2) with engine oil and every time it is disassembled.
fasten it on the heat exchanger (3). Use tool 99360076 (1)
to tighten the oil filter to the prescribed torque.
Figure 278
Figure 280
88252
If present, fit the support (3), drive in the screws (4) and
Fit the fixed backstand (2), drive in the screw (1) and tighten
it to the prescribed torque.
107750
Fit the pipe (4) of the oil level dip rod and fasten the support
bracket on the cylinder head by tightening the screw (3) to
Figure 279 the prescribed torque.
Fit cooling fan (1), if any, back to electromagnetic joint (2).
90650
Fit the air-conditioner compressor (if any) into place, then
tighten the fastening screws to the specified torque and fit
elastic belt (4) into place, as described below.

Figure 281
107702
Fit the items below, if any, into place: Figure 282

- engine cable, by connecting the electric connections of
the same to:
- inlet manifold air pressure/temperature sensor (8);
- high-pressure pump pressure regulator (10);
- phase sensor (2);
- thermostat coolant temperature sensor (9).
- channelling duct (6);
- upper sound-proofing cover (if any);
- fill the engine with lubricating oil of the prescribed grade
107701
and amount.
Fit the swing bar to the engine lifting hooks, then secure the Complete engine assembly.
swing bar to the hoist and take the engine off rotary stand Fit on the left and right engine mountings (3) and tighten the
(12). Take off brackets 99361041 (11). fixing screws to the prescribed torque.
Connect the oil pipe (2) to the turbocharger (1) and to the
crankcase and tighten the fixing screws and the coupling of
the oil pipe (2) to the prescribed torque.

5450 LUBRICATION Figure 283

General
The engine is lubricated by forced circulation performed by the

following parts:
- a gear oil pump with built-in depressor (GPOD);
- a pressure relief valve integrated in the oil pump;
- a heat exchanger made up of five elements;
- A double filtration oil filter with built-in safety valve.
Operation (see Figure 283)
Engine oil is drawn up from the sump by the oil pump via
the suction strainer and delivered under pressure to the
heat exchanger where it is cooled.
The oil continues through the oil filter and goes to lubricate
the relevant parts through ducts or pipes.
At the end of the lubrication cycle, the oil returns to the
sump by gravity. The oil filter can be excluded by the safety
valve built into it if it gets clogged.
In addition, the lubricating oil feeds the chain hydraulic
tightening devices for the control of the auxiliary elements
and the timing system and the hydraulic tappet.
Oil under pressure
Oil in freefall
Coolant
A. Pressure regulating valve closed - B. Pressure regulating valve open - C. Oil pressure switch
107751


OIL PUMP/DEPRESSOR UNIT 503010 Oil pump
Characteristic data
Figure 284 transmission ratio 1
displacement 23.52 cm3
pumping diameter 49.5 mm
number of teeth 7
height 16 mm
oil pump minimum speed 780 rpm
oil pump max. speed 3500 rpm
oil pump over-revs 4200 rpm
oil pump forced over-revs 4900 rpm
speed 3500 rpm
torque - Nm
power draw (calc.) - W
Oil temperature: 100°C — closed recirculation —

max. outlet pressure 5 bars
88625
engine speed rpm
capacity (l/min)
1. Oil pump - 2. Oil pressure adjusting valve - (oil pump speed — rpm)
3. Depressor.
780 (862)
3500 (4485) -
NOTE Should the unit be faulty, not due to the oil
pressure adjusting valve, change the whole unit.
Figure 286
Figure 285
88690
SECTION B-B
Figure 287
88689
SECTIONS OF OIL PUMP/DEPRESSOR UNIT

1. Oil input pipe from cylinder block - 2. Oil suction pipe -
3. Oil pressure adjusting valve - 4. Oil delivery pipe -
5. Depressor air suction pipe - 6. Depressor oil suction pipe.
88691
SECTION A-A

Vacuum pump Figure 289

The vacuum pump (2, Figure 284), with radial blades, is also
incorporated in the GPOD (1, Figure 285). It is driven directly
by the oil pump.
transmission ratio 1
displacement 150 cm3
volume to drain 4.5 litres
chamber diameter 65 mm
rotor diameter 45.5 mm
cam 7.5 mm
number of blades 3
height 34 mm
vacuum pump minimum speed 780 rpm
vacuum pump max. speed 3500 rpm
vacuum pump over-revs 4200 rpm
vacuum pump forced over-revs 4900 rpm 88627
theoretical flow rate at minimum (air) - l/min
Oil pressure adjusting valve open
actual flow rate at minimum (air) —
at atmospheric pressure - l/min If in pipe C the oil pressure is equal or above 4.4 bar, the valve
Theoretical speed at max. speed — (air) - l/min (1), as a result of the pressure itself, wins through the spring
Actual flow rate at max. speed — (air) reaction (2) and goes down, thus opening communication
at atmospheric pressure - l/min between the delivery pipe A and the suction pipe B, through
draining holes D-E, and therefore the pressure drops.
measured power draw (maximum) When the pressure falls below 4.4 bar, the spring (2) takes
speed 3500 rpm the valve (1) to the initial position of closed valve.
torque - Nm
power draw (calc.) - W
Oil temperature: 100°C — engine speed 780 rpm

(pump speed 994 rpm) Disassembly
tank vacuum
0,5 0,8 Figure 290
(litres) (bar)
4,5 4,5 12,5
9 9,5 26,0
543475 Oil pressure adjusting valve
Figure 288
88058
Use the suitable wrench to remove the oil pressure adjusting

valve (1) from the oil pump.
88626
1. Valve - 2. Spring - A. Oil inlet duct from the sump -

B. Oil supply duct to the crankcase - C. Oil return duct
from the crankcase - D. Oil drainage port
Pressure at opening start: 4.4 bar
Description of oil pressure adjusting valve closed
If in pipe C the oil pressure is below 4.4 bar, the valve (1)
closes the holes D - E.

Figure 291 543070 Oil filter

Figure 293
88059
PARTS COMPRISING THE OIL PRESSURE

CONTROL VALVE
1. Split ring — 2. Valve — 3. Spring — 4. Valve casing.
88061
Use the suitable pliers to remove the snap ring (1), take off Oil filter with built in by-pass valve — differential opening
the valve (4) and the spring (3) from the valve body (2). pressure 2.5 ± 0.2 bar.
88060
MAIN DATA OF THE OIL PRESSURE CONTROL

VALVE SPRING
107752
HEAT EXCHANGER COMPONENT DETAILS
1. Heat exchanger made up of five elements - 2. Gasket -
Assembly 3. Box - 4. Pipe union - 5. Screw - 6. Oil filter support -
For refitting, reverse the removal operations. 7. Oil pressure switch - 8. Screw - 9. Heat exchanger box -
10. Gasket.
Disassembly
Remove the screws (5) and take off the heat exchanger (1)
from the box (3) with the gasket (8).
Remove the screws (7) and take off the oil filter support (6)
from the box (3).
Assembly
For refitting, reverse the removal operations and observe the
following warnings.
Clean accurately the heat exchanger (1).
Always change the gaskets (2, 9 and 8). Apply LOCTITE 577
on the threading of the pipe union (4) (if removed), drive it
in the support (1) and tighten it to the prescribed torque.
Tighten the screws to the prescribed torque.

88685
Figure 296 88687
Figure 298
88686 88688
HEAT EXCHANGER SECTIONS

Oil flow from heat exchanger to oil filter
Oil flow from oil filter to cylinder block
Oil flow from cylinder block to heat exchanger

Print 603.43.671
540480 Oil vapour recirculation (Blow-by) Figure 299

Part of the gas produced by the combustion during the
engine operation blows by the piston snap ring ports, in the
oil sump, and mixes with the oil vapours present in the oil
sump. This mixture, conveyed from the chain compartment
to the top, is partially separated from the oil by means of a
device situated on the top side of the distribution cover and
is introduced in the air suction system. This device consists
mainly of a rotating filter (3), fit flush on the stem (1), a high
pressure/shaft control and a cover (2) where the valves (4
and 5), usually closed, are fitted. The diaphragm valve (4)
regulates the partially purified mixture and keeps the pressure
inside the chain compartment around a value of ~ 10 ÷ 15
mbar.
The umbrella valve (5) discharges some of the oil still present
in the mixture coming from the filter (3) in the chain
compartment and the oil condenses in the chamber (6).
Operation
The mixture which passes through the rotating filter (3) is
partially purified from the oil particles, as a result of
centrifugation, and so these particles condense on the cover
walls to return to the lubrication circuit. The resulting purified
mixture is let in through the stem holes (1) and the
diaphragm valve consensus (4) inside the air vent upstream
of the turbocharger. The opening/closing of the valve (4)
depends mainly in the ratio between the pressure operating
the diaphragm (4) and the depression below it. The oil still
present in the mixture coming from the rotating filter (3) and
which condenses in the chamber (6) is drained into the chain
compartment through the umbrella valve (5), when the
pressure that keeps it closed drops as a result of the engine
stop.
Gas with oil level above 10 g/h

Gas with oil level ~ 0,2 g/h
Condensed oil returning to the oil sump
88062

5432 COOLING Figure 300

Description
The engine cooling system is the type with forced circulation
in a closed circuit. It comprises the following parts:
- An expansion tank whose plug has two valves
incorporated in it: an outlet and an inlet, which govern
the pressure of the system.
- A coolant level sensor at the base of the expansion tank.
- A pressure switch (3), of normally closed type (calibrated
at 0.4 bar, absolute pressure 1.4 bar), located on
expansion tank and connected to EDC central unit,
protects engine against overheating caused by cooling
system failure. Where coolant temperature exceeds a
certain threshold and pressure inside expansion tank is
lower than 0.4 bar, EDC central unit reduces engine
performance by changing fuel flow rate (De-rating) until
engine goes off.
- An engine cooling module to dissipate the heat taken
from the engine by the coolant with a heat exchanger
for the intercooler.
- A heat exchanger to cool the lubricating oil.
- A centrifugal water pump incorporated in the crankcase.
- An electric fan comprising an electromagnetic coupling
on whose shaft a hub turns idle that is fitted with an
axially mobile metal plate on which is mounted the
impeller.
- A 3-way thermostat governing the circulation of the
coolant.
Operation
The water pump driven by a poly-V belt by the crankshaft
sends coolant into the crankcase and with a greater head into
the cylinder head.
When the coolant temperature reaches and exceeds the
working temperature, it causes the thermostat to open and
the fluid is channelled from here to the radiator and cooled
by the fan.
The pressure in the system due to the change in temperature
is governed by the outlet (2) and inlet (1) valves incorporated
in the expansion tank filler plug (detail A).
The outlet valve (2) has a twofold function:
- to keep the system slightly pressurized so as to raise the
boiling point of the coolant;
- to discharge into the atmosphere the excess pressure
produced in case of high coolant temperatures.
The function of the inlet valve (1) is to permit transferring the
coolant from the expansion tank to the radiator when a
lower pressure is created in the system due to the reduction
in volume of the coolant as a result of its temperature
lowering.
Outlet valve opening 1 ± 0.1 kg/cm2.
Inlet valve opening 0.005 — 0.02 kg/cm2.
107753

543212 Electromagnetic pulley 543210 Water pump

The water pump cannot be overhauled. In case of coolant
Figure 301 leaking from the seal or damage, it must be replaced.
Figure 302
107755
LONGITUDINAL CROSS-SECTION OF THE

WATER PUMP
1. Pump casing — 2. Pump drive shaft together with
bearing — 3. Seal — 4. Impeller.
107754
CROSS-SECTION OF THE ELECTROMAGNETIC JOINT
Characteristics
Transmissible torque at 20°C with clutch run in 85 Nm
Voltage 12 Volts 543250 Thermostat
Power input at 20°C 48 W
The electric fan control relay is activated or deactivated Figure 303
according to the temperatures of: the engine coolant, the fuel
supercharging air and the pressure of the air conditioner fluid
(if present).
Turbocharging air temperature

Coolant temperature (if the sensor is not defective)
Fuel temperatures 107756

(if the coolant temperature sensor is acknowledged to be
defective by the EDC control unit)
It activates at > 20°C and deactivates at < 10°C. The by-pass thermostat (1) needs no adjustment.
If there is any doubt about its operation, replace it.
The thermostat casing is fitted with the thermometric
With climate control system switch/transmitter and water temperature sensor.
With pressure in the system Valve travel at 79 + 2 5C = 0.1 mm
it turns on 18.5 ± 0.98 bar
it turns off 14.58 ± 0.98 bar Valve travel at 94 + 2 5C, min. 7 mm

TURBOCHARGING
Figure 304
107757
HOT AIR AT ATMOSPHERIC TEMPERATURE

HOT COMPRESSED AIR
COLD COMPRESSED AIR
EXHAUST GAS
COLD EXHAUST GAS
TURBOCHARGING DIAGRAM
Description The function of the turbocharger is to use the energy of the

The turbocharging system comprises an air filter, engine’s exhaust gas to send pressurized air to the cylinders.
turbocharger and intercooler. The intercooler comprises a radiator included in the engine
The air filter is the dry type comprising a filtering cartridge to coolant radiator and its function is to lower the temperature
be periodically replaced. of the air leaving the turbocharger to send it to the cylinders.

542410 Turbocharger type MITSUBISHI TD 4 HL-13T - 6

Figure 305
88620
A. THROTTLE VALVE SHUT B. THROTTLE VALVE OPEN
Figure 306
88621
The turbocharger installed on the engine F1C AE0481 F (146 - a pressure relief valve applied on the turbine body. Its
CV) is fitted with pressure relief valve (waste-gate). function is to choke the output of the exhaust gases
It is basically composed of: (detail B) and send part of them directly into the exhaust
pipe, when the supercharging pressure downstream of
- a central casing housing a shaft supported by bushings at
the turbocharger is above the rated valued;
whose opposite ends are fitted the turbine wheel and
the compressor rotor;
- a turbine casing and a compressor casing mounted on
the end of the central body;

REPAIRS
Figure 308
NOTE On finding irregular engine operation due to the
turbocharging system, it is first expedient to
perform the checks on the turbocharger, check the
efficiency of the seals and the fixing of the couplings,
additionally checking there is no clogging in the
intake sleeves, air filter or radiators. If the
turbocharger damage is due to a lack of lubrication,
check that the oil circulation pipes are not burst or
clogged, in which case replace them or eliminate
the trouble.
88623
Rest the tip of the dial gauge (1) with a magnetic base on the
end of the tie rod (2) and zero it. Using the device 99367121
(3), introduce compressed air into the valve casing (4) at the
prescribed pressure and make sure this value stays constant
throughout the check; replace the valve if it doesn’t. In the
above conditions, the tie rod must have made the prescribed
542418 Pressure relief valve travel.
Pressure-relief valve check
Figure 307
88622
Cover the air, exhaust gas and lubricating oil inlets and
outlets. Thoroughly clean the outside of the turbocharger
using anticorrosive and antioxidant fluid. Disconnect the pipe
(2) from the union of the pressure relief valve (1) and fit on
it the pipe of the device 99367121 (3, SENZA CODICE).

542410 GARRET GT 2260 V variable Figure 310

geometry turbosupercharger
General
The variable geometry turbosupercharger consists of the
following:
- centrifugal supercharger (1);
- turbine (2);
- set of mobile blades (3);
- mobile blade control pneumatic actuator (4), vacuum
controlled by proportional solenoid valve controlled by
EDC 16 ECU.
Variable geometry enables:
- to increase the speed of the exhaust gases running into
the turbine at low engine rpm;
- to decrease the speed of the exhaust gases running into
the turbine at high engine rpm. 82871
To obtain the max. engine volumetric efficiency also at low
rpm (with on-load engine).
Operation at low engine rpm Operation at high engine rpm

62870 62872
1. TURBINE - 2. MOBILE BLADES - 3. PNEUMATIC ACTUATOR - 4. REVOLVING RING

When engine is running at low speed, the exhaust gases The ECU, through the actuator control solenoid valve,
show weak kinetic energy; under these conditions a modulates the vacuum acting on the diaphragm, so actuator
traditional turbine shall rotate slowly, thus providing a limited (3) controls through the tie rod, the gradual opening of the
booster pressure. mobile blades (2) until reaching the max. open position.
In the variable geometry turbine (1), the mobile blades (2) are Blade through-sections results larger thus producing a speed
set to max. closed position and the small through-sections decrease in exhaust gas flow through the turbine (1) with
between the blades increase the inlet gas speed. Higher inlet speeds equal to or lower than those of the low rpm
speeds involve higher tip speeds of the turbine and therefore condition.
of the turbosupercharger. Turbine (1) speed is therefore adjusted to a proper value
Engine speed increase results in a gradual increase of exhaust enabling suitable engine operation at high speeds.
gas kinetic energy, and also in turbine (1) speed and booster
pressure increase.

Proportional solenoid valve controlling Actuator

turbocharger actuator
Figure 314
Figure 312
62875
SECTION ON THE ACTUATOR
62876
The solenoid valve modulates the low pressure controlling The actuator diaphragm, connected to the control rod, is
the turbocharger actuator, taken from the air circuit of the governed by the low pressure on the top of the actuator.
servo brake, according to the information exchanged
The low pressure modulated by the proportional solenoid
between the electronic control unit and the sensors: engine
valve varies the movement of the diaphragm and, as a result,
speed, throttle pedal position and pressure/temperature
of the rod governing the turbine’s mobile blades.
fitted on the intake manifold.
As a result, the actuator varies the opening of the blades of
the turbocharger that adjust the flow of exhaust gases.
Figure 313
62869
TURBOCHARGING FUNCTIONAL DIAGRAM

1. Variable geometry turbocharger - 2. Pneumatic actuator - 3. Proportional solenoid valve - 4. Air filter -
5. EDC 16 control unit - 6. Servo brake - 7. Vacuum device - 8. High-pressure pump.

REPAIRS
Operate the vacuum pump and check whether the tie rod
542451 Checking and adjusting the actuator (3) stroke values correspond to the vacuum values shown in
the following table:
- vacuum 0 mm Hg Fully open valve
NOTE NOT ALLOWED ARE: - vacuum 0,2 bar Valve stroke 0,5 ÷ 2,5 mm
- any replacement or regulation of the - vacuum 0,64 bar Valve stroke 9,5 ÷ 11,5 mm
actuator, since the calibration of such
component is made in an optimal way Where a different value is found, replace turbocharger.
for each turbocharger and is
guaranteed for the turbocharger;
- any operation on nut (5) and ring nut
(4), since such operation does not NOTE During the check the vacuum value shall not fall,
change engine supply characteristics otherwise the actuator shall be replaced.
but may impair engine reliability and
duration.
Ring nut (4) is sealed with antitempering
yellow paint.
In case of engines under guarantee, each
above specified intervention and/or
alteration to paint applied on ring nut (4)
causes the lapse of the guarantee.
Figure 315
62873
Cover air, exhaust gas and lubricant inlets and outlets.

Clean the turbosupercharger outside accurately using
anticorrosive and antioxidant fluid and check the actuator
(6).
Clamp the turbosupercharger in a vice.
Apply vacuometer 99367121 (1) pipe to actuator (6) hose.
Apply the magnetic base gauge (2) to exhaust gas inlet flange
in the turbine.
Set gauge (2) feeler pin on tie rod (3) end and set gauge (2)
to zero.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 316
112220
a. Servo brake vacuum circuit - b. E.G.R. modulated vacuum circuit -

c. V.G.T. modulated vacuum circuit
1. Electronic control unit - 2. Throttle valve assembly - 3. Vacuum connector - 4. Water temperature sensor -
5. Engine revs sensor - 6. E.G.R. pneumatic valve - 7. Air flow meter - 8. Inlet air filter - 9. EGR modulating solenoid valve -
10. VGT actuator modulating solenoid valve (if any) - 11. Auxiliary vacuum tank (vehicles equipped with 176 HP engines) -
12. Vacuum servo brake - 13. Vacuum tank
Operating Thus, the exhaust gas, passing through the heat exchanger
The E.D.C. electronic control unit E.D.C. processes the where it is cooled, will be conveyed into the throttle valve
information from the atmospheric pressure sensor, water assembly chamber where it will be mixed with the air from
temperature sensor, engine revs sensor and accelerator the intercooler and made to flow out into the inlet manifold.
pedal potentiometer. It drives, according to ways and If the vehicle is equipped with the D.P.F. catalyst, the EDC
procedures properly programmed within its own memory, control unit 16 will simultaneously adapt the flow rate of fuel
both the modulating solenoid valve and the throttle valve by to be injected into the cylinders, depending on the amount
means of a PWM signal. of circulated exhaust gas.
The modulating solenoid valve will, every time is it driver by During the engine operating phases not requiring gas
the E.D.C. control unit 16, communicate the servo brake circulation (e.g. particulate filter regeneration, start-up,
vacuum circuit with the E.G.R. one. A vacuum value will be engine cold, idle running, load demands, vehicle running at
obtained within the EGR circuit, depending on the control high altitudes), the control unit control signal to the
signal. modulating solenoid valve will be cancelled. The solenoid
Such vacuum will act on the E.G.R. pneumatic valve valve will close the connection between the servo brake
membrane, by withdrawing and lifting the shutter that vacuum circuit and the E.G.R. one, and will simultaneously
normally obstructs the passage of the exhaust gas towards resume the atmospheric pressure within the E.G.R. circuit.
the intake.

Main system components 772652 Air flow rate meter (flow meter)
Figure 319
540744 E.G.R. valve
Figure 317
105060
1. Connector - 2. Flow meter body - 3. Recirculated oil

vapours air inlet grid - 4. Power supply - 5. Earth - 6. Inlet
105059
The E.G.R. valve is fitted to the heat exchanger end. The air flow meter is of the hot-film type and is placed
To ensure optimum valve efficiency and service life, the valve between the turboblower and the intercooler.
is cooled by the engine coolant flowing out of the heat The air flow meter incorporates the sucked air temperature
exchanger. sensor.
The amount of circulating gas is controlled by means of a
mushroom valve pneumatically controlled through the NOTE The air flow meter body bears an arrow which
vacuum drawn, by means of a calibrated-section connector, indicates the air flow and, therefore, the correct
from the pipe connecting the vacuum pump with the servo assembling of the meter on the vehicle.
brake.
The control vacuum modulated by the solenoid valve will
overcome the force generated by counter spring (1) and will
lift membrane (2) connected with shutter (3) which will Operating
move upwards and allow burnt gas to circulate towards the The operating principle is based on a heated membrane put
inlet manifold. in a measuring channel through which the intake air directed
to the engine flows.
540746 Modulator solenoid valve The hot-film membrane is kept at a steady temperature
Figure 318 (approximately 1205C higher than the incoming air
temperature) by the heating resistor.
The air mass flowing through the measuring channel tends
to take heat away from the membrane; therefore, the current
shall go through the resistor in order for the membrane to
be kept at a steady temperature.
The absorbed current is proportional to the air mass flowing
to the engine. It can be measured by means of a Wheatstone
bridge, and the signal obtained will be sent to the electronic
control unit.
If the vehicle is equipped with a D.P.F. catalyst, the control
unit program will feature a function capable of correcting the
flow rate meter deviation in time. The control unit will, during
vehicle deceleration with the pedal released (overrun), carry
out a few checks, thus determining correction factors for the
flow rate meter readings (self-adapting process). The
112333 replacement of the flow rate meter will therefore involve a
self-correction process.
The modulating solenoid valve is an integral part to the If the control unit is replaced, the flow rate meter correction
vacuum pipes for the E.G.R. system and the servo brake. coefficients (ZFC) stored in the old control unit shall be
A proportional solenoid valve modulates the E.G.R. valve copied and entered into the new control unit. If this is not
control vacuum depending on the PWM signal generated by possible, they shall be reset, and the self-learning process shall
EDC control unit 16. be initiated.


In the event that the throttle valve gets stuck, the control unit
Figure 320
will reduce the engine performance to avoid possible damage
to the engine itself.
When the engine is switched off, the throttle valve will closet
o reduce the engine noise during this phase.

Figure 321
108399
1. Throttle valve - 2. Electric actuator - 3. Throttle position

signal - 4. Ground - 5. Voltage - 6. PWM signal
The throttle valve (N.O.) assembly, fitted on the inlet mani-
fold, controls the amount of air from the intercooler, to be 107949
mixed with the exhaust gas made to circulate by the E.G.R.
valve, according to a programmed percentage. The heat exchanger fitted between the turboblower and the
The circulated exhaust gas will be mixed with the air from the throttle valve assembly is used to lower the exhaust gas
temperature in order to accordingly reduce the volume of
intercooler within a duct obtained in the cylinder head.
the same.
The throttle valve is operated by an electric actuator control- It consists of a body that incorporates a number of
led by a PWM signal from EDC control unit 16. corrugated pipes. The circulated exhaust gas flowing through
the pipes are cooled by the engine coolant flowing inside the
body.
Figure 322

Engine coolant 107948
Hot exhaust gasses

Circulated exhaust gas/air mixture
EXHAUST GAS COOLING SCHEME

A. Intake exhaust gasses - B. Cooled exhaust gasses - C. Coolant to heater -
D. E.G.R. valve exhaust gasses - E. Coolant incoming from cylinder head - F. Air from intercooler

EXHAUST SYSTEM REMOVAL-REFITTING
Figure 323
Exhaust gasses
Under-pressure tube 108419
1. E.G.R. heat exchanger - 2. E.G.R. valve - 3. Engine coolant temperature sensor - 4. Engine revs sensor -
5. E.G.R. modulating solenoid valve - 6. V.G.I. modulating solenoid valve - 7. Vacuum tank (only vehicles equipped with 176
HP engines) - 8. Air filter - 9. Air flow rate meter (air flow meter) - 10. VGT actuator (176 HP engine) - 11. Oil vapour
circulating pipe - 12. Differential pressure sensor (delta p) - 13. Incoming exhaust gas temperature sensor - 14. Outgoing
exhaust gas temperature sensor - 15. DPF catalytic silencer - 16. Vacuum tank - 17. Vacuum pump connector -
18. EDC control unit 16 - 19. Servo brake - 20. Throttle valve assembly - 21. Air pressure/temperature sensor.
General
To keep the exhaust emission levels of pollutants such as nitric oxides (NOx), hydrocarbons (HC) and particulate (PM) within
the limits established by the Euro 4 standard, the engine is equipped with an EGR system combined, where applicable, to the
DPF catalytic silencer for post-treatment of the aforesaid polluting substances.


Figure 324
105064

Description
and steam (H2O). On the contrary, if its temperature is lower, the filter is
Catalyst module is made up of a ceramic structure clogged, with negative effects, on counterpressure, on
impregnated with platinum, as platinum is a catalysing exhaust gasses generated by the filter.
compounds.
A differential pressure sensor (7), connected to D.P.F.

SYSTEM TO REDUCE POLLUTANTS AT EXHAUST

Figure 325
105065
1. E.G.R. valve - 2. Exhaust valve - 3. Differential pressure sensor - 4. Inlet exhaust gas temperature sensor -
5. Outlet exhaust gas temperature sensor - 6. D.P.F. catalysed silencer - 7. E.D.C. 16 central unit -
8. Piston - 9. Inlet valve - 10. Electrical injector - 11. Throttle valve
A. Post-injection - B. Exhaust gasses heated by post-injection - C. Catalyst - D. Particulate filter -
E. Purified exhaust gasses
Operation
Particulate filter regeneration is managed by engine E.D.C. 16 Exhaust gasses, so heated enter into the silencer, where,
central unit. The central unit, based on the temperature of passing through the catalyst, the pollutants they are
exhaust gasses detected by sensors (3 and 4) and particulate composed of (nitrogen oxides) are reduced or transformed
filter clogging grade detected by differential pressure sensor into inert substances (carbon dioxide - steam), then pass into
(3), when exhaust valve (2) is closing at about 1º÷3º from particulate filter where the regeneration process takes place:
T.D.C., causes electrical injectors (8) to inject small quantities exhaust gas high temperature causes the combustion of
of fuel into the cylinders. The combustion of this fuel particulate particles accumulated in the filter.
increases the temperature of flowing gasses. Particulate filter regeneration is realised when following
At the same time, the central unit shuts out: conditions are present:
- Throttle valve (11), to prevent, at opening start, air from - catalyst inlet exhaust gas temperature >230 ºC with the
entering through inlet valve (9), as air would cool help from post-injection;
exhaust gasses; - exhaust gas temperature in particulate filter >530 ºC with
- E.G.R. valve (1), to prevent recirculated oil vapours and presence of free oxygen having a percentage >8%;
gasses produced by post-injection from being sucked - minimum time of permanence in above conditions >10’.
into the cylinders.

Forced regeneration
In order that a regeneration can take place, following
conditions are necessary:
- exhaust gas temperature >530 ºC at particulate filter inlet
and free oxygen present (>8%);
- oxicat inlet gas temperature >230 ºC with the help from
post-injection;
- minimum time of permanence in such conditions
approximately >10 minutes.
In many cases of doubts about particulate filter cleanness
actual conditions and/or of impossibility to regenerate it
owing to very particular engine/vehicle running conditions
(persistent idling, very slow speeds and very frequent stops),
a safety forced regeneration has to be performed.
Independently of all parameters activating the regeneration,
the engine is taken to run without load to a point where
exhaust gasses have a temperature (>230 ºC) such as to
activate the reaction in the Oxicat in presence of
post-injection.
The only limit to this operation is the presence in the filter
of a particulate quantity that is in excess, being anyhow
calculated by the central unit and set as a condition to
regeneration startup.
Refilling engine oil

During vehicle use, the central unit counts post-injected fuel
quantity in order to activate and maintain particulate filter
regeneration.
A small quantity of this fuel, which is injected into the
cylinders after combustion has already taken place and
remains partially unburnt, leaks out through pistons spring
rings into oil sump, accumulating to lubrication oil. Although
a part of it, evaporating, will be burnt in the engine through
recirculation system, its remaining part can degrade oil
characteristics, impairing its functionality.
Quantity of accumulated fuel may increase in case of catalyst
or engine inefficiency, and vehicle use in conditions of low
temperature and/or small amounts of miles covered.
The central unit counts the amounts of post-injections and
consequently determines the quantity of fuel accumulated in
engine oil, and warns about refilling needed.
If, after refilling engine oil, the function is not reset, the central
unit will keep on counting fuel accumulation increase even
with new oil, with consequent engine oil refilling warning.

FUEL SUPPLY
HIGH-PRESSURE ELECTRONIC INJECTION Figure 326
SYSTEM (EDC 16)
General
The main characteristics of the high pressure electronic
injection system are:
- high injection pressures available (1600 bar);
- these pressures can be modulated between 150 bar up to
the maximum operating pressure of 1600 bar, irrespective
of the speed of rotation and engine load;
- capacity to operate at very high speeds (up to 6000 rpm);
- injection control precision (injection duration and
advance);
- lower consumption;
- lower emissions.
The main functions of the system are basically as follows:

- checking fuel temperature;
- checking engine coolant temperature;
- checking amount of fuel injected;
- checking idling speed;
- cutting off fuel in release phase;
- checking cylinder balancing when idling;
- checking anti-sawing;
- checking smokiness at exhaust on acceleration;
- checking exhaust gas recirculation (E.G.R. if present);
- checking top speed limit;
- checking glow plugs;
- checking activation of air-conditioning system (if any);
- checking auxiliary fuel pump;
- checking position of cylinders;
- checking main and pilot injection advance;
- checking closed cycle of injection pressure;
- checking turbocharging pressure;
- self-diagnosis;
- connection with immobilizer unit;
- checking maximum torque limitation.
The system makes pre-injection (pilot injection) possible

before the TDC with the advantage of decreasing the
derivative of the pressure in the combustion chamber,
lowering the noise level of combustion, which is typical of
direct injection engines.
The control unit checks the amount of fuel injected, adjusting
the line pressure and injection times. High pressure pipings
The information the control unit processes to regulate the Low pressure pipings
amount of fuel to be injected comprises:
- engine speed;
- coolant temperature;
107759
- turbocharging pressure;
- air temperature;
DIAGRAM ILLUSTRATING THE POSITION OF THE ELECTRONIC, HIGH-PRESSURE INJECTION SYSTEM COMPONENTS
- intake air quantity;
- battery voltage; 1. Phase sensor - 2. Electric injectors - 3. Preheating plug - 4. EDC coolant temperature sensor - 5. Electromagnetic fan - 6. V.G.T. and E.G.R. valve modulator (if any) - 7. Engine revs sensor - 8. Compressor (if
- diesel pressure; any) - 9. High-pressure pump - 10. Pressure regulator - 11. Connector for heater, fuel temperature sensor and fuel filter clogging sensor - 12. Fuel filter - 13. Fuel tank - 14. Fuel gauge with electric fuel pump -
- position of throttle pedal. 15. Control unit with atmospheric pressure sensor - 16. Battery - 17. Accelerator pedal sensor - 18. Clutch pedal sensors - 19. Brake pedal sensors - 20. Low-pressure fuel pipe assembly - 21. Throttle valve
assembly actuator - 22. Air pressure/temperature sensor - 23. Hydraulic accumulator fuel pressure sensor (rail) - 24. Hydraulic accumulator (rail) - 25. Slotted gear for phase detection from sensor (1) -
26. Engine revs counter - 27. Display - 28. Tachograph


Print 603.93.281
SYSTEM OPERATION Checking regular engine rotation (anti-sawing)

Self-diagnosis — BLINK CODE It ensures regular engine rotation at a constant rate while
The control unit self-diagnosis system checks the signals from increasing revs.
the sensors, comparing them with the admitted limits (see The control unit processes the signals received from the
relative heading): sensors and determines the amount of fuel to be injected via:
- the pressure regulator;
Immobilizer recognition - the electro-injector opening time.
When the control unit receives the signal of the key on ”MAR”
it communicates with the immobilizer control unit to enable Checking smokiness at exhaust on
starting. acceleration
Checking fuel temperature from the air introduction meter and engine speed sensor, the
control unit determines the optimum amount of fuel to inject:
With the fuel temperature greater than 75°C, detected by the
sensor on the fuel filter, the control unit operates the pressure - it operates the pressure regulator;
regulator to decrease the line pressure (injection times are not - it varies the electro-injector injection time.
changed). If the temperature exceeds 90°C, the power is
reduced to 60%. Checking exhaust gas recirculation (E.G.R.)
Checking engine coolant temperature accelerator pedal sensor, the control unit limits the amount of
The control unit, depending on the temperature: air taken in, actuating partial suction of the exhaust gases.
- of the engine coolant, turbocharging air and fuel, operates Checking top speed limit
the electromagnetic fan (Baruffaldi) and switches on the
coolant temperature warning light. Depending on the number of revs, the control unit actuates
two action strategies:
Checking quantity of fuel injected - at 4250 rpm it cuts off the fuel, decreasing the
According to the signals from the sensors and the mapped electro-injector opening time;
values, the control unit: - over 5000 rpm it deactivates the electro-injectors.
- operates the pressure regulator;
Checking regular rotation on acceleration
- varies the ”pilot” injection time to 2200 rpm;
- varies the ”main” injection time. Regular progression is assured in all conditions by the control
of the pressure regulator and the electro-injector opening
Checking idling adjustment time.
The control unit processes the signals from the various sensors
and regulates the amount of fuel injected: Checking glow plug control unit
- it operates the pressure regulator; The injection control unit, in the phase of:
- it varies the injection times of the electro-injectors. - starting
Within certain thresholds the speed takes account of the - after-starting
battery voltage. times operation of the glow plugs according to the engine
temperature.
Fuel cut-off in release phase
In the phase of releasing the throttle pedal the control unit Checking activation of air-conditioning system
actuates the following logic elements: The control unit operates the air-conditioning compressor:
- it cuts off supply to the electro-injectors; - switching it on/off when the relative switch is pressed;
- it partially reactivates supply to the electro-injectors before - momentarily turning it off (approximately 6 sec.) if the
reaching idling speed; engine coolant reaches the set temperature.
- it operates the fuel pressure regulator.
Checking fuel pump
Checking cylinder balancing on idling Irrespective of the speed, the control unit:
According to the signals received from the sensors, the control - supplies the auxiliary fuel pump with the key on MAR;
unit controls the regularity of the torque at idling speed: - cuts off auxiliary pump supply if the engine is not started up
- it varies the amount of fuel injected into the single within a few seconds.
electro-injectors (injection time).

Checking diesel warming Correcting flow rate to avoid noise, smoke or

It times operation of diesel warming in relation to ambient overloading
temperature. The behaviour that could lead to this kind of trouble is well
known.
Checking cylinder position The designer has therefore included special instructions in the
During each turn of the engine, the control unit recognizes control unit to avoid it.
which cylinder is in the power stroke and operates the
injection sequence for the appropriate cylinder. De-rating
In the event of the engine overheating, injection is modified,
Checking pilot and main injection timing decreasing the delivery to a varying degree, in proportion to
According to the signals from the various sensors, including the the temperature reached by the coolant.
absolute pressure sensor built into the control unit, the control
unit determines the optimum point of injection according to Injection timing electronic test
internal mapping.
The advance (start of delivery, expressed in degrees) may be
different from one injection to the next, also differentiated
Checking injection pressure closed cycle from one cylinder to another. It is calculated, similarly to the
Depending on the engine load, determined by processing the delivery, in relation to the engine load (accelerator position,
signals from the various sensors, the control unit operates the engine speed and air introduced).
regulator to obtain optimum line pressure. The advance is appropriately corrected:
Fuel supply - according to the water temperature.
The fuel supply is calculated in relation to: And also to obtain:
- accelerator pedal position - lower emissions, noise and overloading;
- engine speed - better vehicle acceleration.
- quantity of air introduced. An extremely high advance is set on starting, depending on the
The outcome may be corrected in relation to: water temperature.
- the water temperature. Feedback from the start of delivery is supplied by the change
in impedance of the injector solenoid valve.
Or to avoid:
- noise Speed governor
- smoke
The electronic speed governor has both features of
- overloading governors:
- overheating
- idling and top speed
- all speeds
It is stable in ranges where conventional, mechanical governors
- action of external devices (ABS), ABD, EDB are imprecise.
- serious trouble decreasing the load or stopping the engine.
After determining the mass of air introduced by measuring its Engine starting
volume and temperature, the control unit calculates the During the first few turns of the engine, the timing and cylinder
corresponding mass of fuel to inject into the relevant cylinder no. 1 recognition signals (flywheel sensor and camshaft sensor)
(mg per delivery) also taking into account the temperature of are synchronized.
the diesel. The accelerator pedal signal is ignored on starting. Starting
The mass of fuel calculated in this way is first converted into delivery is set only according to water temperature, by a
volume (mm3 per delivery) and then into degrees of throw, special map.
or duration of injection. When the control unit detects such speed and acceleration of
the flywheel as to be able to consider the engine started up
Correcting flow rate according to water and no longer driven by the starter motor, it re-enables the
temperature accelerator pedal.
A cold engine meets with greater resistance during operation:
friction is high, the oil is still very viscous, and the various
clearances are not yet optimized.
In addition, the injected fuel tends to condense on the metal
surfaces that are still cold.
The fuel supply for a cold engine is therefore greater than for
a warm one.

Cold starting Cut-off

If even just one of the three temperature sensors (water, air This function cuts off fuel delivery when the vehicle is
or diesel) records a temperature lower than 10°C, pre-post decelerating (accelerator pedal released).
heating is activated.
When the key makes contact the pre-heating indicator light Cylinder balancing
comes on and stays on for a length of time that varies in
relation to the temperature (while the glow plugs in the Individual cylinder balancing contributes to increasing comfort
cylinder head heat the air), then flashes. It is now possible to and handling.
start up the engine. This function permits individual, customized control over the
When the motor is running this indicator light goes out, while delivery of fuel and the start of delivery for each cylinder, even
the glow plugs continue to be powered for a certain length of differently from one cylinder to another, to compensate for
time (variable) for post-heating. the hydraulic tolerances of the injector.
If, with the indicator light flashing, the engine is not started up The differences in flow (delivery specifications) between the
within 20-25 seconds (inattention time), the operation is various injectors cannot be evaluated directly by the control
cancelled so as not to run down the batteries pointlessly. unit. This information is supplied by Modus reading the bar
The pre-heating curve is also variable in relation to the battery code of each injector at the time of assembly.
voltage.
Synchronization search
Warm starting
If the reference temperatures all exceed 10°C, when the key is anyhow able to recognize the cylinders into which the fuel
makes contact the indicator light comes on for approximately is to be injected.
2 sec., for a short test, and then goes out. It is now possible to If this occurs when the engine is already running, the
start up the engine. combustion sequence has already been acquired, so the
Run up already been synchronized.
When the key makes contact, the control unit transfers the If this occurs when the machine is at a standstill, the control
information stored in memory when the engine was last unit energizes a single solenoid valve. Within at most 2 turns
stopped into the main memory (see After Run) and makes a of the crankshaft, injection will take place in that cylinder, so
diagnosis of the system. the control unit just needs to get synchronized on the firing
After run
Whenever the engine is switched off with the key, the control
unit stays powered for a few seconds by the main relay.
This makes it possible for the microprocessor to transfer some
data from the main memory (volatile) to a non-volatile
memory, which can be erased and written over (EEPROM),
so as to make it available at the next start up (see Run Up).
- fault memory.
NOTE It is extremely important for this procedure not to

be broken off, for example by switching off the
engine with the battery cut-out, or by disconnecting
the battery cut-out before 10 seconds have passed
since switching off the engine.
If this happens, the functioning of the system is
ensured, but repeated interruptions may damage
the control unit.

OPERATION HYDRAULIC SYSTEM

In this injection system, the pressure regulator, located The hydraulic system is composed of:
upstream from the high-pressure pump, governs the flow of - tank
fuel needed in the low-pressure system. Afterwards, the
- fuel pre-filter
high-pressure pump correctly supplies the hydraulic
accumulator. - electric supply pump
- fuel filter
This solution, pressurizing solely the necessary fuel, improves - high pressure supply pump with supply pump built
the energy efficiency and limits heating the fuel in the system. inpressure regulator
The relief valve fitted on the high-pressure pump has the
- manifold (rail)
function of keeping the pressure, at the pressure regulator
inlet, constant at 5 bars; irrespective of the efficiency of the fuel - electro-injectors
filter and of the system upstream. The action of the relief valve - supply pipes and fuel recirculation
causes an increase in the flow of fuel in the high-pressure pump
cooling circuit.
The high-pressure pump continually keeps the fuel at the
working pressure, irrespective of the timing and the cylinder
Fuel pipes
that is to receive the injection and accumulates it in a duct
common to all the electro-injectors. Figure 327
At the electro-injector inlet, there is therefore always fuel at
the injection pressure calculated by the electronic control unit.
When the solenoid valve of an electro-injector is energized by
the electronic control unit, fuel taken straight from the
hydraulic accumulator gets injected into the relevant cylinder.
The hydraulic system is made out of a low-pressure fuel
recirculation circuit and a high-pressure circuit.
The high-pressure circuit is made up of the following pipes:
- pipe connecting the high-pressure pump outlet to the
hydraulic accumulator (rail);
- hydraulic accumulator (rail);
- pipes feeding the electric injectors from the hydraulic
accumulator.
112218
The low-pressure circuit is made up of the following pipes:
- fuel intake pipe from the tank to the filter; 1. Quick-connect coupling for high-pressure pump feed
- pipe assembly made up of the following: pipe - 2. Quick-connect coupling for feed pipe -
- feed pipe from the fuel filter to the high-pressure pump; 3. Fuel filter support
- fuel return pipe from the high-pressure pump to the tank;
- fuel exhaust pipe from the injectors to the fuel return pipe
to the tank. NOTE Due to the very high pressure existing within this
According to the high performance of this hydraulic system, hydraulic system, the following precautions shall be
for reasons of safety it is necessary to: taken for safety reasons:
- avoid connecting high-pressure pipe fittings with - avoid connecting the high-pressure pipe fittings
approximate tightening; by means of makeshift fasteners: tighten them
- avoid disconnecting the high-pressure pipes with the engine to the specified torque;
running (NEVER try bleeding, which is both pointless and
dangerous). - avoid disconnecting the high-pressure pipes
The integrity of the low-pressure circuit is also essential for the when the engine is running (DO NOT make
system to work properly; it is therefore necessary to avoid all any attempt at draining: this is absolutely
manipulation and modifications and act only in the event of useless and dangerous!).
leakage. To ensure correct operation of the system, it is
essential that the low-pressure circuit is intact.
Therefore, any modification or attempt at
tampering shall be avoided, and corrective actions
shall be taken immediately in case of leaks.
In the event that fuel pipes (1 and 2) are
disconnected from support (3), make sure, when
reattaching the pipes, that their respective fittings
are fully clean.
Such precautions shall be taken to avoid detective
sealing, with resulting fuel leaks.

FEED SYSTEM AND FUEL RECIRCULATION

Figure 328
High pressure fuel pipes
Low pressure fuel recirculation pipes 112217
FUEL FEED AND CIRCULATION SYSTEM
1. Injector fuel exhaust pipe - 2. Cap - 3. Electric injector - 4. Coupling - 5. Pressure regulator -
6. CP3.2 high-pressure pump with built-in feed pump - 7. Connector for heater connection, temperature sensor, clogging sensor
(optional item) and water sensor - 8 Water drain screw - 9. Fuel filter - 10. Fuel return pipe from the tank -
11. Fuel delivery pipe to the high-pressure pump - 12. Air drain screw - 13. Fuel return pipe to the tank -
14. Pressurized fuel pipe assembly - 15. High-pressure fuel delivery pipe to the hydraulic accumulator (rail) -
16. Pressure sensor - 17. High-pressure fuel delivery pipe to the electric injectors - 18. Hydraulic accumulator (rail)

Figure 329
109124
FUNCTIONAL DIAGRAM OF HYDRAULIC SYSTEM
1. High-pressure pump - 2. High-pressure delivery pipe - 3. Electric injector return pipe - 4. Electric injectors - 5. Common rail -
6. Fuel pressure sensor - 7. Filter with water separator - 8. Fuel electric pump non-return valve - 9. Injector return line
pressure-relief valve - 10. Tank - 11. Fuel electric pump - 12. Fuel electric pump intake filter - 13. Fuel electric pump
overpressure valve - 14. Pressure-relief valve - 15. Proportional pressure-relief valve
Relative pressures within the circuit:
a. 4,15 bar < p < 5,35 bar

b. 3,5 bar < p < 5,0 bar
c. p < 0,8 bar
d. 0,3 bar < p < 0,8 bar

HYDRAULIC SYSTEM 773010 Fuel pump

The hydraulic system is made up of the following items: The fuel electric pump is of the volumetric, low-pressure type.
- tank; It is built into the fuel level indicator located in the fuel tank.
- electronic fuel pump;
- fuel filter;
- high-pressure feed pump;
- pressure regulator;
- manifold (rail);
- electric injectors;
- low-pressure feed pipe assembly;
- high-pressure pipes.
Figure 330
109073
FUEL ELECTRIC PUMP ASSEMBLY SECTION

1. Return - 2. Connector - 3. Delivery - 4. Float - 5. Level sensor (+) - 6. Level sensor (-) - 7. Pump (-) - 8. Pump (+) -
A. Return line - B. Delivery line - C. Level sensor - D. Prefilter - E. Jet pump
Electric connector (2), located in the upper portion of the assembly, features the pins both for the electric pump and the level
sensor. During the installation, the assembly shall not be stressed with axial loads of more than 67 N and torque of more than 3
Nm. The maximum fastening torque on the gasket shall be 60 Nm.
Figure 331
109123

542011 ”Filtrauto” fuel filter
Figure 332
109072
1. Body - 2. Gasket - 3. Cover bottom - 4. Drain screw gasket - 5. Customer reference - 6. Diesel oil outlet - 7. Diesel oil inlet -
8. Air drain screw - 9. Supplier code - 10. Air bleeding or water draining screw - 11. Lower bottom - 12. Inner pipe -
13. Filtering paper - 14. Upper bottom - 15. Heating earth - 16. NTC1 - 17. NTC2 - 18. Clogging sensor (if foreseen) -
19. Water sensor - 20. Heating - 21. Feed - 22. GND
The fuel filter consists of an internal filtering-paper cartridge Clogging sensor (if any) features
(15) and is equipped with a water separator. - differential working pressure: 0.7 ÷ 0.85 bar
The maximum water storage capacity of the filter is 150 cm3.
The water sensor detects the presence of water in the filter Tightening torque
starting from an existing volume of 70 cm3. 5. Cover 35±5 Nm
This sensor is located in the lower part of the filter. 12. Air/water drain screw 1±0.2 Nm
The temperature, water and clogging (if any) sensors are inter-
faced with the electronic circuit (13) located inside in the NTC and heating features
upper portion of the assembly. - rated voltage 13.5 V
When the diesel fuel temperature is lower than a limit value, - max. permitted voltage 30 V
the electric resistor will come into operation by properly hea- - rated output 250 W at 185 l/h, T = -10˚C
ting the diesel fuel before the latter is conveyed to the high- - temperature range -30÷120˚C
pressure pump.
542011 ”UFIfilters” fuel filter

Figure 333
112723
1. Fuel filter support- 2. Diesel oil outlet - 3. Diesel oil inlet - 4. Diesel oil filter - 5. Drain screw - 6. Electronic unit - 7. Fastener
- 8. 12-way connector - 9. Screw securing Diesel oil filter: H-G-B, water present sensor; - H-C, clogging sensor (if foreseen); -
D-E, NTC temperature sensor; - F-A, heater.
Fuel filter (4) is made up of a filtering cartridge with water (Optional) filter clogging sensor
separator, inside which electronic unit (6) is housed. Normally open contact type.
Water accumulation capacity is equal to 140 cm3. Operation differential pressure delta p: 0.8 bar
Electronic unit (6) includes water present sensor, (optional)
NTC temperature sensor
filter clogging sensor and temperature sensor.
-30 ˚C = 26.114 ohm ± 9,7%
Water present sensor 0 ˚C = 5.896 ohm ± 7,3% +0,05
Water present sensor detects water present in the filter +25 ˚C = 2.057 ohm ± 5,6% -0,5
starting from 110 cm volume present. Water present +60 ˚C = 596 ohm ± 3,8%
sensor provides values of: +100 ˚C = 186 ohm ± 2,0%
- low voltage in presence of water; +110 ˚C = 144 ohm ± 2,4%
- high voltage in absence of water. Temperature range: -40˚C to +130˚C
Characteristics Heater
12V nominal voltage (8V minimum -16V maximum) Nominal voltage 12 V
Absorbed current: Maximum allowed voltage 30 V
- lower than 15 mA in rest conditions; Nominal power 250 W
- lower than 150 mA in alarm conditions (including load).
Voltage on load: Tightening torques
- in rest conditions: higher than 11.8 V; 9. Screw securing filter 1.5 + 0.5 Nm
- in alarm conditions: lower than 3.9 V. 4. Water draining or air bleeding screw 1.5 + 0.5 Nm
At key-on operation, the sensor makes a self-test issuing 2.5
second duration sound signal.

775010 CP3.2 high-pressure pump

Figure 334
109126
Pump with three radial plungers, controlled by the timing belt

gear. It does not require timing. NOTE The high-pressure pump/feed pump assembly
The pump is lubricated and cooled by the fuel itself. cannot be overhauled; therefore, the fastening
It differs from the CP3.2 high-pressure pump (Euro 3 version) screws shall not be removed or tampered with. The
is that it does not feature the mechanic feed pump. only operation that can be carried out is the
replacement of the pressure regulator drive gear.

771034 Pressure regulator Replacing pressure regulator

The fuel pressure regulator is mounted on the low-pressure
circuit of the CP3 pump. The pressure regulator modulates Figure 337
the amount of fuel sent to the high-pressure circuit according
to the commands received directly from the engine control
unit. The pressure regulator is mainly composed of the
following components:
- connector
- casing
- solenoid
- pre-load spring
- shutter cylinder.
When there is no signal, the pressure regulator is normally
open, therefore with the pump providing maximum delivery.
The engine control unit, via the PWM (Pulse Width
Modulation) signal, modulates the change in fuel flow rate in
the high-pressure circuit by partially closing or opening the
sections of passage of the fuel in the low-pressure circuit. 108359
Accurately clean high pressure pump.
Operation Take off screws (2) and unthread pressure regulator (3) from
Figure 335 high pressure pump.
Figure 338
75574
1. Solenoid — 2. Magnetic core — 3. Shutter cylinder —

4. Fuel inlet — 5. Fuel outlet. 108360
When the engine control unit governs the pressure regulator Accurately clean the seat (→) of pressure regulator and the
(via PWM signal), the solenoid (1) is energized that, in its turn, connection surface (→) of the regulator.
generates the movement of the magnetic core (2). The shift
of the core causes the shutter cylinder (3) to move axially,
choking the flow of fuel. NOTE For cleaning, do not use a tool which could damage
the surfaces and pay attention that impurities are
not introduced into channels.
Figure 336
Figure 339
75575
1. Solenoid — 2. Magnetic core — 3. Pre-load spring —

4. Shutter cylinder.
When the solenoid (1) is not energized, the magnetic core is
pushed into the rest position by the pre-load spring (3). In this 88408
condition, the shutter cylinder (4) is in such a position as to Mount new seal rings (1 and 2) on pressure regulator (3) and
offer the fuel the greatest section of passage. lubricate the rings with vaseline.

Figure 340 774510 Hydraulic accumulator (rail)
Figure 342
108361
Mount pressure regulator (1) on high pressure pump (2).
NOTE Mounting operation must be performed keeping

the regulator perpendicular to connection plane 108387
without angling it, in order not to damage seal rings
(1-2, Figure 339).
Figure 341
The hydraulic accumulator is fitted on the cylinder head on the
suction side.
With its volume of approximately 23 cm3 it dampens the
pressure ripples of the fuel due to:
- the operation of the high-pressure pump;
- the opening of the electro-injectors.
On the hydraulic accumulator (1) there is the fuel pressure
sensor (2).
Fuel pressure sensor (2) is fitted on hydraulic accumulator (1).
Small valves (throttle valves) or control bushes (3), with ”j” =
0.85 mm, have been fitted to the fuel delivery couplings, which
control the fuel pressure waves generated by the
high-pressure pump. Their function is to protect the electric
108362 injectors by reducing their wear in time.
Fuel pressure sensor (2) may affect the accuracy of the injector
Screw up screws (1) and tighten them at 6 ÷ 7 Nm (0.6 ÷ 0.7 minimum flow rate correction, since the minimum flow rate
kgm) torque. depends both on the injection time and the actual pressure of
the hydraulic accumulator.
NOTE Where pressure regulator is replaced on the engine In case of replacement, the EDC control unit 16 correction
mounted on the vehicle, it is needed, after coefficients (ZFC) shall be set to zero.
replacement, to check that there are no fuel leaks The correction coefficients (ZCF) can be corrected by means
after an engine working period. of the IVECO MODUS - E.A.SY. - IT 2000 diagnosis
performing the sensor replacement procedure, in accordance
with the instructions given by the diagnosis instruments.

775010 ELECTRO-INJECTORS Operation

Electro-injector operation can be broken down into three
Figure 343 phases:
- ”rest position”
The coil (4) is de-energised and the shutter (6) is in closed
position and does not allow the fuel to get in the cylinder,
Fc > Fa (Fc: due to the fuel pressure operating the rod (1)
control area (7). Fa: due to the line pressure operating in the
pressure chamber (8).
- ”start of injection”
75588 The coil (4) is energized and causes the shutter (6) to rise.
The electro-injectors have high-pressure supply (up to 1600 The fuel of the control volume (9) flows off towards the
bar) and recirculation at atmospheric pressure, necessary for return manifold (10) causing a drop in pressure in the
control area (7).
the diesel used to operate the pilot valve.
At the same time, the line pressure through the fuel pipe
The temperature of the diesel put back into circulation by the (12) exerts in the pressure chamber (8) a force equal to Fa
electro-injector can get very high (approximately 120°C). > Fc and thus makes the pin (2) lift and so the fuel gets in
The head of the electro-injector has a fitting for the electrical the cylinders.
connector.
They are mounted on the cylinder head and operated by the - ”end of injection”
injection control unit. The coil (4) is de-energized and makes the shutter (6) return
The electric injector can be subdivided into two parts (see to its closed position. This recreates such a balance in the
SENZA CODICE): forces as to make the pin (2) return to its closed position
and consequently end injection.
The electro-injector can be divided into two parts:
- actuator/jet composed of pressure rod (1), pin (2) and
nozzle (3);
- control solenoid valve composed of coil (4) and pilot valve
(5).
Figure 344 755010 Replacing an electrical injector
Figure 345
Fc
105066
1. IMA Matrix code- 2. Bosch spare part no.-

6. Series no. - 7. Production date
Electrical injectors are not assigned any more to classes Min (01)
Fa - Med (02) - Max (03); therefore, flow rate deviations from design
values are detected, during final check step, by the manufacturer
on each single injector and printed with I.M.A. (Injector Menge
50704 Abgleichung) [Injector Quantity Offset] code on injector magnet.
At engine production plant, I.M.A. code is read on line from an
1 Pressure rod — 2 Pin — 3 Nozzle — 4 Coil — 5 Pilot valve — automatic reading station, converted into bar code, printed on
6 Ball shutter — 7 Control area — 8. Pressure chamber - engine identification label and applied on the engine itself.
9 Control volume — 10 Low-pressure fuel return — At vehicles production plant, at line end, E.D.C. 16 central unit is
11 Control pipe — 12. Feeding pipe - 13 Electrical programmed automatically reading the engine identification label.
connection — 14 High-pressure fuel inlet fitting — 15 Spring.

llllk
Figure 346 The correction coefficients (ZFC) can be set to zero by means
of the IVECO MODUS - E.A.SY. - IT 2000 diagnosis
performing the replacement procedure indicated by the
instrument itself.
ELECTRIC/ELECTRONIC COMPONENTS
766161 Electronic control unit EDC 16
k
Figure 347
85711
Conversion table of OCR
characters into ARIEL characters 105067 The control unit is of the ”flash EPROM” type, i.e. it can be
reprogrammed from the outside without acting on its
hardware.
At assistance, code written in clear has to be used (3, Figure 31) The control unit processes the signals from the sensors by
for central unit replacement and reprogramming procedures. applying software algorithms, and also controls the actuators
In the table there is shown the conversion of OCR characters into (in particular, the electric injectors and the pressure regulator).
Ariel characters. The control unit records, in the memory non-labile area, the
When electrical injectors mounted on the vehicle must be information on the engine parameters originally set or
replaced, meet following warnings: acquired during engine operation.
- where electrical injectors are dismounted and do not The injection control unit incorporates the absolute pressure
need to be replaced, their mounting position has to be sensor, in order to further improve the injection system
noted down in order to remount them later in the same control.
position; this is done to avoid to reprogram the central The control unit is fitted to the left side of the engine
unit; compartment and is connected to the vehicle wiring by means
- after replacing one or more injectors, the central unit has of two connectors:
to be reprogrammed; - 60-pole connector ”A” for the components available on the
- before mounting a new electrical injector, note down IMA engine;
code printed on the injector, because the code is difficult - 94-pole connector ”K” for the components on the vehicle.
to read after the injector has been mounted; In addition to controlling the system functions described in the
- where the central unit is replaced, reprogram the new respective charter, the electronic control unit is interfaced
central unit with the IMA codes of the electrical injectors with the other electronic systems found on the vehicle, such
mounted on the engine and copy down the rectification as ABS - EBD, cruise control, speed limiter, immobilizer
coefficients (ZFC) of replaced central unit; where it is not (IVECO CODE), EGR, preheating plugs.
possible, they must be reset and self-learning process On the vehicles equipped with D.P.F. catalyst, the control unit
must be started up again. also controls the catalyst regeneration system. In this case,
During engine running, EDC 16 central unit performs some after any of the operations below is carried out:
checks on electrical injectors minimum flow rate. - replacing one or several injectors,
- replacing all the injectors,
In certain conditions (overrun: vehicle deceleration with pedal - replacing the air flow meter,
released) an increasing (very small) fuel quantity starting from - replacing the hydraulic accumulator pressure sensor
zero is injected and its effect on engine rotation smoothness (common rail),
is observed. - replacing the EDC control unit 16;
Injection start threshold is detected and stored by the central - changing the engine oil,
unit. - replacing the D.P.F. catalyst,
This self-learning process is carried out on each single cylinder. - replacing the filter differential pressure (Dp) sensor,
Therefore, replacing an electrical injector involves the need of - replacing any significant component as regards emission
reprogramming the central unit by entering the IMA codes of levels,
new electrical injectors and resetting the rectification factors - performing forced regeneration,
(ZFC) of the cylinder considered. the control unit shall be programmed again by means of the
Replacing all electrical injectors extends the need of resetting IVECO MODUS - E.A.SY. - IT 2000 diagnosis instrument, and
to all the rectification coefficients (ZFC) of each single the replacement procedure for the concerned component
electrical injector. shall be performed, in accordance with the indications of the
diagnosis instruments.

761917 Glow plug electronic control unit SENSORS

764266 Engine speed sensor
Figure 348 It is an inductive sensor and is positioned on the phonic wheel
fitted on the front end of the drive shaft
It generates the signals resulting from the magnetic flow lines
which close through the teeth of the phonic wheel.
Tooth number 58.
The electronic control unit uses this signal to measure the
speed of rotation of the engine, its angular position and to
operate the electronic rev counter.
If this signal fails the rev counter will not work.
764264 Camshaft timing sensor

It is an inductive sensor and is positioned on the camshaft gear
of the suction valves.
It generates the signals resulting from the magnetic flow lines
which close through a slot on the gear itself.
The signal generated by this sensor is used by the electronic
75578
control unit as a redundant signal to measure the different
engine speeds.
During the phases below:
- starting phase,
- post-starting phase,
the engine management control unit will time the plug
preheating control unit operation depending on the engine
Figure 350
temperature.
The plugs will be triggered through the plug preheating control
unit, depending on the engine temperature, under direct
control of the engine management control unit.
The preheating control unit incorporates a ”smart”
remote-control switch that sends a return response
(”feed-back”) to the management control unit: the latter will
therefore be informed about the preheating control unit
failure (if any) or the plug short-circuit to the ground.
761915 Glow plugs

Figure 349
75579
CONTROL VALUES 88056
With a constant supply voltage of 11 V: SENSOR ASSEMBLING DIAGRAM

- max. current drawn 18 A The sensor gap shall be as follows:
- min 5 sec. 11 ±1.5 A
- in 30 sec. 6 ±0.9 A - 1 + 0.5 mm, between distributing shaft pulley (4) and
phase sensor (1);
- temperature after 7 sec. 850°C
- tightening torque 8-10 Nm - 1 mm, between phonic wheel (2) and revs sensor (1).

772655 Air temperature and pressure sensor 772641 Clutch pedal position sensor
Positioned on the intake manifold, it measures the pressure of Mounted on the pedal board, it provides the control unit with
the turbocharging air introduced into the intake manifold. a positive signal when the clutch is engaged (pedal released).
This value, together with that of the air temperature sensor, Every time the clutch is disengaged to change gear, the control
makes it possible for the electronic control unit to calculate the unit fails to receive this signal and deactivates the Cruise
exact quantity of air introduced into the cylinders so as to Control function.
operate the injectors adjusting the fuel delivery, limiting
harmful emissions, improving consumption and performance. 772642 Brake pedal position sensor
The sensor contains an electronic temperature correction
circuit to optimize the pressure measurement in relation to the There are two of these sensors mounted on the pedal board.
temperature of the intake air. With the brake pedal released, they provide the control unit
with a positive signal that is used to detect brake operation so
772656 Fuel temperature sensor as to deactivate the Cruise Control function and stop delivery
of fuel.
Integrated in the fuel filter, it measures the fuel temperature In addition, a sensor switches on the brake lights.
and transmits it to the electronic control unit.
When the fuel temperature is too high (ambient temperature 764261 Vehicle speed sensor
condition, engine at full load and tank in reserve), correct
lubrication of the high-pressure pump is no longer assured. On This sensor, mounted on the gearbox by the drive output
the basis of the values received, the control unit determines the shaft, transmits the vehicle speed signal, through the electronic
density and volume of the fuel, correcting the delivery limiting tachograph, to the control unit.
engine performance.
540743 Differential pressure sensor - delta p
774511 Fuel pressure sensor (Dp)
It is fitted on the hydraulic accumulator end (rail) and its This sensor detects the difference between the pressure (Dp)
function is to transmit a “feed-back” signal to the injection of the incoming exhaust gas and the pressure of the gas flowing
control unit for: out of the D.P.F. catalyst.
The measured value indicates the extent of particulate (PM)
- adjust injection pressure particle accumulation or clogging in the D.P.F. filter.
- adjust the duration of injection. This value will, through a proper signal (feed-back), be
processed by the EDC control unit 16, which will cause
post-injection so as to increase the exhaust gas temperature
(630˚-650˚C) and also cause the particulate particles
accumulated in the D.P.F. filter to be burned.
NOTE In case of replacement, the control unit shall be

programmed again by means of the IVECO NOTE In case of replacement, the control unit shall be
MODUS - E.A.SY. - IT 2000 diagnosis instrument, by programmed again by means of the IVECO
performing the replacement procedure indicated MODUS - E.A.SY. - IT 2000 diagnosis instrument, by
by the diagnosis instrument itself. performing the replacement procedure indicated
by the diagnosis instrument itself.
766161 Atmospheric pressure sensor
This is integrated in the electronic control unit. It provides a
criterion of correction for the measurement of the air flow Exhaust gas temperature sensor
rate and to calculate the reference air flow rate to check the The D.P.F. catalyst includes two temperature sensors located
EGR. at the D.P.F. catalyst inlet and outlet, respectively.
The temperature values are processed by the control unit to
764254 Engine coolant temperature sensor determine post-combustion, in order to increase the exhaust
gas temperature needed to burn the particulate particles.
This provides the control unit with an index of the thermal
status of the engine in order to determine corrections for the
fuel delivery, injection pressure, EGR injection advance when
starting cold (if mounted) and warm-up.
505910 Throttle pedal position sensor

The accelerator pedal position sensor provides the control
unit with a voltage value in proportion to the angle of
operation of the pedal determining fuel delivery.

ACTUATORS
The injection system comprises three classes of actuators
interlocked with the electronic control unit:
- electro-injectors (see relevant heading);
- regulators (see relevant headings) requiring PWM control
(Pulse Width Modulation):
• for pressure
• EGR (if mounted)
• turbocharger with variable geometry (if mounted);
- actuators with continuous ON/OFF signal to:
• engage electromagnetic coupling for radiator cooling
fan;
• turn on/off air-conditioner compressor (if mounted);
• Cruise Control;
• starter heater control;
• fuel filter heating;
• electric supply pump.
NOTE All the power controls are made with relays located
in the cab.
PWM (Pulse Width Modulation) controls

A PWM control has an active and an inactive state that
alternate within a constant set length of time. During the active
state the actuator control circuit is closed, which is thus
powered with the control voltage; whereas, during the
inactive state the circuit is open.
The duration of the two states may be varied with the
condition that the sum of the two times is equal to the length
of the modulation delivery.
The duration of the active state determines the duty-cycle,
which is normally expressed as a percentage of the total time.
Therefore, if the duration of the two active and passive states
are the same, the duty-cycle is equal to 50%.
For reasons of diagnostics, the duty-cycle is limited between
1% and 99%; the control resolution is equal to 0.005%
(1/20000 of the time).
The time length has been chosen taking account of the
dynamic actuator response specifications.
Too low a carrier frequency could cause oscillations in the
actuator, while too high a frequency would decrease control
resolution.
The control of the E.G.R. (if fitted) and the turbocharger with
variable geometry (if fitted) occurs through the idle
modulating valve.


DAILY EURO 4 CLUTCH 1
SECTION 3
5052 Clutch
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHARACTERISTICS AND DATA . . . . . . . . . . . 7
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 13
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CLUTCH REMOVAL AND REFITTING . . . . . . . 14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
THRUST BEARING REMOVAL

AND REFITTING . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC CLUTCH DRIVE . . . . . . . . . . . . . . 16
HYDRAULIC CLUTCH DRIVE REMOVAL - REFITTING 18
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PEDAL BOARD REMOVAL - REFITTING . . . . . 20
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PEDAL BOARD . . . . . . . . . . . . . . . . . . . . . . . . . 21
CLUTCH WITH AUTOMATIC WEAR RECOVERY -

COMBINED WITH 6 AS’300 VD GEARBOX 22
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL AND REFITTING OF CLUTCH WITH

DEVICE RECOVERY COMBINED . . . . . . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2 CLUTCH DAILY EURO 4

DESCRIPTION
The clutch unit consists of the following: The introduction of a diaphragm spring (or Belville washer) as
an elastic driving brings about important advantages, such as:
- a driven disk - lined on both sides with friction seals and
fitted with a hub at the centre. Additionally, a hub spring - smaller axial size and reduced sensibility of the centrifugal
is provided to make it more elastic and soft; force, due to the absence of the release lever;
- a thrust pad - fixed to the cover or body of the friction - greater constructive accuracy due to the reduced number
clutch mechanism by means of plates that allow for axial of components;
movement when the diaphragm spring is driven by the
- improved cooling capacity due to the reduced contact
collar bearing;
surfaces between diaphragm and disk driver;
- a diaphragm spring made from a certain number of blades
- less unbalance;
arranged in a dial form;
- easy maintenance thanks to:
- a collar bearing mounted on the diaphragm spring and
locked to the same by means of the split ring. With this 1. no regulation required for clearance;
solution it is no longer necessary to adjust the clearance
2. no further need to level-off the thrust pad.
between the collar bearing and diaphragm spring since
both the components are in contact. Moreover, the clutch Finally, it must be noted how the non-linear characteristics of
is released by traction of the collar bearing. the diaphragm spring offer a reduced variation of the release
force as the control pedal gradually completes its travel and,
with a load on the disk driver not less than the rated value even
with worn seals.
Figure 1
52233
VIEW OF CLUTCH ASSEMBLY

DIAGNOSTICS
Main operating faults of the clutch are:

4. - The clutch does not release;
1. - Noise when the clutch pedal is pressed;
5. - The clutch slips;
2. - Noise when the pedal is released;
6. - Abnormal wear of driven disk seals.
3. - Clutch jerks;
NOISE WHEN CLUTCH PEDAL

1
IS PRESSED
Collar bearing excessively worn, damaged or not Replace the collar bearing.
properly lubricated. YES
NO
Excessive play between the clutch engagement grooves Replace the shaft and, if necessary, the driven disk also.
on the shaft and the relevant seat on the hub of the YES
driven disk.
2 NOISE WHEN THE PEDAL

IS RELEASED
Driven disk springs are broken or weakened. Replace the driven disk.
YES
NO
Clutch engagement shaft worn. Replace the shaft and, if necessary, the driven disk also.
YES
NO
Collar bearing has excessive play in the joint. Replace the collar bearing.
YES

3 CLUTCH JERKS
Oil or grease on the engine flywheel, or on the seals of Replace the oil or grease, clean the flywheel, and
the driven disk. YES replace the driven disk.
NO
Thrust pad deformed. Replace the clutch.

YES
NO
Friction seals worn due to off centring of the driven disk. Replace the driven disk.
YES
NO
Clutch diaphragm spring weak or broken. Replace the driven disk.

YES
NO
Driven disk springs broken or yielded. Replace the driven disk.

YES
4 THE CLUTCH DOES NOT RELEASE
Oil or grease on the seals of the driven disk. Remove the oil or grease; clean the flywheel and
YES replace the driven disk.
NO
Grooves on the clutch engagement shaft are worn and Replace the shaft and, if necessary, the driven disk.
impede the movement of the driven disk. YES
(Continue)

Clutch pedal height not adjusted (only mechanical The driver must stop this habit and use the clutch pedal
control). YES only when necessary.
Adjust the height of the clutch pedal.
NO
Clutch release hydraulic control not efficient. Replace the hydraulic control.
YES
5 THE CLUTCH SLIPS
Driven disk seals worn or burnt. Replace the driven disk.

YES
NO
Clutch diaphragm springs weak or broken. Replace the clutch.

YES
NO
Oil or grease on the seals of the driven disk. Remove the oil or grease, and replace the driven disk.
YES
ABNORMAL WEAR OF DRIVEN

6
DISK SEALS
The driver keeps the clutch pedal pressed while driving. The driver must stop this habit and use the clutch pedal
YES only when necessary.
NO
Clutch diaphragm spring blades weakened or broken. Replace the clutch.

YES

CHARACTERISTICS AND DATA

Models 29 L 10 - 29 L 12 - 35 S 10 - 35 S 12 - 35 C 10 - 35 C 12 - 40 C 10 - 40 C 12
(except for the vehicles equipped with 6 S 400 A O.D. gearbox unit)
9 ” 1/4 CLUTCH BORG & BECK
Type Dry single disk
Clutch mechanism “Pull” with diaphragm spring
Driven disk With friction seals
Driven disk hub with single elastic coupling
0
External Ø seal mm 235 −1
+ 1, 5
Internal ∅ seal mm 160
Disk thickness (new) mm 7,7 ± 0,3
Under load N 6850

Minimum thickness due to wear mm 1,25
Max. off centring driven

disk mm ~ 0,2
Minimum load on
thrust plate N 6850
Max. release load at 9

mm. release height N
1400
Maximum rise thrust pad

at 9 mm. release height mm 1,6
Disengagement stroke mm 9+1
Max. depression stroke mm 9,5
Disengagement control hydraulic
Lubricant -
NOTE Values refer to new clutch

Models 29 L 10 - 29 L 12 - 35 S 10 - 35 S 12 - 35 C 10 - 35 C 12 - 40 C 10 - 40 C 12
(only vehicles equipped with 6 S 400 A O.D. gearbox unit)
10 ” 1/2 CLUTCH SACHS
Clutch mechanism Pull-type, with automatic wear recovery diaphragm spring
Driven disk hub with double elastic coupling springs
0
+ 1, 5
Internal ∅ seal mm 180
Under load N 9000


disk mm ~ 0,4
Minimum load on
thrust plate N 7900

9100

Disengagement stroke mm 12 + 1
Max. consumption travel

4
at the thrust block mm
Disengagement control Electric actuator controlled by the gearbox control unit
Lubricant -

Models 29 L 14 - 35 S 14 - 35 C 14 - 40 C 14
10 ” 1/2 CLUTCH VALEO
Driven disk hub With double hub springs
0
+1
Internal ∅ seal mm 171 − 0, 5
Under load N 8000


disk mm ~ 0,2
Minimum load on
thrust plate N 6500

1600

Disengagement stroke mm 9+1
Hydraulic control hydraulic
Lubricant -

Models 35 C 15 - 40 C 15 - 45 C 15 - 50 C 15 - 60 C 15 - 65 C 15
11” CLUTCH VALEO

280 0
External Ø seal mm
-0.4
170 0
Internal ∅ seal mm
-0.4
Under load N 8000


disk mm ~ 0,2
Minimum load on
thrust plate N 7000

1850

0
Disengagement stroke mm 9
-0.4
Lubricant -

Models 35 S 18 - 35 C 18 - 40 C 18 - 45 C 18 - 50 C 18 - 60 C 18 - 65 C 18
11” CLUTCH VALEO

280 0
External Ø seal mm
-0.4
170 0
-0.4
Under load N 8000


disk mm ~ 0,2
Minimum load on
thrust plate N 7500

1850

0
-0.4
Lubricant -

Models 35 S 18 - 35 C 15/18 - 40 C 15/18 - 45 C 15/18 - 50 C 15/18 - 60 C 15/18 - 65 C 15/18

(only vehicles equipped with 6 S 400 A O.D. gearbox unit)
11” CLUTCH SACHS

280 0
External Ø seal mm
-0.4
175 0
-0.4
Under load N 9100


disk mm ~ 0,2
Minimum load on
thrust plate N 7900

1100

0
-0.4
Max. consumption travel

4
at the thrust block mm
Disengagement control Electric actuator controlled by the gearbox control unit
Lubricant -

TIGHTENING TORQUES
TORQUE
PART
Nm kgm
Screw securing clutch to engine flywheel 46,5 4,7
Screw securing operator cylinder mounting to gearbox 10 ± 1 1 ± 0,1
Screw secuing pedal board mounting - -
Screw to secure clutch disengagement lever support to gearbox front cover 23,5 ± 2,5 2,3 ± 0,2
TOOLS
99370205 Guide pin for centring clutch driven disk
Figure 2
52230

505210 CLUTCH REMOVAL AND CHECKS

REFITTING The checks to be made are as follows:
- the mating surface, on the engine flywheel, of the driven
Removal disk must not be excessively worn or scored.
The operation consists of:
- the teeth of the toothed crown must not be worn or
- removal-refitting of transmission shafts (see section
broken.
505620)
- removal-refitting of gear box (see section 530210). If this is not the case, disassemble the engine flywheel
(operation 540850) as described in the relevant paragraph at
section 2.
Proceed on the engine flywheel as described in relevant
paragraph (operation 540853) at section 2.
Figure 3 Check that there are no oil leaks, even of a slight entity, from
the seal of the rear drive shaft; otherwise remove the flywheel
as described in the relevant paragraph. Remove the rear cover
complete with sealing rings and replace the same as described
at section 2.
Check that the support bearing or bushing of the take up shaft
on the gears fitted to the drive shaft are not worn or broken
and, if necessary, replace them as described in the relevant
paragraph (540852).
Check the condition of the thrust pad; the driven disk support
surface must not be scored or excessively worn or should
there be signs of overheating; the diaphragm spring must be
in perfect condition.
44570 Check the condition of the driven disk:
- the friction seals must not be excessively worn or present
Insert the centering pin 99370205 (1) in the gear infeed shaft signs of overheating, or traces of oil or grease;
support bearing, to facilitate clutch removal operations.
- there should be very little backlash between the hub and
Remove the fixing screws (2) and remove the thrust pad (3) gear take up shaft;
from the engine flywheel.
- the hub rings must not be loose or broken.
When any defects are found, replace the part in question.
The complete clutch is supplied with a spare kit.
The following are supplied singularly:
- the driven disk and collar bearing.
In this case it will necessary to assemble the new parts of the
driven disk spring that is to be reused.
Figure 4
44571
Remove the clutch disk (3) by extracting the centring pin

99370205 (2).
Disk plate centering pin (1) located on the engine flywheel.

Figure 5 - remove the guide pin;

- reconnect the gears after spreading the grooved shaft
with molybdenum disulphide Molikote as described in
Section 4;
- adjust the clutch travel as described in the relevant
paragraph (operation ..).
Before fitting a new driven disk check that it is centred as

follows:
Position the driven disk (1) on a lathe and, with the use of a
magnetic base dial gauge (2), check that the surface of the disk
is not out of line at any point.
Maximum tolerance allowed for the driven disk is 0.20 mm.
505254 THRUST BEARING REMOVAL

Figure 6
AND REFITTING
Figure 7
If the disk is out of line use a hook wrench (1) as in the figure.
36800
Refitting
Follow the same procedures as for removal in reverse order
and: - removal-refitting of transmission shafts (see section
505620);
- carefully clean the faying surface of the flywheel - removal-refitting of gear box (see section 530210).
disk using methylated spirits or petrol; if any slight By using the appropriate pliers open the split pin (1) and
scratches are noted remove with an abrasive extract the collar bearing (2) from the thrust pad (3).
cloth;
To assemble, carry out the disassembly operations in reverse.
- position the driven disk (3, SENZA CODICE), using the
guide pin (2, SENZA CODICE) to obtain perfect centring
and to avoid straining the hub when the gears are
reconnected;
- position the thrust pad by aligning the holes with the
centring grub screws (1, SENZA CODICE) on the
engine flywheel; NOTE The new part must be of the same supply as the
driven disk that is to be reused.
- assemble and lock the thrust pad fixing screws to the
correct torque;

505260 HYDRAULIC CLUTCH DRIVE

Figure 8
50967
The hydraulic clutch drive is composed of:

- a master cylinder (1) mounted on the pedal board and
connected to the clutch pedal (5), with an integrated oil
tank (3).
- an operating cylinder (7) fixed to the gearbox (6).
- an oil pipe (4).
NOTE The components of the hydraulic drive must never

be dismantled or separated from each other in any
way.
The cover (2) of the oil tank (3) must not be
removed.
This assembly requires no maintenance and the
hydraulic circuit must not be vented.
In the event of defectiveness, the entire assembly
needs to be replaced as it is supplied as a spare part,
proceeding as described under the relevant
heading.
The clip (8) holding the push rod (9) on the
assembly supplied as a spare part must not be
removed or cut.

Figure 9
SPECIFICATIONS AND DATA 62090
Main cylinder diameter 18 mm

Main cylinder section 254,47 mm2
Operating cylinder diameter 22 mm
Operating cylinder section 346,36 mm2
Clutch pedal ratio 5,85
Hydraulic ratio 1,36
Clutch disengagement lever ratio 1,67
Overall reduction ratio 13,28
Max disengagement stroke X Y (94) F (99) J (98.7) mm
Max wear stroke Y Y (67,5) F (70.8) J (69,1) mm
Y 9 ” 1/4 CLUTCH
F 10 ” 1/2 CLUTCH
J 11” CLUTCH

HYDRAULIC CLUTCH DRIVE REMOVAL - REFITTING

Figure 10
50968
Refitting
Removal
Position the vehicle over the pit or on the lift. For refitting, carry out the operations for removal in reverse
From inside the cab, using a screwdriver, unhook the swivel order, taking the following precautions:
head (2) of the master cylinder push rod from the clutch pedal
link pin (3). - Do not press the clutch pedal until refitting is complete.
- During assembly, handle parts carefully.
- Lubricate the contact surfaces of the clutch

NOTE Do not act on the pin (3) to prevent it coming out of disengagement lever with the clutch pedal link pin.
the pedal board (1).
- Lubricate the contact surface of the master cylinder swivel
head with the clutch pedal link pin.
Working from the engine bay, turn the master cylinder (4) to
the right (approx. 1/8 of a turn) to align the square of the hole - After refitting the operating cylinder mounting to the
(A) in the pedal board (1) with the square (B) of the master gearbox, check that the cylinder push rod is aligned with
cylinder body and extract it from the pedal board (1). the clutch disengagement lever seat.
Working under the vehicle, disengage the operating cylinder - If replacing with a new hydraulic drive assembly, after
(8 detail C) by unscrewing the screws (6 detail C) securing the refitting, press firmly on the clutch pedal so as to break or
cylinder mounting (7 detail C) from the gearbox. free the clamp holding the push rod (9).
Remove the hydraulic clutch drive assembly from the vehicle.
- Lift the clutch pedal by hand with a force of no greater
than 5 daN to its limit and hold it in this position for at least
five seconds so that the oil from the tank will supply the
master cylinder. Repeat this operation if necessary.

Figure 11
52235
MASTER CYLINDER
Figure 12
52236
OPERATING CYLINDER
Figure 13
87895
The operating cylinder makes up for the wear of the driven disc marking an increase in load on the pedal during disengagement when
the wear on the driven disc gets to be 90%.
Maximum disengagement position when new a = 121.8 mm. a1 = 112.8 mm.
Engagement position when new b = 99.3 5.8 mm. b1 = 89.8 mm
Minimum position with worn disc c = 73.3 mm. c1 = 63.8 mm

502601 PEDAL BOARD REMOVAL - REFIT- Figure 16

TING
Removal
Figure 14
52240
Remove the four nuts (2) fixing the servo brake (3) and take
this out of the engine bay.
52238
Disconnect the electrical connection (1) from the sensor on
the clutch pedal and the electrical connection (4) from the
Set a proper container under the brake pipes (4) and remove sensor on the brake pedal. Disconnect the electrical
them from the brake pump (1) of the vacuum brake (3). connection (5) from the switch on the brake pedal.
When draining the brake oil, take care it does not Figure 17
come into contact with anyone, clothes, or painted
parts.
Disconnect the electrical connection (2) from the brake liquid

tank plug.
Figure 15
52241
Disconnect the clutch drive master cylinder (1) from the pedal
board as described under the relevant heading and set it aside
appropriately in the engine bay, taking care not to damage or
bend the oil pipe.
Take out the nuts (2) and remove the pedal board (3).
Refitting
For refitting, carry out the operations described for removal

in reverse order, taking the following precautions:
- tighten the nuts/screws to the required tightening torque
52239 under the relevant heading;
- refit the clutch drive cylinder as described under the
From inside the cab: relevant heading;
- fill the brake liquid tank with the required quantity and
Remove the side guard (7), disconnect the electrical grade and bleed the air (operation 784010) as described
connection (6) from the accelerator pedal (4). Take out the under the relevant heading;
screws (5) and remove the accelerator pedal (4) from the
pedal board. - after making the electrical connections, check the
efficiency of the connected components.

PEDAL BOARD
Figure 18
62091
A. Pedal board with mechanical accelerator pedal

B. Electronic accelerator pedal
NOTE The only repair operations to be performed on the pedal-assy are the following:
- accelerator pedal replacement;
- sensor replacement.
In any other case, replace the pedal using the above-mentioned components if they are serviceable.

CLUTCH WITH AUTOMATIC WEAR RECOVERY - COMBINED WITH 6 AS’300 VD GEARBOX
Figure 19
102089
1. Sliding wedge - 2. Wedge (1) actuating spring - 3. Wear recovery ring (6 & 7) actuating spring - 4. Wear indicator - 5.
Retainer - 6. Wear recovery upper sliding ring - 7. Wear recovery lower ring - 8. Diaphragm spring
Description
The automatic wear recovery device is placed between the diaphragm spring and the thrust plate of the pressure plate assembly.
It is essentially made up of wedge-shaped rings which recover, under sliding conditions, the clutch disc wear real-time, while keeping
both the diaphragm spring characteristics and the force required to actuate the spring unchanged.
Operation
Automatic wear recovery takes place in two separate phases:
- Phase 1: every time the clutch is closed (engaged) and the clutch disc wear — as detected by retainer (3) — is such that the
pressure plate is made to travel an extra stroke, spring (4) will disengage wedge (1), which will be pulled by spring
(2) and will stop again against spring (4) and retainer (5) after travelling a stroke equal to the disc wear.
- Phase 2: when the clutch is opened (disengaged), diaphragm spring (8) will release wear recovery rings (6 & 7); as a result, spring
(3) will, by causing lower ring (6) to slide over upper ring (7) due to the inclined planes of the same, lift the latter by
an amount equal to the clutch disc wear.

Figure 20
102090
CLUTCH DISC AUTOMATIC WEAR RECOVERY DIAGRAM
A. Position of the diaphragm spring with a new clutch disc - B. Position of the diaphragm spring with a worn clutch disc prior to
operation of the automatic wear recovery device - C. Position of the diaphragm spring with a worn clutch disc after operation
of the automatic wear recovery device
1. Retainer - 2. Lower ring - 3. Upper ring - 4. Clutch disc - 5. Retainer (1) spring -
6. Diaphragm spring - 7. Wear recovery ring actuating spring
= ring (2) sliding
= ring (3) lifting

505210 REMOVAL AND REFITTING OF Figure 23

CLUTCH WITH DEVICE RECOVERY
COMBINED
Removal
- removal-refitting of transmission shafts (see section
505620)
- removal-refitting of gear box (see section 530210).
Figure 21 44571
Remove the clutch disk (3) by extracting the centring pin

99370205 (2).
CHECKS
The checks to be made are as follows:
- the faying surface, on the engine flywheel, of the driven
disk must not be excessively worn or scored.
- the teeth of the toothed crown must not be worn or
broken.
If this is not the case, disassemble the engine flywheel
(operation 540850) as described in the relevant paragraph at
102091 section 2.
Insert clutch centring pin 99370205 (1) in the shaft support Proceed on the engine flywheel as described in relevant
bearing. paragraph (operation 540853) at section 2.
Locate the position of retainer (2): it is positioned between the Check that there are no oil leaks, even of a slight entity, from
engine flywheel plug for clutch assembly centering and a hole the seal of the rear drive shaft; otherwise remove the flywheel
for the screw used to fasten the same. It sticks out the clutch as described in the relevant paragraph.
assembly by approximately 3 mm. Replace the seal ring as described in section 2.
Check that the support bearing or bushing of the take up shaft
on the gears fitted to the drive shaft are not worn or broken
Figure 22 and, if necessary, replace them as described in the relevant
paragraph (540852).
Check the condition of the thrust pad; the driven disk support
surface must not be scored or excessively worn or should
there be signs of overheating; the diaphragm spring must be
in perfect condition.
Check the condition of the driven disk:
- the friction seals must not be excessively worn or present
signs of overheating, or traces of oil or grease;
- there should be very little backlash between the hub and
gear take up shaft;
- the hub rings must not be loose or broken.
Should any anomaly be found, the full clutch shall be replaced.
Inspect the conditions of the clutch-release bearing and the
102092 release lever, should any anomaly be found, the concerned
Loosen screws (4) that secure pressure plate (1) to the
flywheel in 5 steps in crossed sequence until a distance of 2 part shall be replaced.
mm is obtained between retainer (2) and the clutch. Also
make sure that retainer (2) is released from pressure plate (1);
otherwise, use a suitable beater (3) to hit the top of retainer NOTE In the event that the clutch release lever is replaced,
(2). calibration shall be carried out after re-attaching the
Then remove screws (4) and take the pressure plate off the gearbox, as described in the relevant charter of the
engine flywheel. “Gearbox” section.

Refitting
Follow the same procedures as for removal in reverse order
and:
- carefully clean the faying surface of the flywheel

disk using methylated spirits or petrol; if any slight
scratches are noted remove with an abrasive
cloth;
- position the driven disk (3, SENZA CODICE), using the
guide pin to obtain perfect centring and to avoid straining
the hub when the gears are reconnected;
- position the thrust pad by aligning the holes with the grub
screws (1, SENZA CODICE) on the engine flywheel;
- screw down the pressure plate fastening screws in four
subsequent steps and in crossed sequence, then tighten
them to the specified torque


DAILY EURO 4 TRANSMISSION 1
SECTION 4
5302 Transmission
Page
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION REMOVAL - REFITTING . . . . . 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Gear control check and adjustment . . . . . . . . . 8
GEAR CONTROL . . . . . . . . . . . . . . . . . . . . . . . 10
- Flexible cable replacement . . . . . . . . . . . . . . . . 10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GEAR SHIFT LEVER SUPPORT . . . . . . . . . . . . . 11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 S 300 TRANSMISSIONS . . . . . . . . . . . . . . . . . 13
6 S 400 O.D. TRANSMISSION . . . . . . . . . . . . . . 49
6 S 400 A O.D. TRANSMISSION . . . . . . . . . . . . 91
POWER TAKE OFF. . . . . . . . . . . . . . . . . . . . . . . 127

2 TRANSMISSION DAILY EURO 4

DIAGNOSTICS
Main transmission operation faults: 3 - Gear spontaneous disengagement
1 - Noisy transmission 4 - Difficult speed engagement or selection
2 - Noisy transmission only in reverse speed 5 - Leakages of lubricant.
1 NOISY TRANSMISSION
Insufficient lubricating oil level. Add TUTELA TRUCK GEARLITE oil up to

YES proper level.
NO
Screws which fasten the transmission to the chassis are Tighten loose screws properly.
loose. YES
NO
Excessive backlash between gears. Overhaul transmission and replace worn gears.
YES
NO
Gears, bearings, synchronizer rings and sliding sleeves Replace worn or damaged components.
worn. Springs broken. YES
2 NOISY TRANSMISSION ONLY

IN REVERSE SPEED
Reverse speed or connected gears damaged. Overhaul transmission.

YES

3 GEAR SPONTANEOUS
DISENGAGEMENT
Speed engagement/selection rod release ball spring Remove the cap and replace the spring.
yielded or broken. YES
NO
Sliding sleeves positioning springs yielded or broken. Remove the transmission and replace the springs.
YES
DIFFICULT SPEED ENGAGEMENT

4
OR SELECTION
Incorrect clutch disengagement. Check the command or replace clutch.

YES
NO
Wrong quality of oil in the box. Insufficient oil level. Drain the oil and refill with TUTELA TRUCK
YES GEARLITE oil up to proper level.
NO
Movement of sliding sleeves hindered. Forks, sliding Disassemble the gearbox and look for the cause and
sleeves, synchronizer rings worn. YES carry out repairs if necessary.
NO
Wrong assembly of levers on selection and/or gear Check and/or mount the levers as described under the
engagement levers. YES relevant heading.

5 LEAKAGES OF LUBRICANT
Oil level too high. Restore proper level

YES
NO
Breather clogged Clean breather

YES
NO
Input and/or output shaft retaining rings worn. Replace retaining rings.
YES
NO
Loose screws and/or nuts which fasten: covers, Remove the component; clean coupling surfaces.
support, boxes YES Spread on them some LOCTITE 5206 sealing, re-fit
and tighten screws and/or nuts to the prescribed
torque.


TRANSMISSION REMOVAL - REFITTING

Removal Figure 1
Here we describe the removal-refitting operations for the 5 S 300 transmission
that, unless specified otherwise, also hold for the 6 S 400 O.D. transmission.
Position the vehicle over the pit or on a lift or on special stands.
Act from inside the engine compartment to remove the screws securing the
starting motor to the gearbox case front cover (the upper screw also secures
the fuel pipe supporting bracket).
Remove the starter motor and put it appropriately aside in the engine bay.
Act from under the vehicle to:
- remove screws (11) and take sound-proofing guards (12) off;
- disconnect exhaust pipe (13) from the turboblower pipe.
On 6 S 400 O:D. gearbox units: remove screws (17) securing exhaust pipe
supporting bracket (16) to the gearbox unit.
Remove the sealing from ring (25), then unscrew the same and disconnect the
speed indicator control cable.
Disconnect reversing light electric connection (22) (on 6 S 400 O.D. gearbox
units, the reversing light switch is located on the left side of the gearbox unit).
Remove bolts (23) securing propeller shaft (24) to the gearbox unit; if
necessary, remove screws (19) securing elastic support (18) to the chassis, and
properly secure the propeller shaft to the chassis.
Disconnect the jointed heads:
- of the selection cable: 4 (max. pull-out load: 250 N - max. pull-in load: 60
N);
- of the engagement cable: 5 (max. pull-out load: 100 N - max. pull-in load:
80 N, from lever 6 and 7). Use a suitable screwdriver to open out flexible
cable fins (3) so that the pawls are disengaged from the support (see detail
A).
Undo fastening screws (2), move clutch control cylinder (1) together with its
bracket and properly secure it to the chassis.
Use a hydraulic jack to place bracket 99370629 under the gearbox unit, then
lay the chain onto the gearbox unit and fit a link of the chain into the bracket
slot. Screw down the nut so as to firmly secure the gearbox unit to the bracket
through the chain. Remove screws (20) securing the gearbox case to the engine
base.
Undo fastening screws (15) and elastic dowel fastening screw (21), then
remove gearbox supporting crosspiece (14) together with its dowel.
Move the gearbox back until the gearbox input shaft has come off the clutch
disc hub. Then lower the hydraulic jack while simultaneously verifying that the
gearbox unit does not, during the downward movement, hit or get stuck into
a component.
Refitting
Gearbox unit reattachment is not particularly difficult and is carried out by

properly reversing the order of the detachment operations. However, the
following instructions shall be followed when coupling the clutch with the
gearbox.
Use suitable pliers to open safety snap ring (10) and take pressure plate bearing
(9) out of clutch diaphragm spring (8). Fit the bearing onto the motion input
shaft cover quill, by connecting the same to the clutch disengagement lever.
Apply Molikote molybdenum disulfide grease to the gearbox input shaft.
Engage a gear to allow the output shaft to rotate by turning the propeller shaft
mount flange. Push the gear shift fully down so that pressure plate bearing (9)
is properly engaged into the diaphragm spring.
When connecting the propeller shaft, use new nuts for the fastening screws of
the respective flanges. All the bolts and nuts shall be tightened to the prescribed
torque values indicates in the relevant tables. 6
Prior to assembling, lubricate the flexible cable (Bowden) jointed head
connection points with MOLIKOTE 33 LIGHT or MOLIKOTE G72 grease.
After the gearbox unit has been reattached, check for correct connection of
electric cables.
Verify that the gears are engaged correctly; otherwise, proceed as described in
108848
the ”Gear control check and adjustment” chapter.

Gear control check and adjustment Figure 2

Verify that the cable length as measured at the points shown in the figures
corresponds with the values shown in the following table:
Selection cable (8) Left-hand drive Right-hand drive

A 156 156
B 783 ± 2 894 ± 2
C 146 ± 1 146 1
Selection cable (4)
D 150 150
E 790 ± 2 859 ± 2
F 180 ± 1 180 ± 1
Check, with the gears idling, the distance ”C” as measured between the outer
side of support (16) and the centre of jointed head (11) of the selection cable.
This distance shall be 146 + 1 mm; otherwise, proceed as follows:
- disconnect jointed head (11) from lever (15) (pull-out load: 250 N),
loosen nut (10) and properly rotate jointed head (11) until distance ”C”
is obtained, then tighten the nut (10) to the prescribed torque;
- loosen nuts (22) and rotate tie-rod (23) until the same aforesaid distance
”C” is obtained between the ball pin (11) centre and the outer side of
support (16), then tighten nuts (21) to the prescribed torque so that the
vertical axes of the jointed heads are aligned with a maximum deviation
of 30˚;
- lubricate the jointed head (11) inside with MOLIKOTO 33 LIGHT or
MOLIKOTO G 72 grease, then connect the head to lever (15) ball pin
(pull-in load: 60 N).
Check, with the gears idling, the distance F measured between the outer
side of support (16) and the centre of jointed head (12) of engagement
cable (4). This distance shall be 180 + 1 mm; otherwise, proceed as
follows:
- disconnect jointed head (12) from lever (13) (pull-out load: 100 N),
loosen nut (14) and properly rotate jointed head (12) until distance ”F”
is obtained, then tighten the nut to the prescribed torque;
- loosen nuts (17) and rotate tie-rod (18) until the same aforesaid distance
”F” is obtained between the ball pin (12) centre and the outer side of
support (16), then tighten nuts (17) to the prescribed torque so that the
vertical axes of the jointed heads are aligned with a maximum deviation
of 30˚;
- lubricate jointed head (12) inside with MOLIKOTO 33 LIGHT or
MOLIKOTO G 72 grease, then connect the head to lever (13) ball pin
(pull-in load: 80 N).
Verify that spring (21) ends come into contact with selection lever (15) or
are at least 1 mm within the same. Otherwise, loosen screw (20) so that the
spring is correctly positioned, due to plate (19) being released.
108849

Act from inside the cab (see figure 2) to take off knob (1) and protection boot (2), then screw down knob (1) again and proceed
as follows.
5-speed gearbox unit (detail A, figure 2)
Selection cable adjustment (8):
- put the gear shift lever in neutral;
- open the adjusting device, by lifting the lock ring (6) selection cable (8);
- position gear lever (9) in such a way that it is perpendicular to support (7) plane;
- under the above conditions, release lock ring (6).
Engagement cable adjustment (4).
Engage the 5th speed, then move the lever forwards: under such condition, verify that the distance between knob (1) and the
dashboard is ~ 70 mm. Otherwise, proceed as follows:
- disconnect jointed head (4) from lever (3) (pull-out load: 100 N);
- loosen nut (5);
- properly rotate jointed head (4) until, at the aforesaid distance of 70 mm, jointed head (4) is aligned with the connecting
ball pin;
- lubricate the jointed head inside with MOLIKOTE 33 LIGHT or MOLIKOTE G 72 grease, then connect the head to lever
(3) ball pin (pull-in load: 60 N);
- tighten nut (5) to the prescribed torque so that the axis of jointed head (4) is aligned with the axis of lever (3) ball pin.
Adjustment check
Verify that all the gears are correctly engaged. In particular, the 1st and 2nd gears shall be engaged without control lever (9) coming
into contact with the safety barrier. Otherwise, repeat selection cable (8) adjustment procedure, by positioning lever (9) slightly
inclined to the left instead of perpendicular.
Verify that, after engaging the 5th gear, the distance between knob (1) and the dashboard is close to the prescribed distance
of 70 mm.
6-speed gearbox unit (detail B, figure 2)
Selection cable adjustment (8):
- engage the 2nd gear;
- move control lever (9) fully to the left, then verify that the distance between restraint quill (d) and reverse gear safety barrier
(C) is 2 P 3 mm. Otherwise, place a spacer of 2 P 3 mm in between the above parts, open the adjusting device by lifting
lock ring (6), bring lever (9) into contact with the spacer, and release lock ring (6).
Engagement cable adjustment (4):
Engage the 5th speed, then move the lever (9) forwards: under such condition, verify that the distance between knob (1) and
the dashboard is ~ 70 mm. Otherwise, proceed as follows:
- disconnect jointed head (4) from lever (3) (pull-out load: 100 N);
- loosen nut (5);
- properly rotate jointed head (4) until, at the aforesaid distance of 70 mm, jointed head (4) is aligned with the connecting
ball pin;
- lubricate jointed head (4) inside with MOLIKOTE 33 LIGHT or MOLIKOTE G 72 grease, then connect the head to lever
(3) ball pin (pull-in load: 60 N);
- tighten nut (5) to the prescribed torque so that the axis of jointed head (4) is aligned with the axis of lever (3) ball pin.
Adjustment check
Verify that all the gears can be engaged with no crawling. In particular:
- verify that the 1st and 2nd gears can be engaged without problems (by pressing the clutch pedal, if possible), also by trying
to engage them while keeping lever (9) slightly moved away from safety barrier (C) or by lifting quill (6) while going slightly
further. If the gears can be engaged more easily after the above procedure is performed, you will have to act on the selection
cable adjustment:
- if gear engagement proves to be better when moving over barrier (C), adjust the cable by allowing for a greater distance
between lever (9) and barrier (C);
- if, on the contrary, gear engagement proves to be better when moving away from barrier (C), adjust the cable by allowing
for a smaller distance between lever (9) and barrier (C);
- verify that, when the 5th gear is engaged, the distance from the dashboard is not too far from the prescribed dimension (70
mm).

GEAR CONTROL
Flexible cable replacement Act from the upper part of the gearbox unit and use a suitable
Removal screwdriver to open out flexible cable fins (6 and 7) so that the
pawls are disengaged from bracket (5).
Proceed as follows, by acting from inside the cab (see figure
Figure 3 4):
- unscrew and remove knob (1);
- remove protection boot (2);
- remove the fastening screws, then take covering (3) off;
- remove glove compartment (4);
- remove the fastening screws, then take lower central
covering (5) off.
108850
Place the vehicle on a pit or auto lift.

Act from under the vehicle to disconnect the jointed heads of:
- selection cable (2, max. pull-out load: 250 N - max. pull-in
load: 60 N) from lever (1);
- engagement cable (4, max. pull-out load: 100 N - max.
pull-in load: 80 N) from lever (1).
Figure 4
108851

Figure 5 GEAR SHIFT LEVER SUPPORT

Removal
Figure 7
108852
Disconnect the jointed heads of:
- selection cable (2, max. pull-out load: 250 N - max. pull-in 108854
load: 60 N); Proceed as described in figures 5 and 6, by acting from inside
- engagement cable (6, max. pull-out load: 100 N - max. the cab.
pull-in load: 80 N) from levers (1 and 5). Remove fastening screws (2), then take gear shift lever
Use a suitable screwdriver to open out flexible cable fins (3 support (1) off the cab.
and 7) so that the pawls are disengaged from support (4). Refitting
- prior to assembling, lubricate the flexible cable
Figure 6 (Bowden) jointed head connection points with
MOLIKOTE 33 LIGHT or MOLIKOTE G72
grease;
- tighten the nuts and screws to the prescribed
torque;
- adjust the gear control, as described in the
respective chapter.
108853
Remove nuts (3) securing flange (2) to the cab floor, then take
flexible cable assembly (1) out.
Refitting
Reattachment is carried out by reversing the order

of the detachment operations. Moreover, the
following instructions shall be observed:
- prior to assembling, lubricate the flexible cable
(Bowden) jointed head connection
points with MOLIKOTE 33 LIGHT or
MOLIKOTE G72 grease;
- tighten the nuts and screws to the prescribed
torque;
- adjust the gear control, as described in the
respective chapter.


DAILY EURO 4 5 S 300 TRANSMISSIONS 13
5 S 300 Transmissions
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GEAR SELECTION AND ENGAGEMENT

CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . 17
- Engagement locking device . . . . . . . . . . . . . . . 17
- Reverse gear anti-engagement device . . . . . . . 17
SPECIFICATIONS AND DATA . . . . . . . . . . . . . 18
- Gearbox uonit . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Gearbox control . . . . . . . . . . . . . . . . . . . . . . . 21
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OVERHAULING THE TRANSMISSION . . . . . . 28
- Gear control box . . . . . . . . . . . . . . . . . . . . . . . 28
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Selection and adjustment tie-rod assembling . . 30
- Disassembling the transmission . . . . . . . . . . . . 31
- Disassembling the rear cover bearings . . . . . . . 33
- Disassembling the transmission bearings . . . . . 33
- Disassembling the main shaft . . . . . . . . . . . . . . 34
- Drive input shaft . . . . . . . . . . . . . . . . . . . . . . . 36
- Disassembling the transmission shaft . . . . . . . . 36
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Hubs - sliding sleeves - forks . . . . . . . . . . . . . . 39
- Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Shafts - gears . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Synchronizing devices . . . . . . . . . . . . . . . . . . . 39
- Mounting the transmission shaft . . . . . . . . . . . . 40
- Mounting the main shaft . . . . . . . . . . . . . . . . . 40
- Rods - forks - selector - driver . . . . . . . . . . . . . 43

14 5 S 300 TRANSMISSIONS DAILY EURO 4
Page
- Disassembly - assembly . . . . . . . . . . . . . . . . . . 43
- Mounting the transmission . . . . . . . . . . . . . . . . 43
- Adjusting the transmission shaft bearing

end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

GENERAL
The 5 S 300 transmission is mechanical with synchronized The gears splined on the main and reverse gear shafts idle on
engagement of forward gears. straight roller bearings.
It is composed of a light alloy box (which also serves as a clutch The input and main shafts are supported, in the transmission,
cover), a rear cover (where the speed engagement controls by watertight, non-adjustable ball bearings.
and gearing are housed) and a control box.
The transmission shaft is supported, in the transmission, by
There is an opening on the side of the transmission to apply tapered roller bearings that can be adjusted axially by means
a power take-off. of ring shims.
Drive transmission is accomplished by a set of helical-toothed Gear engagement synchronization is accomplished by means
constant mesh gears, for both forward and reverse gears. of free ring synchronizing devices with a single cone for 5th -
4th - 3rd gears -R.G. and dual cone for 1st - 2nd gears.
The splined or machined gears are on four shafts: input, main,
transmission and reverse gear. Control inside the transmission is accomplished with four
rods:
- a main rod to select and engage gears;
- three rods equipped with forks for engaging gears.
The external control is achieved by means of two levers:
(selection and engagement levers). The levers are actuated by
tie-rods through a transfer case, connected to the gear shift
lever located in the cab, by an assembly made up of two
flexible cables (BOWDEN cables).
The external engagement lever features two opposed
weights, used to dampen the flexible control cable
(BOWDEN) engagement thrust and, as a result, its noise.
Figure 1
108637

GEAR SELECTION AND ENGAGEMENT CONTROL

The combined action of the selection (2) and engagement (1) levers bring about the rotation and/or axial shift of the rod (4) in two
successive stages, engaging the desired gear by means of one of the rods (9, 8 or 7).
First Stage
Depending on the angular position of the selection lever (2), the driver (3) (integral with it) turns the selector (5) with the rod (4)
(connected together), setting the selector on the rod of the chosen gear.
Second Stage
Depending on the movement given to the engagement lever (1), the driver (3) (integral with it) shifts the selector (5) (already
prepared) axially with the rod (4) and consequently also the engagement rod of the chosen gear.
Position of transmission in neutral and/or ready Ready for 1st/2nd gear
to select 3rd/4th gear
Figure 2 Figure 3
SECTION A-A SECTION A-A
49373 49372
1. Gear engagement lever - 2. Gear selection lever - 3. Driver - 4. Gear selection/engagement control rod -
5. Selector - 6. Driver - 7. Rod for 3rd/4th gear engagement fork - 8. Rod for 1st/2nd gear engagement fork -
9. Rod for 5th/reverse gear engagement fork.
The position of the transmission in neutral coincides with This arrangement is accomplished by shifting the selection
being ready to select 3rd/4th gear. lever (2) anticlockwise by 7.1° to the control axis, which
corresponds to a clockwise change in the angle of the rod (4)
In this case the vertical axis of the selection lever (2) is exactly
of 10°.
90° from the horizontal control axis, corresponding to no
change in the angle of the rod (4).

Ready to select 5th/reverse gear

Figure 4 SAFETY DEVICES
The transmission is equipped with two mechanical safety
devices:
Engagement locking device to prevent more than one gear
getting engaged at the same time.
Reverse gear anti-engagement device when passing from 5th
to 4th gear.
SECTION A-A Engagement locking device
Figure 5
49374 49375
This device is composed of a plate (1), housed in the rear

cover, operated by the gear selection/engagement control rod
1. Gear engagement lever - 2. Gear selection lever - (2). When selecting/engaging a gear, the rod (2)
3. Driver - 4. Gear selection/engagement control rod - simultaneously turns the plate (1) in which it is inserted. In this
5. Selector - 6. Driver - 7. Rod for 3rd/4th gear way, the plate (1) will free itself from the slot of the rod
engagement fork - 8. Rod for 1st/2nd gear engagement fork involved in engaging the gear and will lock the other two rods
- 9. Rod for 5th/reverse gear engagement fork. by inserting itself into their slots.
Above presetting is implemented by moving selector (2) Reverse gear anti-engagement device
clockwise by 7.1º with respect to control vertical axis, that
corresponds to 10º anticlockwise angular displacement of rod
(4). Figure 6
51381
This device is composed of a plate (8) and a spring (7) housed in the transmission. When passing from the 4th gear position (Figure
A) to the 5th gear position (Figure B), the driver (9), moving in the direction of the arrow, disengages the plate (8), which under the
action of the spring (7) moves onto the driver (9) preventing reverse gear from getting engaged in the opposite manoeuvre.

SPECIFICATIONS AND DATA
TRANSMISSION 5 S 300
Type Mechanical
Input torque Nm 300

Weight kg 44.6
5 forward speeds
Speeds 1 reverse speed
Speed control Mechanical
Power take-off Optional
Speed engagement:
Forward speeds
- 5th / 4th / 3nd Single-cone synchronizer

- 2nd / 1st Dual-cone synchronizer
Reverse speed Rapid shift
Speed retention mechanism Sliding sleeves retained by pawls and springs.
Gears Helical-toothed constant mesh gears
Gear ratio
First 5.00
Second 2.62
Third 1.54
Fourth 1.00
Fifth 0.78
Reverse 4.58
Shaft bearings:
Main shaft watertight ball bearing
Straight roller bearing tapered roller

TRANSMISSION 5 S 300
Transmission shaft bearing end play: 0 ÷ 0.05 mm
Transmission shaft bearing end play adjustment by shims
Shim thickness for transmission shaft bearing 2.00 - 2.30 - 2.45 mm

end play adjustment with 0.05 mm progressive sequence
Main shaft
Assembly temperatures:
sliding sleeve hubs 150 oC
2nd and 3rd speed gear bushings and spacer 170 ºC ÷ 160 ºC
5th speed gear spacer 90 ºC
Secondary shaft
bearings 80 ºC (max 120 ºC)
5th speed gear 140 ºC ÷ 170 ºC
5th speed gear driving load 31 KN
5th speed gear removing load 50 KN
Input shaft
front bearing* 80 ºC (max 120 ºC)
Gear axial backlash:

0.15 ÷ 0.3 mm
1st - 3rd - 4th - R - 5th speed
0.25 ÷ 0.4 mm
2nd speed
3rd and 4th speed sliding sleeve hub retaining

0 ÷ 0.05 mm
circlip axial backlash
3rd and 4th speed sliding sleeve hub retaining

circlip thickness 2 - 2.85 mm with progression of 0.05 mm
Transmission shaft rear bearing retaining ring

0 ÷ 0.05 mm
end float
Transmission shaft rear bearing retaining ring 2.05 ÷ 2.45 mm

thickness with progression of 0.05 mm
242
LOCTITE sealant 510
5206
Type of oil: TUTELA TRUCK GEARLITE
Quantity 2 lit
litres
1 8 kg
1.8 k
* = Do not use hot air equipment to heat bearing.

TIGHTENING TORQUES
Gearbox unit
Figure 7
108855
TORQUE
DESCRIPTION
Nm kgm
1 Clutch housing, screw to fasten clutch housing to chassis 80 8
2 Screw to fasten clutch housing to box 23 ± 15% 2.3 ± 15%
3 Constant mesh shaft cover fastening screw 23±15% 2.3 ± 15%
4 Spring retaining plug 32 ± 10% 3.2 ± 10%
5 Grub screw securing gear selection sector to rod 60 ±15% 6 ±15%
6** Screw securing p.t.o. side cover 46 ± 15% 4.6 ± 15%
7 Plug 28÷30 ± 15% 2.8÷3 ± 15%
8 Screw securing reverse gear shaft 22 ± 15% 2.2 ± 15%
9 Screw securing rear cover 23 ± 15% 2.3 ± 15%
10 Screw locking sleeve for transmission coupling on main shaft 120 ± 15% 12 ± 15%
11D Screw securing ball bearing retaining ring 9.5 ± 15% 0.9 ± 15%
12 Screw securing control cable bracket 23 ± 15% 2.3 ± 15%
13 Screw securing gear control mounting 23 ± 15% 2.3 ± 15%
14 Nut for screw securing lever to control rod 34 ± 15% 3.4 ± 15%
15 Nut securing articulation pin to control lever 23 ± 15% 2.3 ± 15%
16 Nut for screw securing lever to control rod 34 ± 15% 3.4 ± 15%
17 Oil vapour breather 10 ± 15% 1± 15%
18 Nut to secure articulation pin to control lever 23 ± 15% 2.3 ± 15%
* Spread LOCTITE 5206 sealant on the contact surfaces
D Spread LOCTITE 242 on the thread
** Spread LOCTITE 510 on the thread

0,
TIGHTENING TORQUES
Gearbox control
Figure 8
108856
TORQUE
DESCRIPTION
Nm kgm
1 M8 screw for gearbox control support fastening 14 ± 17 1.4 ± 1.7
2 Nut securing the jointed heads to the cable 4 ± 4.8 0.4 ± 0.48
3 M8 screw securing the transfer case to the gearbox 21 ± 25 2.1 ± 2.5
4 M8 self-locking nut securing the flange to the cab 3.5 0.35
5 Nut securing the jointed head to the tie-rod 4 ± 4.5 0.4 ± 0.5
6 Plate fastening screw 7.8 ± 9.25 0.78 ± 0.95
After tightening nuts (4), the jointed head hole axis shall be aligned with the axis of the ball pin to which it is connected. After tightening
nuts (5), the vertical axes of tie-rod (5) jointed heads shall be aligned, with a maximum deviation of less than α < 30˚ (lower).

TOOLS
99322205 Assemblies overhaul revolving stand
99322225 Unit support (to use with stand 99322205)
99340205 Percussion extractor
99341002 Single-acting scaffold

TOOLS
99341012 Pair of brackets
99341015 Press
99341017 Couple of brackets whit hole
99341019 Pair of tie rods with grips
99341025 Grips
99345003 Extractor for gearbox front half-casing

TOOLS
99348001 Extractor with locking device
99348004 Universal male extractor from 5 to 70 mm
99360521 Tool to extract and insert main shaft, transmission shaft and
rod - fork assembly
99370006 Handle for interchangeable drivers
99370234 Tool for fitting main shaft in rear bearing and fitting output flange
on main shaft

TOOL
99370317 Reaction lever with extension for holding flange
99370629 Transmission support during removal from and refitting to vehicle
99371057 Bracket for supporting gearbox during overhaul

(use with 99322205-99322225)
99374091 Punch for fitting bearing external races (dia. 55 ÷ 69 mm)

(use with 99370007)
99374452 Keying device to fit gasket on transmission rear cover

(use with 99370006)
99374453 Keying device to fit gasket on transmission

Figure 9
75420
Figure 10 Figure 11
47371 47369
TRANSVERSE SECTION ON THE GEAR TRANSVERSE SECTION ON THE REVERSE GEAR

SELECTION/ENGAGEMENT ROD ANTI-ENGAGEMENT DEVICE
POSITIONING PUSH ROD

Figure 12
49364
SECTION ON GEAR ENGAGEMENT ROD POSITIONING PAWLS
Figure 13
49368
TRANSVERSE SECTION ON INTERNAL CONTROL BOX

530210 OVERHAULING THE TRANSMISSION

Figure 14 Figure 16
51383
108638
Take out the fixing screws (1) and remove the gear control box
Remove the plug and drain off the lubricating oil. (2).
The used oil must be disposed of according to the law Figure 17

in force.
Fit the gearbox (1) with the bracket 99371057 (4) and secure
this to the brackets 99322225 (3) on the rotary stand
99322205 (2).
530220 Gear control box

Disassembly
Figure 15
51384
Loosen the nuts (3) for the retaining screws (6).

Extract the levers (2 and 7) from the shafts (1 and 8) and
extract these from the box (5). Take off the caps (4).
Figure 18
108857
Take tie-rod (3) off by disconnecting jointed heads (1) from

levers (4 and 7).
levers (10 and 2).
NOTE Tie-rods (3 and 8) are interchangeable.

51385
Remove screws (5), then take transfer case (6) off the gearbox With a punch (3), remove the spring pin (4) and extract the
unit. shaft (2) from the internal lever (1).
Repeat these steps for the other shaft.

Figure 19 Figure 22
87896
Mount the selection and engagement levers (1) on their

respective shafts (2) and fasten them with the spring pins (3).
51386
Use a punch on the point shown by the arrow and eject the NOTE The spring pin (3) must be positioned with the cut
O-rings and roller bushes (2) from the box (1). horizontal. Fit spring peg (4), with cutting edge
positioned at 180° from spring peg (3) cutting edge,
in spring peg (3) engagement lever.
Assembly
Figure 20 Figure 23
51390
Lubricate the roller bearings (1, Figure 19) with TUTELA MR3
grease and mount the shafts (3 and 6) complete with the
51387
internal levers (4 and 5) in the box (2). Mount the caps (8 and
Thoroughly clean the oil vapour vent (3). 9) and levers (1 and 10) on the shafts (3 and 6) tightening the
With a suitable punch, mount the roller bearings (1) in the box nuts for the fixing screw (7).
(2).
Figure 24
Figure 21
51391
Thoroughly clean the mating surfaces of the gear control box

(2) and apply LOCTITE 5206 sealant on them.
51388
Fit the box (2) on the transmission, taking care that the levers
Using a suitable punch, mount the O-rings (1) in the box (2), and shafts are positioned correctly in their respective seats.
positioning them at the height shown. Tighten the screws (1) to the required torque.
Pack the gap between the O-ring and roller bearing with grease.

Figure 25 Figure 27
108858 108860
Fit transfer case (1) into place, by tightening fastening screws Verify that the tie-rod (4) length ”X”, as measured between
(2) to the prescribed torque. the jointed head centres is not greater than 342 mm.
Lubricate the jointed head inside with MOLIKOTE 33 LIGHT
Selection and adjustment tie-rod assembling or MOLIKOTE G 72 grease, then connect the jointed heads
to levers (1 and 5).
Measure the distance ”y” between transfer case (3) outer
surface and ball pin (6) centre: it shall be ”y” = 180 ± 1 mm.
Figure 26 Otherwise, loosen nuts (2) and properly rotate tie-rod (4)
until the prescribed distance is obtained. Then tighten nuts (2)
to the prescribed torque, so that the vertical axes of the
jointed heads are aligned, with a maximum deviation of less
than 30˚ (lower).
Figure 28
108859
Verify that the tie-rod (4) length ”X”, as measured between

the jointed head centres is not greater than 342 mm.
or MOLIKOTE G 72 grease, then connect the jointed heads
Otherwise, loosen nuts (2) and properly rotate tie-rod (4)
jointed heads are aligned, with a maximum deviation of less 108861
than 30˚ (lower).
Verify that spring (3) ends come into contact with selection
lever (4) or are at least 1 mm within the same. Otherwise,
loosen screw (1) so that spring (3) is correctly positioned, due
to plate (2) being released.

Disassembling the transmission

Figure 29 Figure 32
51393 51396
Dismantle the gear control box as described under the Remove the screws (1) and take off the cover (2) protecting
relevant heading. the input shaft (3).
Remove the reverse gear stop plate (2) and the spring (1).
Figure 30 Figure 33
74955 51397
Block rotation of the sleeve (1) by applying the lever Drill the O-ring (2).
99370317 (3). With the bushing (2) remove the screw (5)
Using a suitable hook and extractor (1), remove the O-ring (2)
with the washer beneath (4).
from the transmission.
Take out the lever 99370317 (3).
Figure 34
Figure 31
51398
74956
Apply the bridge 99341003 (1) and clamps 99341017 (2)

onto the sleeve (3). Remove the circlip (2) retaining the front bearing (3) from the
Extract the sleeve (3) from the main shaft. input shaft (1).

Figure 35 Figure 38
51399
Take out the plug with the washer (1), extract the springs (2
and 3) and the push rod (4). Remove the screw (6) securing
the reverse gear shaft to the transmission (5). Push the two
centring pins (7) downwards to free them from the
transmission (5). Remove the screws (8) securing the rear
cover (9) to the transmission (5).
Figure 36
51402
Insert an Allen wrench (2) into the engagement locking plate

(5). Turn the Allen wrench (2) to position the engagement
locking plate (5) outside the slots (⇒) in the engagement rods
(1, 3 and 4).
Figure 39
74957
Fit the drive input shaft (1) with tool 99345003 (2) and secure
this to the gearbox (4) with screws (3). Screw down the screw
(5) of the tool (2) to extract the gearbox from the bearing (6).
Figure 37
74959
Mount the tool 99360521 (3) onto the rods (4, 5 and 6), on
the input shaft (1) and on the transmission shaft (10). Secure
the tool 99360521 (3) on the input shaft (1) with the retaining
ring (2) and with the screw (9) to the transmission shaft (10).
Hook the tool 99360521 (3) onto the lift. Apply the extractor
74965 composed of the bridge 99341004 (13) and ties 99341012
Take out the screw (3) and extract the shaft (1) from the rear (12) onto the rear cover (7). Use the screw of the bridge (13)
cover (4). Remove the reverse gear (2). Drill the cups (10) and work on the lift to extract the main shaft (11) from the
screw a special screw into them; with the aid of the screw, rear bearing. Set this assembly on the workbench. Remove the
extract the cups (10) from the rear cover (4). Remove the tool 99360521 (3) and separate the transmission shaft (10),
springs (9) and the pawls (8). Extract the rod (7) together with input shaft with relative synchronizing ring and the rods (4, 5
the selector (5) and driver (6). and 6) from the main shaft.

Disassembling the rear cover bearings

Figure 40 Figure 43
51404 74961
Remove the screws (2) securing the plates (3). Turn over the rear cover (3). Take out the O-ring (1) and the
”phonic wheel” (2). Using a suitable punch, remove the ball
Take out the plates (3) and the engagement locking plate (1). bearing (4, Figure 36). Remove the tachograph sensor (5) and
the reversing light switch (4).
Figure 41 Disassembling the transmission bearings
Figure 44
74960
Using universal extractor 99348004 (1), remove the outer

74962
ring (2) of the transmission shaft bearing.
Figure 42 ring (2) of the transmission shaft bearing.
Figure 45
51406
51409
Using the percussion extractor 99340205 (1) and part Using the percussion extractor 99340205 (1) and part
99348004 (2), extract the bushing with the ball bearings (3). 99348004 (2), extract the bushing with the ball bearings (3).

Figure 46 Disassembling the main shaft
NOTE Mark the assembly position of each synchronizing

device on the respective gears.
Figure 49
51410
Remove the screws (1) securing the plates (2).

Take out the plates (2).
51413
Clamp the main shaft (1) in a vice. Remove the roller bearing
Figure 47 (2) and the synchronizer ring (3). Remove the sliding sleeve
(6) for engaging 3rd-4th gear from the hub (5) and, taking care
as the plugs (8) come out with their relative balls (9) and
springs (7), recover them.
Figure 50
51411
Turn over the transmission.

Using a suitable punch, remove the ball bearing (1).
51414
Remove the retaining ring (4, Figure 44). Extract the hub (2)
with the extractor 99348001 (1).
Figure 48
Figure 51
51412 51415
Using the percussion extractor 99340205 (1) and part Remove the synchronizer ring (1), 3rd gear (2) and roller
99348004 (2), extract the roller bearing (3). bearing (3).

Figure 52 Figure 55
76010
51419
Using bridge 99341003 (1), screw stays 99341019 (2), grips
Using the bridge 99341003 (1), ties 99341012 (2) and clamp
99341025 (4) and clamp 99341015 (3), take out the 2nd gear
99341015 (3), extract the 1st gear (6), with the synchronizer
(7), spacer (6) and bushing (5).
ring (7), middle ring (8) and ring (9), hub (5) and bushing (4).
Remove the roller bearing (10).
NOTE Force of extraction of the bushing (4) 40 kN.

NOTE Force of extraction of the bushing (4) 40 kN.
Figure 53 Figure 56
51417 51420
Take out the synchronizer ring (4), middle ring (3), ring (2) and Turn over the main shaft (1). Take out the spacer ring (2) and
roller bearing (1). remove the 5th gear (3).
Figure 54 Figure 57
51418
Remove the sleeve (2) for engaging 1st-2nd gear from the hub 51421
(1) and, taking care as the plugs (5) come out with their relative
balls (3) and springs (4), recover them. Remove the half roller bearings (1), the synchronizer ring (3)
and the retaining ring (4) holding the hub (2).

Figure 58 Figure 61
51425
If the cog-wheel (2) of the 5th gear (1) shows any sign of
75416
damage, take out the retaining ring (3), replace the cog-wheel
Using the bridge 99341003 (1), ties 99341012 (2) and clamp (2) and refit the retaining ring (3).
99341015 (3), extract the reverse gear (5) and the
Drive input shaft
synchronizer assembly (4).
Figure 62
Figure 59
51426
If the cog-wheel (2) of the input shaft gear (1) shows any sign
of damage, take out the retaining ring (3), replace the
51423 cog-wheel (2) and refit the retaining ring (3).
Remove the roller bearing (1). Disassembling the transmission shaft
Figure 63
Figure 60
5
51427
51424
Take out the retaining ring (1) and extract the internal ring (2)
Remove the sliding sleeve (2) for engaging reverse - 5th gear of the rear bearing. Turn over the shaft (3) and extract the
from the hub (1), taking care as the plugs (3) come out with internal ring (4) of the front bearing.
their relative balls (4) and springs (5), recover them. Shaft (3) gear (5) removal, if required, shall be performed by
hydraulic press; 50 kN removing load.

Figure 64
51428
INPUT SHAFT ASSEMBLY DRAWING
Figure 65
76011
MAIN SHAFT ASSEMBLY DRAWING
Figure 66
51430
TRANSMISSION SHAFT ASSEMBLY DRAWING

Figure 67
51431
1st-2nd GEAR DUAL CONE SYNCHRONIZER ASSEMBLY
Figure 68
75414
3rd - 4th - 5th GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY

CHECKS
Transmission Shafts - gears

The transmission and relative covers must show no sign of The seats on the shafts, for bearings, must be neither damaged
cracking. nor worn. The toothing of the gears must be neither damaged
The mating surfaces of the covers and transmission must not nor worn.
be damaged or deformed. Remove any remains of sealant
from them.
Synchronizing devices
The seats of the bearings, reverse gear shaft and gear control Check the wear on the synchronizer rings (3, Figure 70)
rods must be neither damaged nor too worn. proceeding as follows:
- position the synchronizer ring (3) on the respective
Hubs - sliding sleeves - forks cog-wheel (2, 7, 8, 9 and 11, Figure 70);
The grooves on the hubs and relative sliding sleeves must not
- turn the synchronizer ring so as to ensure correct coupling
be damaged. The sliding sleeve must run freely on the hub. The
on the tapered surface of the cog-wheel of the gear.
plugs and balls for positioning the sliding sleeve must be
neither damaged nor worn. The toothing of the sliding sleeves - With a feeler gauge, check the distance A on two
must not be damaged. The forks must be sound with an end diametrically opposite points.
float, in the radial groove of the sleeve, no greater than 1 mm. If the average measured value A is less than 0.5 mm,
replace the synchronizer ring.
Bearings
The roller bearings must be in perfect condition with no signs
of wear or overheating. They must only be removed if they are
to be replaced. NOTE After this check, the synchronizer rings must be
marked on their respective gears to avoid swapping
their positions over when assembling.
Figure 69
87897
1st - 2nd GEAR SYNCHRONIZERS 3rd - 4th GEAR SYNCHRONIZERS 5th GEAR SYNCHRONIZER
A. Synchronization reserve +0,25
A. Synchronization reserve A. Synchronization reserve
1st-2nd gear 1.4 -0.35 mm 3rd - 4th gear 1.15 + 0.2 mm 5th gear 1.15 + 0.2 mm
B. 1st-2nd gear release clearance 0.9 +0,6
-0.35
mm B. 3rd - 4th gear release clearance 1.40 + 0.65 mm B. 5th gear release clearance 1.10 + 0.4 mm
Force of sliding of sliding sleeves 80 ÷ 95 Nm.

Maximum admitted wear on the synchronizers, distance A - 0,5 mm
1. Sliding sleeve - 2. 1st gear cog-wheel - 3. Synchronizer ring - 4. Middle ring - 5. Ring - 6. Hub -
7. 2nd gear cog-wheel - 8. 3rd gear cog-wheel - 9. 4th gear cog-wheel - 10. Reverse gear - 11. 5th gear cog-wheel

Mounting the transmission shaft

Figure 70 Figure 73
51433
75418
Gear (5) fitting on shaft (3), if required, shall be performed by
Heat the hub (2) for the 5th - reverse gear engagement sliding
hydraulic press after heating the gear to 140°C ÷ 170°C;
sleeve to a temperature no higher than 150°C and mount it
31 kN driving load.
on the main shaft with a suitable punch (1).
Heat the internal rings (2 and 4) of the tapered roller bearings
to a temperature of approx. ~ 80°C and, with a suitable
punch (1), mount them on the transmission shaft (3). NOTE When fitting, make sure that the projecting parts (3)
of the synchronizer ring get positioned in the hub (2)
Figure 71 correctly.
Figure 74
51434
51437
Mount the retaining ring (1) whose thickness gives an end float
when in its seat of 0 ÷ 0.05 mm. Mount the retaining ring (1) whose thickness makes for null
clearance in its seat.
Mounting the main shaft Check the end float of the reverse gear (2). It should be
0.15 ÷ 0.3 mm.
NOTE Mount the synchronizer rings on their respective gears
according to the marks made during disassembly or Figure 75
when checking in the case of replacement.
Figure 72
51438
Mount the sliding sleeve (5) on the hub (4) facing as shown
75417 in the figure.
Tighten the main shaft (1) in a vice and mount on it: the roller Put the springs (3), plugs (1) and balls (2) into the seats of the
cage (2), reverse gear (4) and synchronizer ring (3). hub (4), settling them under the sliding sleeve.

Figure 76 Figure 79
51439
51441
Positioning the synchronizer ring (2) and the half roller Mount the 1st gear (1).
bearings (1). Lubricate the ring (4), middle ring (3), synchronizer ring (2)
with TUTELA MR3 grease and mount them on the gear (1).
Figure 77
NOTE Make sure the tongues of the rings (2 and 3) are
positioned correctly in their respective seats.
Figure 80
51420
Install the 5th speed gear (3).

Heat spacer ring (2) to 90°C and install it.
Upset the main shaft (1).
Figure 78
51442
Heat the hub (1) for the 1st - 2nd gear sliding sleeve to a
temperature no higher than 150°C and mount it on the main
shaft with a suitable punch.
NOTE When assembling, make sure the tongues of the rings

51440
(3 and 4, Figure 79) and the projections of the
synchronizer ring (2) are positioned correctly in the
hub (1). Check that the end float of the 1st gear (3)
is 0.15 ÷ 0.30 mm.
Position the roller bearing (2) on the main shaft (1).

Figure 81 Figure 83
51443 51445
Heat the bushing (2) to a temperature no higher than 170°C Mount the 2nd gear (4).
and mount it on the main shaft (1). Heat the spacer (3) to a temperature no higher than 170°C
Mount the sliding sleeve (4) on the hub (3). and mount it on the main shaft (1).
Put (3) the springs (7), plugs (5) and balls (6) into the seats in Check the end float of the 2nd gear (4). It should be
the hub, settling them under the sliding sleeve (4). 0.15 ÷ 0.30 mm.
Heat the bushing (2) to a temperature no higher than 170°C
and mount it on the main shaft (1).
Figure 82 Figure 84
51417 51446
Lubricate the synchronizer ring (4), middle ring (3) and the ring Mount the roller bearing (1) and the 3rd gear (3). Position the
(2) with TUTELA MR3 grease. synchronizer ring (2) on the 3rd gear (3).
NOTE Make sure the tongues of the rings (2 - 3) and the

projections of the synchronizer ring (4) are
positioned correctly in their respective seats.
Mount the roller bearing (1).

Figure 85 Rods - forks - selector - driver

Disassembly - assembly
Figure 87
51447
51449
Heat the hub (2) to a temperature no higher than 150°C and
mount it on the main shaft (1) checking that the projections To replace the forks of the selector and driver from their
respective control rods it is sufficient to remove the retaining
(3) of the synchronizer ring are positioned in the spring pins with a suitable punch.
compartments of the hub (2).
For assembly, carry out these steps in reverse order, replacing
Mount the retainer ring (4) whose thickness determines an the spring pins.
end float in its seat of 0 ÷ 0.05 mm.
Check the end float of the 3rd gear (5). It should be NOTE Spring pegs must be positioned with the cutting edge
0.15 ÷ 0.30 mm. placed level.
Mounting the transmission
NOTE During assembly, the gaskets, retaining rings, O-rings,

spring pins, safety plates and springs must always be
replaced with new parts.
The nuts and screws must be tightened to the required

torque unless specified otherwise, with the thread dry and
greased.
Adjusting the transmission shaft bearing end float
Figure 88
Figure 86
51413
Mount the sliding sleeve (6) on the hub (5). Put the springs (7), 51450
plugs (8) and balls (9) into the seats in the hub (5), settling Determine the thickness S of the ring (1) for adjusting the
them under the sliding sleeve (6). transmission shaft bearing (2) end float, proceeding as follows:
Grease the roller bearing (2) and fit it on the main shaft (1). - measure the distance A between the end of the
transmission (3) and the seat of the ring of the front
Position the synchronizer bearing (3) on the hub (5). bearing (2);

Figure 89 Figure 91
51451
- measure the distance B between the end of the rear

cover (1) and the seat of the ring of the rear bearing;
41452
Position the adjustment ring (1, Figure 88) of the thickness

determined with the above measurement in the transmission (1).
Heat the bearing seats of the box (1) to a temperature of
approx. 80°C and mount:
- the external ring (6) of the front tapered roller bearing
with punch 99374091 and grip 99370007;
- the ball bearing (7) with a general punch;
- the bushing with ball bearing (4) and the roller bearing (5)
with a general punch.
Position the retaining plates (3) and secure them to the box,
Figure 90 tightening the screws (2) to the required torque.
NOTE Apply LOCTITE 242 onto the thread of the screws

(2, Figure 91 and 5, Figure 92).
Figure 92
51452A
- mount the internal rings (2 - 4) of the tapered roller

bearings on the transmission shaft (5);
- position the external rings (1 - 3) on the internal ones
(2 - 4);
- apply a load F of 100 ÷120 N on the external rings (1 - 3).
- In these conditions, measure the distance C between the
ends of the rings (1 - 3).
51453
- The thickness S of the bearing end float adjustment ring
Heat the bearing seats of the box (1) to a temperature of
is given by:
approx. 80ºC and mount:
- the external ring (7) of the tapered roller bearing with
S = A + B − C − 0, 10 punch 99374091 and grip 99370007;
- the ball bearing (4) and the bushing with ball bearings (2)
Where:
A - B - C are the measured values Position the retaining plates (6) and the engagement locking
0.10 = constant value, including the deformation of the plate (3) in their seats.
external rings (1 - 3) after driving them into their seats and the Secure these to the box, tightening the screws (5) to the
end float of the bearings of 0.05 mm. required torque.

Figure 93 Figure 95
51454
Clamp the main shaft in a vice.

Mount the input shaft (8) on the main shaft (4) and couple this
with the transmission shaft (5).
Fit tool 99360521 (6) on shafts (8 and 5) and tie it to input
shaft (8) by circlip (9) and to secondary shaft (5) by screw (7).
Set forks and rods thereof (1 - 2 - 3) on sliding sleeves and tie
by tool 99360521 sleeves (6).
74964
Set properly clutch locking plate (5) by setscrew wrench (2) to

avoid control rods (1 - 3 - 4) interference with plate during next
operation.
Screw the pin (11) of tool 99370234 into the hole in the output
shaft (6). Mount the bushing (8) and spacer (9) on the tool
99370234.
Screw on the nut (10) and at the same time lower the hoist so
the output shaft (6) is positioned on the ball bearing (7).
Remove the tool 99360521 and the parts (8 - 9 - 10 - 11) of
the tool 99370234.
Figure 94
Figure 96
74965
74963
Mount the rod (7) complete with selector (5) and driver (6).
Hook the hoist onto tool 99360521 (1). Lift the assembly (2) Put the pawls (8) and springs (9) into the rear cover (4).
as put together beforehand and mount it in the rear cover (3). Mount the cups (10).
Mount the reverse gear idler (2) with the shaft (1) and secure
During this operation, check that the output shaft (7) goes into the shaft to the rear cover (4) tightening the screw (3) to the
the supporting ball bearing and the control rods (4 - 5 - 6) go required torque.
into their respective seats. Apply LOCTITE 5206 sealant to the mating surfaces of the
transmission.

Figure 97 Figure 99
74966 51398
Warm up the roller bearing inner ring (→) at 80°C and fit the Mount the front bearing (3) retaining ring (2) on the input shaft
gearbox (1) on the rear cover and check that the shafts and (1).
the control rods fit correctly in the respective seats.
Figure 100
Figure 98
51461
Mount the O-ring (2) with the key 99374453 (1).
Figure 101
51459
Insert the centring pins (⇒) in the rear cover (5).

Screw on the screws (11) fixing the rear cover (5) to the
transmission (3) and tighten them to the required torque.
Tighten the screw (4) fixing the reverse gear idler shaft to the
transmission (3) to the required torque.
Insert the push rod (6) and springs (7 - 8) and tighten the plug
(10) with a new gasket (9) to the required torque.
51396
If the side cover (1) has been removed, apply LOCTITE 5206
sealant on the mating surface and tighten the screws (2) to the
required tightening torque. Mount input shaft (3) protection cover (2) and tighten screws
(1) to the required torque.

74969
74967
Mount the output flange (1) on the main shaft with the tool
Mount the phonic wheel (2) onto the main shaft (3). 99370234 (2).
Mount the reversing light switch (4) and the tachograph Remove the tool 99370234 (2).
sensor (1).
74968 74970
Mount the washer (3) and screw on the screw (4).

Mount the O-ring (3) in the rear cover (4) with the key
Lock the rotation of the flange (1) with the lever 99370317
99374452 (1) and the grip 99370007 (2).
(2) and tighten the screw (4) to the required torque.
Mount the control box as described under the relevant heading.
Fill the transmission with lubricating oil in the required quantity
and grade.


DAILY EURO 4 6 S 400 O.D. TRANSMISSION 49
Print 603.43.351
6 S 400 O.D. Transmission
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
GEAR SELECTION AND ENGAGEMENT . . . . . 52
- Gear control box . . . . . . . . . . . . . . . . . . . . . . . 57
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OVERHAULING THE TRANSMISSION . . . . . . . 66
- Gear control box . . . . . . . . . . . . . . . . . . . . . . . 66
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
- Selection and adjustment tie-rod assembling . . 68
- Disassembling the transmission . . . . . . . . . . . . 69
- Disassembling the rear cover bearings . . . . . . . 72
- Disassembling the transmission bearings . . . . . 73
- Disassembling the main shaft . . . . . . . . . . . . . . 73
- Disassembling the drive input shaft . . . . . . . . . 75
- Disassembling the transmission shaft . . . . . . . . 75
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- Hubs - sliding sleeves - forks . . . . . . . . . . . . . . 79
- Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- Shafts - gears . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- Synchronizing devices . . . . . . . . . . . . . . . . . . . 79
- Mounting the transmission shaft . . . . . . . . . . . . 81
- Mounting the main shaft . . . . . . . . . . . . . . . . . 82
- Rods - forks - selector - driver . . . . . . . . . . . . . 85
- Disassembly - assembly . . . . . . . . . . . . . . . . . . 85
- Mounting the transmission . . . . . . . . . . . . . . . . 85
- Adjusting the transmission shaft bearing

end float 85

50 6 S 400 O.D. TRANSMISSION DAILY EURO 4

GENERAL
The 6 S 400 O.D. transmission is mechanical with synchronized The input and main shafts are supported, in the transmission,
engagement of forward gears. by watertight, non-adjustable ball bearings.
It is composed of a light alloy box (which also serves as a clutch The transmission shaft is supported, in the transmission, by
cover), a rear cover (where the speed engagement controls roller bearings that can be adjusted axially by means of ring
and gearing are housed) and a control box. shims.
There is an opening on the side of the transmission to apply 6th, 5th, 4th, 3rd and reverse gears (new version transmissions)
a power take-off. are synchronised by means of single taper free synchroniser
rings; double taper wheels are used for 1st and 2nd gear.
Drive transmission is accomplished by a set of helical-toothed
constant mesh gears, for both forward and reverse gears. Control inside the transmission is accomplished with five rods:
a main rod to select and engage gears; four rods equipped with
The splined or machined gears are on four shafts: input, main,
forks for engaging gears.
transmission and reverse gear.
The external control is achieved by means of two levers:
(selection and engagement levers). The levers are actuated by
tie-rods through a transfer case, connected to the gear shift
lever located in the cab, by an assembly made up of two
flexible cables (BOWDEN cables).
The external engagement lever features two opposed
weights, used to dampen the flexible control cable
(BOWDEN) engagement thrust and, as a result, its noise.
Figure 1
108639


The combined action of the selector lever (2) and the engagement lever (1) cause the rotation and axial movement of the rod (4)
in two subsequent steps to engage the required gear by means of the rods (8-7-6 and 9).
Neutral arrangement and/or 3rd/4th gear 1st/3rd gear selection election and engagement
selection and engagement arrangement arrangement
Figure 2 Figure 3
84147
3rd/4th gear selection 84148
According to the angular position of the selector lever (2), the This arrangement is obtained by moving the selector lever (2)
slider (3) turns with the rod (4) (which is integral) and the anticlockwise. In this way, the selector (4) is inserted in the
selector (5) arranges the slider on the 3rd/4th gear rod (9). At 1st/2nd gear engagement rod (5).
the same time, the slider (3) moves the rod (10) to prevent By moving the lever (1), the slider (3) will axially move the
the simultaneous engagement of two gears, to keep the 3rd 1st/2nd gear engagement rod (5).
and 4th gear engagement rod (9) free and to prevent
movement of the other rods by engaging the grooves in the
rods.
3rd/4th gear engagement
According to the movement of the engagement lever (1), the
slider (3) axial moves the rod (4) (which is integral), the
selector (5) (previously arranged) and consequently the
chosen 3rd and 4th gear engagement rod (9).
Neutral position coincides with the 3rd/4th gear selection
arrangement.
In this case, the vertical axis of the selector lever (2) is exactly
at 90° with respect to the horizontal axis of the control
corresponding to no angular variation of the rod (4).

5th/6th gear selection and engagement Reverse gear selection and engagement
arrangement arrangement
Figure 4 Figure 5
SECTION A-A SECTION A-A
84150
84149
This arrangement is obtained by moving the selector lever (2)
anticlockwise. In this way, the selector (4) is inserted in the re-
This arrangement is obtained by moving the selector lever (2) verse gear engagement rod (5).
clockwise. In this way, the selector (4) is inserted in the 5th/6th By moving the lever (1), the slider (3) will axially move the re-
gear engagement rod (5). verse gear engagement rod (5).
By moving the lever (1), the slider (3) will axially move the
Safety device
5th/6th gear engagement rod.
The transmission is equipped with a device which prevents the
simultaneous engagement of two gears.
It consists of a suitably shaped rod (6) fitted transversally in the
transmission box.
The slider (3), moves the rod (6) under the action of the lever
(2). This keeps the selected gear engagement rod free and
prevents movement of the other gears by engaging their
respective grooves.

Print 603.43.351/D

TRANSMISSION 6 S 400 O.D.
Type Mechanical
Input torque 400 Nm

Weight 63 kg
6 forward speeds
Speeds
1 reverse speed
Speed control Mechanical
Power take-off Optional
Speed engagement:
Forward speeds
- 5th/6th - 3rd/4th Single-cone synchronizer
- 1st/2nd Dual-cone synchronizer
clip-on, in new version transmission with

Reverse speed
single taper synchroniser ring
Gear ratio
First 5.375
Second 3.154
Third 2.041
Fourth 1.365
Fifth 1
Fifth 0.791
Reverse 4.838
Shaft bearings:
Straight roller bearing tapered roller
O.D.. = Over Drive

Transmission shaft bearing end play 0 ÷ - 0.05 mm
Shim thickness for transmission shaft bearing

-
end play adjustment
Main shaft
Temperature for fitting:
- hubs for sliding sleeves 80° ÷ 110oC
- 1st-R gear bushes and gear 110° ÷ 150oC
- front bearing* 90° ÷ 110oC
Transmission shaft
- bearings 80°C (max 120oC)
- 5th-4th gears 170° ÷ 160oC
Gear end float:
0.15 ÷ 0.40 mm
1st - 3rd - 4th - R - 5th gear
0.25 ÷ 0.5 mm
2nd gear
5th - 4th gear sliding sleeve hub retaining

0 ÷ - 0.15 mm
ring end float

-
ring thickness
Retaining ring end float:
- transmission shaft front bearing 0 ÷ - 0.1 mm
- main shaft roller bearing 0 ÷ - 0.1 mm
Transmission shaft rear bearing retaining
-
ring thickness
LOCTITE 510
Sealant LOCTITE 242
LOCTITE 5206
Quantity 2.2 litres

TIGHTENING TORQUES
Figure 6
108862
TORQUE
DESCRIPTION
Nm kgm
1 Plug retaining spring and reverse gear hardening push rod 32±10% 3.2±10%
2 M22x1.5 plug 50 5
3D 3rd and 4th gear fork articulation pins 45D 4.5
4 Plugs for rod preventing gear engagement 32 3.2
5 Clutch housing, screw to fasten clutch housing to crankcase 80 8
6 Constant mesh shaft cover fastening screw 23±15% 2.3±15%
7J Screw securing p.t.o. side cover 46±15% 4.6±15%
8 Screw securing reverse gear shaft 23±15% 2.3±15%
9 Side plug on rear cover 35 3.5
10 Screw securing rear cover 23±15% 2.3±15%
11 Speedometer transmitter fixing 50 5
12 Screw locking sleeve for transmission coupling on main shaft 235 23.5
13 Fixing switches and reversing lights 40 4
14D Screw securing ball bearing retaining ring 9.5±15% 0.9±15%
15 Nut for screw securing lever to control rod 34±15% 3.4±15%
16 Screw securing gear control mounting 23±15% 2.3±15%
17 Oil vapour breather 10±15% 1±15%
18D Screw securing driver to main rod 9.5D 0.9
19D 5th and 6th gear fork articulation pins 45 4.5
: Spread LOCTITE 5206 sealant on the contact surfaces

F Spread LOCTITE 242 on the thread
J Spread LOCTITE 510 on the thread

0,
TIGHTENING TORQUES
Gearbox control
Figure 7
108856
TORQUE
DESCRIPTION
Nm kgm
1 M8 screw for gearbox control support fastening 14 ± 17 1,4 ± 1,7
2 Nut securing the jointed heads to the cable 4 ± 4,8 0,4 ± 0,48
3 M8 screw securing the transfer case to the gearbox 21 ± 25 2,1 ± 2,5
4 M8 self-locking nut securing the flange to the cab 3,5 0,35
5 Nut securing the jointed head to the tie-rod 4 ± 4,5 0,4 ± 0,5
6 Plate fastening screw 2,3 ± 15% 0,78 ± 0,95
After tightening nuts (4), the jointed head hole axis shall be aligned with the axis of the ball pin to which it is connected. After
tightening nuts (5), the vertical axes of tie-rod (5) jointed heads shall be aligned, with a maximum deviation of less than α 30˚ (lower).

TOOL
99322205 Assemblies overhaul revolving stand
99322225 Unit support (to use with stand 99322205)
99340205 Percussion extractor
99341003 Single-acting bridge

TOOL
99341015 Constrictor
99341017 Pair of brackets with hole
99341019 Pair of tie rods with grips
99341025 Grips
Extractor for gearbox front half-casing

99345003

TOOL
99348004 Universal male extractor from 5 to 70 mm
99360522 Tool to extract and insert main shaft, transmission shaft

and rod - fork assembly
99370234 Tool for fitting rear bearing and sleeve on main shaft

TOOL
99370317 Reaction lever with extension for holding flange
99370629 Transmission support during removal from and refitting to vehicle
99371057 Bracket for supporting gearbox during overhaul

(use with 99322205-99322225)
99374091 Punch for fitting bearing external races

(dia. 55 ÷ 69 mm use with 99370007)
99374452 Keying device to fit gasket on transmission rear cover

(use with 99370006)
99374453 Keying device to fit gasket on transmission

Figure 8
87880
Figure 9
C-C
87881

Figure 10
M-M
87900
Figure 11
G-G
87901
Figure 12
P-P
87902

TRANSMISSION TRANSVERSAL CROSS-SECTIONS
Figure 13 Figure 15
E-E N-N
87885 87887
Figure 14 Figure 16
R-R F-F
87886 87888

TRANSMISSION TRANSVERSAL CROSS-SECTIONS
Figure 17
D-D
87889
Figure 18 Figure 19
A-A
87890
87891

Print 603.43.351/D
530210 OVERHAULING THE TRANSMISSION

Figure 20 Figure 22
85941
108640 Shift to neutral.
Take out the fixing screws (1) and remove the gear control box
Remove the rev sensor (4). (2).
Fit the gearbox (1) with the bracket 99371057 (6) and secure
this to the brackets 99322225 (3) on the rotary stand
99322205 (2). Figure 23
Remove the plug (5) and drain off the lubricating oil.
The used oil must be disposed of according to the law

in force.
530220 Gear control box

Disassembly
Figure 21
85942
Loosen the nuts (4) for the retaining screws (5).

Extract the levers (1 and 7) from the shafts (2 and 6) and
extract these from the box (8). Take off the caps (4).
Figure 24
108857

levers (4 and 7).
levers (10 and 7).
51385
NOTE Tie-rods (3 and 8) are interchangeable.
With a punch (3), remove the spring pin (4) and extract the
shaft (2) from the internal lever (1).
Remove screws (5), then take transfer case (6) off the gearbox Repeat these steps for the other shaft.
unit.
NOTE The coupling lever is bound to the stem by two snap

pins.

Figure 25 Figure 28
87896
Mount the selection and engagement levers (1) on their

respective shafts (2) and fasten them with the spring pins (3).
51386
Use a punch on the point shown by the arrow and eject the NOTE The spring pin (3) must be positioned with the cut
O-rings and roller bushes (2) from the box (1). horizontal. Fit spring peg (4), with cutting edge
positioned at 180° from spring peg (3) cutting edge,
in spring peg (3) engagement lever.
Assembly
Figure 26 Figure 29
51390
Lubricate the roller bearings (1, Figure 27) with TUTELA MR3
51387
grease and mount the shafts (3 and 6) complete with the
internal levers (4 and 5) in the box (2). Mount the caps (8 and
Thoroughly clean the oil vapour vent (3). 9) and levers (1 and 10) on the shafts (3 and 6) and tightening
With a suitable punch, mount the roller bearings (1) in the the nuts for the fixing screw (7).
box (2).
Figure 30
Figure 27
85941
51388
Using a suitable punch, mount the O-rings (1) in the box (2), Thoroughly clean the mating surfaces of the gear control box
positioning them at the height shown. (2) and apply LOCTITE 5706 sealant on them.
Pack the gap between the O-ring and roller bearing with Fit the box (2) on the transmission, taking care that the levers
grease. and shafts are positioned correctly in their respective seats.
Tighten the screws (1) to the required torque.

Figure 31 Figure 33
108858
Fit transfer case (1) into place, by tightening fastening screws 108860
(2) to the prescribed torque. Verify that the tie-rod (4) length ”X”, as measured between
Selection and adjustment tie-rod assembling the jointed head centres is not greater than 342 mm.
Figure 32 Measure the distance ”y” between transfer case (3) outer
than < 30˚ (lower).
l
Figure 34
108859
Verify that the tie-rod (4) length ”X”, as measured between

the jointed head centres is not greater than 342 mm.
than α < 30˚ (lower).
108861
Verify that spring (3) ends come into contact with selection
lever (4) or are at least 1 mm within the same. Otherwise,
loosen screw (1) so that spring (3) is correctly positioned, due
to plate (2) being released.

Disassembling the transmission

Figure 35 Figure 38
51924
Shift to neutral.
Dismantle the gear control box as described under the 90250
relevant heading. Extract the sleeve (3) from the main shaft.
Remove the two side plugs (1 - 3). Remove the screw (2) and
take off the rod (5) dragging device (4). NOTE If difficult, remove the sleeve (3) with extractor made
up of link 99341003 (1) and grips 99341017 (2) and
block (4).
NOTE The screw threading (2) is treated with LOCTITE
242.
Figure 36 Figure 39
51928
51925
Mark the assembly position of the rod (1) preventing NOTE When putting away the sleeve (1) take care not to
engagement of more than one gear at the same time and damage the phonic wheel (→) obtained by machining.
remove it from the transmission.
Figure 37
Figure 40
1
1
51926
Block rotation of the sleeve (1) by applying the lever

99370317 (3). With the bushing (2) remove the screw (5) 51829
with the washer beneath (4).
Take out the lever 99370317 (3). Remove the screws (1) and take off the cover (2) protecting
the input shaft (3).

Figure 41 Figure 44
51930
90209
Perforate the o-ring (2) with a suitable hook and ram extractor Remove the two fork knuckle pins (1) which control the 3rd
99340205 (1) and remove the o-ring from the transmission — 4th speed and the two fork knuckle pins (2) which control
box. the 5th — 6th speed.
Figure 45
Figure 42
51934
51931
Push the two locating pins (2) downwards until taking them
Remove the circlip (2) retaining the front bearing (3) from the out of the rear cover (4).
input shaft (1). Remove the screws (3) securing the rear cover (4) to the
transmission (1).
Figure 43 Figure 46
74957
51932
Fit the drive input shaft (1) with tool 99345003 (2) and
secure this onto the gearbox (4), with the screws (3); screw
Take out the plug (4) with the washer (3), and extract the down the screw (5) of tool (2) to extract the gearbox from
spring (2) and the push rod (1). the bearing (6).

Figure 47 Figure 50
51936
Drill the cups (2), screw a special screw into them.

90212
Using the screw, extract the cups (2) from the rear cover (1).
Remove the springs (3) and pawls (4). Mount the tool 99360522 (3) onto the rods (4, 5 and 6), on
the input shaft (1) and on the transmission shaft (9).
Secure the tool 99360522 (3) on the input shaft (1) with the
retaining ring (2) and with the screw (8) to the transmission
Figure 48 shaft (9).
Insert the part (13) of the bracket (11) into the reverse gear
(14) and tighten the screw (12).
Hook the tool 99360522 (3) onto the lift.
Apply the extractor composed of the bridge 99341004 (16)
and ties 99341012 (15) onto the rear cover (7).
NOTE In order not to damage the rear cover (7), place

special protections between it and the ties (15).
Using the extractor screw and the lift on the main shaft (10),
remove the main shaft (10) from the rear ball bearing and ex-
tract the shaft-rod assembly from the rear cover (7).
90210
Remove the rod (1) controlling the 3rd/4th gear and the main
rod (2) from the rear cover (3). Figure 51
Figure 49
90211
90213
Take out the screw (3) and remove the reverse gear shaft (1)
with the mounting (2) from the rear cover (4). Remove the rod (1) from the rear cover (2).

Figure 52 Figure 54
74960
90214
Clamp the primary shaft (6) in a vice. ring (2) of the transmission shaft bearing.
Remove the rods (10 and 11) with the relevant forks. Remove
the forks (3 and 4) and the small blocks. Figure 55
1
Support the secondary shaft (2), slacken the screw (1)
and remove the secondary shaft (2).
Remove the RM gear (4).

Remove the snap ring (8) and the tool 9936522 (9).
Remove the input shaft (7).
51943
Using the percussion extractor 99340205 (1) and part

99348004 (2), extract the bushing with the ball bearings (3).
Disassembling the rear cover bearings
Figure 53 Figure 56
51951a
51944
Remove the screws (1) securing the plates (2). Turn over the rear cover (4).
Take out the plates (2).
Take out the O-ring (6).
Turn over the rear cover (4) and remove the bearing (3).
Using a suitable punch, remove the ball bearing (5). Remove
the tachograph sensor (7) and the reversing light switch (1)
with the washer (2) and extract the push rod (3).

Disassembling the transmission bearings

Figure 60
Figure 57
51948
Using the percussion extractor 99340205 (1) and part

99348004 (2), extract the roller bearing (4-3).
Disassembling the main shaft
74962
Using universal extractor 99348004 (1), remove the outer NOTE Mark the assembly position of each synchronizing de-
ring (2) of the transmission shaft bearing. vice on the respective gear.
Figure 61
Figure 58
<<
85944
51946
Tighten the primary shaft (1) in a vice. Remove the
Using the percussion extractor 99340205 (1) and part synchroniser ring (4) and the circlip (2). Remove the circlip (3)
99348004 (2), extract the bushing with the ball bearings (3). from its housing.
Figure 62
Figure 59
51410
85945
Remove the screws (1) securing the plates (2).
Take out the plates (2). Remove the sliding sleeve (2) for engaging 5th - 6th gear from
Turn over the transmission. Using a suitable punch, remove the hub (1) and, taking care as the plugs (5) come out with the
the ball bearing (3). balls (4) and springs (3), recover them.

Figure 63 Figure 66
85949
Remove the reverse gear engagement sliding sleeve (2) from

the reverse gear (1). Retrieve hub (1) and pads (3) with
85946 respective balls (4) and springs (5).
Use extractor 99348001 (6) as shown in the figure to extract
the primary shaft (1), the 5th gear (7), the synchroniser ring (5),
the hub (4), the circlip (3) and the roller bearing (2). Figure 67
Figure 64 1
51954
Take out the synchronizer ring (4), middle ring (3), ring (2) and
roller bearing (1).
Using a hydraulic press, remove the 2nd gear (10), ring (9),
middle ring (8), synchronizer ring (7), synchronizer assembly
(6) and the bushing (5). Take out the roller bearing (11).
85947
Remove the roller half cages (1).
Figure 65
Figure 68
90215
108863
Use the hydraulic vice to remove from the primary shaft (1):
the 1st speed gear (8), the spacer (7), the bush (6), the roller Take 1st/2nd gear engagement sliding sleeve (2) and dowels
cage (5), the R.M. gear (4) together with the coupling (3), together with balls (4) and springs (5), off hub (1).
elements, the synchronising ring (3) and the serrated ring (2).

Disassembling the drive input shaft Figure 72

Figure 69
1
51956
To replace the cog-wheel (1), use the same general tools for
disassembly as for assembly, heat it to a temperature of 80ºC.
51959
Using a hydraulic press, extract the 6th gear (2) and the
internal ring (1) of the tapered roller bearing from the
Disassembling the transmission shaft transmission shaft.
Figure 70
Figure 73
90217 51960
Using a hydraulic press, remove the 5th gear (2) from the
Take out the retaining ring (1) holding the 5th gear (2). transmission shaft (1).
Figure 71 Figure 74
90216 51961
Using general tools, extract the internal ring (2) of the rear Remove the 3rd gear (1) and the roller bearing (2).
tapered roller bearing from the transmission shaft (1). Remove the synchronizer ring (3). Remove the retaining ring
(5) securing the hub (4).

Figure 75 Figure 76
51962 51424
Using a hydraulic press, remove the 4th gear (3), the Remove the sleeve (2) for engaging the 3rd-4th gear from the
synchronizer ring (2) and the synchronizer assembly (1). hub (1) and, taking care over the plugs (3) coming out with
their relative balls (4) and springs (5), recover them.
Remove the half roller bearings (4).
Figure 77
90218
TRANSMISSION SHAFT ASSEMBLY DRAWING

1. Transmission shaft assembly - 2. Tapered roller bearing - 3. Transmission shaft with reverse gear toothing (A), 1st gear (B),
2nd gear (C) - 4. Tapered bearing - 5. 4th gear - 6. Synchronizer ring - 7. Sliding sleeve - 8. Ball - 9. Spring - 10. Plug -
11. Hub - 12. Retaining ring - 13. Half roller bearings - 14. 3rd gear - 15. 6th gear - 16. 5th gear.

Figure 78
108864
PRIMARY SHAFT AND INPUT SHAFT ASSEMBLY

1. Input shaft with 5th speed gear. - 2. Retaining ring - 3. Roller bearing - 4. Single cone synchronizer ring - 5. Sliding sleeve -
6. Plug - 7. Ball - 8. Spring - 9. Hub - 10. 6th gear - 11. Main shaft with 3rd gear toothing (A), 4th gear toothing (B) -
12. Roller bearing - 13. 2nd gear - 14. Dual-cone synchronizing unit for 1st/2nd speed - 15. Dowels with built-in ball springs
for 1st/2nd speed hub - 16. Bushing - 17. 1st gear - 18. Spacer ring - 19. Reverse gear - 20. Synchroniser ring - 21. Gear.

Figure 79
108865
1ST-2ND GEAR DUAL CONE SYNCHRONIZER ASSEMBLY

Figure 80
85978
3RD - 4TH - 5TH - 6TH GEAR SINGLE CONE SYNCHRONIZER ASSEMBLY
Figure 81
86130
SINGLE CONE SYNCHRONIZER ASSEMBLY REVERSE GEAR

CHECKS
Transmission With a feeler gauge, check the distance S on two diametrically
The transmission and relative covers must show no sign of opposite points.
cracking. If the measured value S is less than 0.8 mm, replace the
The mating surfaces of the covers and transmission must not synchronizer ring.
be damaged or deformed. Remove any remains of sealant
from them. Turn the synchronizer ring (1) so as to ensure correct coupling
on the cog-wheel.
The seats of the bearings, reverse gear shaft and gear control
rods must be neither damaged nor too worn.
Hubs - sliding sleeves - forks

The grooves on the hubs and relative sliding sleeves must not
be damaged. The sliding sleeve must run freely on the hub.
The plugs and balls for positioning the sliding sleeve must be
neither damaged nor worn. The toothing of the sliding sleeves
must not be damaged. The forks must be sound with an end
float, in the radial groove of the sleeve, no greater than 1 mm.
Bearings
The roller bearings must be in perfect condition with no signs
of wear or overheating. They must only be removed if they are
to be replaced.
Shafts - gears
The seats on the shafts, for bearings, must be neither damaged
nor worn. The toothing of the gears must be neither damaged
nor worn.
Synchronizing devices
Check the wear on the synchronizer rings, proceeding as
follows:
D-type dual cone synchronizers for 1st/2nd gears
After this check, the synchronizer rings must be Figure 83

! marked on their respective gears to avoid swapping
their positions over when assembling.
- See that the friction surface is not undulated.
BK-type single cone synchronizers for 3rd/4th/5th/6th

gears
Figure 82
4
52511
Position the internal ring (3), middle ring (2) and the
synchronizer ring (1) on the tapered cog-wheel (4) of the gear.
Turn the synchronizer ring (1) so as to ensure correct coupling
between the parts.
Applying a uniform force of 50 N on the synchronizer ring (1),
52510
measure the distance S on two diametrically opposite points
with a feeler gauge.
Arrange the synchroniser ring (1) on the respective gear or
reverse taper ring (2). If the average measured value S is less than 1.5 mm, replace
all the rings.

Figure 84 Figure 86
90220
85918
5TH - 6TH GEAR SYNCHRONISERS 2ND-1ST GEAR SYNCHRONISERS

A. synchronization reserve 6th-5th gear: 1÷1,4 mm A. synchronization reserve 2nd-1st gear: 1,6÷2,0 mm
B. 5th-6th release clearance: 0,3÷0,7 mm B. 1st-2nd release clearance: 0,9÷1,5 mm
Figure 85 Figure 87
85917 85919
3TH/4TH GEAR SYNCHRONISERS REVERSE GEAR SYNCHRONISER

A. synchronization reserve 1st-2ndgear: 1÷1,4 mm A. Synchronization reserve: 0.9÷1,4 mm
B. 1st-2nd release clearance: 0,3÷0,7 mm B. release clearance: 0,35÷0,85 mm
1. Hub - 2. 5th gear - 3. Synchronizer ring - 4. Sliding sleeve - 5. 6th gear cog-wheel - 6. 3rd gear cog-wheel -
7. 4th gear cog-wheel - 8. 2nd gear cog-wheel - 9. 1st gear cog-wheel - 10. Middle ring - 11. Ring - 12. Reverse gear -
13. Reverse gear ring

Mounting the transmission shaft

Figure 88 Figure 91
51969
51966 Mount the retaining ring (1) whose thickness produces null
Clamp the transmission shaft (1) in a vice and position the half end float in its seat.
roller bearings (2) on it.
Check the end float of the 4th gear (2). It should be
Figure 89 0.15 ÷ 0.40 mm.
Figure 92
1
1
51967
51970
Mount the 4th gear (2) and position the synchronizer ring (1)
on this. Mount the sliding sleeve (1) on the hub (2). Put the springs (5),
plugs (3) and balls (4) into the seats in the hub (2), settling
Figure 90 them under the sliding sleeve (1).
Figure 93
1
51968
Heat the hub (2) to a temperature of 110° ÷ 150°C and 51971

mount it on the transmission shaft (1), taking care that the
protrusions (3) of the synchronizer ring are positioned Position the synchronizer ring (2) on the hub (3) so that its
correctly in their seats in the hub (2). protrusions enter the seats in the hub (3). Mount the roller
bearing (1).

Figure 94 Figure 97
90222
Mount the retaining ring (1) whose thickness produces null

end float in its seat.
51974
Figure 98
Mount the 3rd gear (1).
Figure 95
90223
Heat the internal rings (1-3) of the tapered roller bearings to

a temperature of approx. 80°C and, with a suitable punch (1),
mount them on the transmission shaft (2).
51975
Mounting the main shaft
With a hydraulic press, mount the 6th gear (1) pre-heated to
approx. 170°C.
NOTE Mount the synchronizer rings on their respective gears
Check the end float of the 3rd gear (2). It should be 0.15÷0.40 according to the marks made during disassembly or
mm. when checking in the case of replacement.
Figure 96 Figure 99
90221
51973
With a hydraulic press, mount the 5th gear (1) pre-heated to Tighten the main shaft (1) and position the roller bearing (2)
approx. 170°C. on it.

108866
51980
Fit sliding sleeve (2) onto hub (1). Fit dowels (4) with built-in
Mount the 2nd gear (4) and position the ring (3), middle ring springs (5) and balls (3) into hub (1) housings.
(2) and synchronizer ring (1) on it, taking care that the tongues
(→) of the middle ring (2) enter the slots (→) in the gear (4).
Figure 103
51983
Position the synchronizer ring (3), middle ring (2) and ring (1)
on the hub (4), taking care that the tongues (→) of the ring
Figure 101 (1) and the projections (→) of the ring (3) enter the seats in
the hub (4).
Figure 104
51981
Heat the hub (2) to a temperature of 80° ÷ 110°C and mount

it on the main shaft (1), taking care that the projections (3) of
the synchronizer ring and the tongues (→) of the ring (3,
Figure 100) are positioned correctly in the seats in the hub (2). 51984
Check the end float of the gear (4). It should be Position the roller bearing (2). Mount the 1st gear (1) taking
0.25 ÷ 0.5 mm. care that the tongues (3) of the middle ring enter the slots in
the gear (1).

85961
Heat the spacer ring (2) to a temperature of approx. ~80° 51952
÷ 110°C and mount it on the main shaft (1). Check the end Turn the main shaft over and position the half roller bearings
float of the gear (4); this should be 0.15 ÷0.3 mm. (3) on it.
Heat the bushing (3) to a temperature of approx. 80° ÷ 110°C Mount the 6th gear (2) and position the synchronizer ring (1)
and mount it on the main shaft (1). on it.
Mount the roller bearing (5).
Figure 109
Figure 106
51990
85950
Fit reverse gear (1). Heat the hub (2) to a temperature of approx. ~ 80° ÷ 110°C
Fit sliding sleeve (2) on reverse gear hub (1). and mount it on the main shaft (1) taking care that the projec-
Insert the springs (5), the pads (3) and the balls (4) in the hub tions (3) of the synchronizer ring are positioned in the seats
seats (1) and arrange them with respect to the sliding sleeve in the hub (2).
(2).
Mount the retaining ring (4) whose thickness produces null
end float in its seat.
85951 51991
Fit the synchroniser ring (2).

Heat the gear ring (3) to 110° ÷ 150° and fit on primary shaft Mount the sliding sleeve (2).
(1). Put the springs (3), plugs (5) and balls (4) into the seats in the
Check reverse gear play (4) which must be 0.15 ÷ 0.4 mm. hub (1) and position them under the sliding sleeve (2).

Figure 111 Mounting the transmission
NOTE During assembly, the gaskets, retaining rings, O-rings,

spring pins, safety plates and springs must always be
replaced with new parts.
The nuts and screws must be tightened to the re-
quired torque unless specified otherwise, with the
thread dry and degreased.
Adjusting the transmission shaft bearing end

float
85952 NOTE The transmission shaft bearing end float is only ad-
justed if the bearings, transmission shaft gears, trans-
Heat the bearing (2) to 80÷110°C and fit on primary shaft (1). mission shaft, transmission or rear cover have been
Fit the circlip (4) and synchroniser ring (3). replaced or if too much clearance has been found.
Rods - forks - selector - driver
Disassembly - assembly Figure 113

Figure 112
51993
Determine the thickness S of the ring (1) for adjusting the

transmission shaft bearing end float, proceeding as follows:
- position the thinner adjustment ring (1) 1.65 mm thick in
90224
the seat in the transmission (3);
1. Rod with reverse gear engagement fork - 2. Main rod -
3. Rod with 1st-2nd gear engagement fork. - 4. Fork control - heat the seat of the bearing (2) to approx. 60°C. Mount
rod (5).- 5. 3rd-4th gear engagement fork - 6. Fork control the external ring of the bearing (2) with the punch
rod (7) - 7. 5th-6th gear engagement fork 99374091 and grip 99370007, see Figure 115;
- mount the transmission shaft complete with the internal
rings of the tapered roller bearings;
Check the state of the plugs (2) of the 3rd-4th-5th-6th gear en- - mount the external ring of the rear bearing in the rear
gagement fork and replace them if they are worn. cover in a similar manner to the front one (see
To replace the forks of the selector and driver from their re- Figure 115);
spective control rods it is sufficient to remove the retaining
spring pins with a suitable punch. - mount the rear cover on the transmission;
For assembly, carry out these steps in reverse order, replacing
the spring pins. - screw on the 8 fixing screws so that between one screw
and another there is a hole for a free screw and tighten
them to the required torque;
NOTE Spring pegs must be positioned with the cutting edge - turn the transmission shaft to settle the bearings;
placed level.

52512 51997
- using a comparator (2) zeroed on the 5th gear toothing

of the transmission shaft (1) measure its end float A Heat the bearing seats of the rear cover (1) to a temperature
through the opening for the power take-off connection of approx. ~ 80°C and mount:
and note it down. - the external ring (3) of the tapered roller bearing with
punch 99374091 (2) and grip 99370007 (1);
The thickness S is given by:
S=A+B+C - the ball bearing (4) and the bushing with ball bearings (7)
Where:
Position the retaining plates (6). Secure these to the rear
A = measured end float, e.g. 0.18 mm; cover, tightening the screws (5) to the required torque.
B = average bearing pre-load, e.g. 0.02 mm;
C = adjustment value used for the measurement 1.65 mm;
S = 0, 18 + 0, 02 + 1, 65 = 1, 85
Figure 117
Then mount the rear cover, transmission shaft and external
ring of the front bearing.
Figure 115
90225
51996
Clamp the primary shaft (13) in a vice, fit on it the synchronis-
Position the adjustment ring (1, Figure 119) of the thickness ing ring and the input shaft (8).
determined with the above measurement. Heat the bearing Fit tool 99360522 (10) on the input transmission shaft (8) and
seats of the box to a temperature of approx. 80°C and fasten with the circlip (9).
mount: Couple the secondary shaft (2) to the primary shaft (13) and
- the external ring (3) of the front tapered roller bearing fasten by tightening the screw (1) on the tool (10).
with punch 99374091 (2) and grip 99370007 (1); Fit the clutch forks: 3rd — 4th speed (4) and 5th — 6th speed (3)
- the ball bearing (6) with a general punch; on the relevant sliding sleeves.
Couple the rods (11 and 13), fit the relevant forks on the slid-
- the bushing with ball bearing (9) and the roller bearings ing sleeves and clamp the rods with the sleeves of tool
(4-5) with a general punch. 99360522 (10).
Position the retaining plates (7) and secure them to the box, Couple the reverse gear (7) with the shafts (2 and 13) and
tightening the screws (8) to the required torque. fasten it to them with the part of the bracket (5) tighten the
screw (6).

eft
90226 90227
Fit the rod (3) in the rear cover (4). Place the roller bearings (2) in the reverse gear (1).
Hook hoist to tool 99360522 (1), lift the unit (2) as previously Fit the stem (2) and the support (3) so that the respective
mounted, and partially insert it into the rear cover (4). holes for the fastening screw are aligned with the relevant hole
on the rear cover (5).
During this operation, check that the output shaft goes into the
Drive in the fastening screw (6) of the stem (3) and the
supporting ball bearing and the control rods (5 -6) go into their
support (4) on the rear cover (5) and tighten it to the
respective seats.
prescribed torque.
52000 90210
Screw tool 99370234 pin (7) into output shaft hole (2) and Fit the control rod (1) of the 3rd — 4th speed and the main rod
fit bushing (4) and spacer (5) on tool. (2) in the rear cover (3).
Screw on the nut (6) and at the same time lower the hoist so
the output shaft (2) is positioned on the rear ball bearing (3).
Remove tools 99360522 (1) and 99370234 (4-5-6-7).

Figure 122
NOTE When fitting the gearbox, check that the shafts and
the control rods fit correctly in the respective seat and
that the fork (1, Figure 117) does not disconnect from
the clutch rod (2, Figure 122) for the 3rd — 4th speed.
Figure 125
90229
1
Apply some grease on the pin of the dragging device (2) and
fit the clutch fork (1) for the 3rd — 4th speed on this device.
Figure 123
51931
Fit a new retaining ring (2) securing the front bearing (3) onto
the input shaft (1).
51936
Put the pawls (4) and springs (3) in the rear cover (1) and drive
in the retaining cups (2) with a suitable punch.
Apply LOCTITE 5206 on gearbox attachment.
Figure 126
Figure 124
90231
Screw on the screws (2) securing the rear cover (3) to the
transmission (1) without fully tightening them.
90230
Mount the centring pins (4) in the rear cover (3) and in the
Warm up the front bearing inner ring (2) at 90÷110°C and fit transmission (1).
the gearbox (1) on the rear cover.
Tighten the screws (2) to the required torque.

90209
52005
Using the key 9937455 (3), mount the O-ring (2) in the trans-
NOTE Make sure that the clutch control rods are all in mission (1).
neutral position.
Figure 130
Apply LOCTITE 242 to the thread of the pins (1).
Screw the pins (1) into the box, checking that their ends go
into the hole of the 3rd/4th gear engagement fork link (1,
Figure 122) and then tighten them to the required torque.
Drive in the pins (2) and check that their ends fit in the knuckle
hole of the clutch fork for the 5th — 6th speed and tighten it to
NOTE If during these assembly operations the fork (1,

Figure 122.) comes free of the control rod, it will not
be possible to mount the pins (1) until they have been 52006
reconnected.
Mount the cover (1) protecting the input shaft and tighten the
screws (2) to the required torque.
Figure 128
Figure 131
51932
52007
Mount the O-ring (2) in the rear cover (1) with the key
Mount the push rod (1) and the spring (2). Screw on the plug 99374454 (4) and the grip 9937006 (3).
(4) with a new washer (3), tightening it to the required torque.

51924
52008
Apply sealant to the thread of the plugs (1 - 3), screw them
Fit the transmission shaft coupling (1) onto the output shaft. into the box, tightening them to the required torque.
If there is any interference, use the tool 99370234 (2) for as- Position the driver (4) on the rod (5).
sembly with the lever 99370317 (3) to lock the coupling.
Secure it with the screw (2) after applying LOCTITE 242 onto
its thread.
Figure 133
Figure 136
52009
Mount the washer (3) and screw on the screw (4).

Lock the rotation of the flange (1) with the lever 99370317
(5) and tighten the screw (4) to the required torque.
Mount the tachograph sensor (2) and the reversing light
switch.
Figure 134
52118
Fit a new gasket (1) onto the transmission.

1 Apply LOCTITE 510 on the screw threading (2).
Mount the side cover (3) and tighten the fixing screws (2) to
the required torque.
Mount the control box as described under the relevant hea-
ding.
Mount the oil drainage plug, tightening it to the required torque.
Fill the transmission with lubricating oil in the required quantity
51925
and grade.
Mount the rod (1) preventing engagement of more than one Mount the oil filler and level indicator cap, tightening it to the
gear at the same time, in the position marked during disas- required torque.
sembly.

DAILY EURO 4 6 S 400 A O.D. TRANSMISSION 91
6 S 400 A O.D. Transmission
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
MAIN COMPONENTS LOCATION . . . . . . . . . 94
MAIN SYSTEM FUNCTIONS . . . . . . . . . . . . . . . 95
- Startup/start procedure . . . . . . . . . . . . . . . . . . 95
- Check procedures . . . . . . . . . . . . . . . . . . . . . . 95
- Limp Home . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
- Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
- Start up with tow . . . . . . . . . . . . . . . . . . . . . . 96
HILL HOLDER (FUNCTION ONLY AVAILABLE TO

VEHICLES WITH ESP8 BRAKING SYSTEM) . 97
- Functional features . . . . . . . . . . . . . . . . . . . . . 97
SYSTEM STRUCTURE . . . . . . . . . . . . . . . . . . . . 98
- System central unit . . . . . . . . . . . . . . . . . . . . . 98
- Clutch actuator . . . . . . . . . . . . . . . . . . . . . . . . 99
- Gears actuator . . . . . . . . . . . . . . . . . . . . . . . . 99
- Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . 100
- Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
- Gear selector . . . . . . . . . . . . . . . . . . . . . . . . . 101
GEAR SELECTION AND ENGAGEMENT . . . . 102
- Neutral arrangement and/or 3rd/4th gear selection

and engagement arrangement . . . . . . . . . . . . . 102
- 1st/3rd gear selection election and engagement

arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . 102
- 5th/6th gear selection and engagement

arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . 103
- Reverse gear selection and engagement

arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . 103
- Safety device . . . . . . . . . . . . . . . . . . . . . . . . . . 103

92 6 S 400 A O.D. TRANSMISSION DAILY EURO 4
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
- Diagnosis instruments . . . . . . . . . . . . . . . . . . . 108
MODUS - IT 2000 - E.A.SY. CONNECTION . . . . 109
GEARBOX REMOVAL/REFITTING . . . . . . . . . . . . 110
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
GEARBOX UNIT OVERHAULING . . . . . . . . . . . . 117
CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 117
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
CLUTCH ACTUATOR . . . . . . . . . . . . . . . . . . . . . . 119
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
GEARBOX ACTUATOR . . . . . . . . . . . . . . . . . . . . 120
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
CHASSIS WIRING GEARBOX . . . . . . . . . . . . . . . . 121
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
GEARBOX WRING - GEARBOX . . . . . . . . . . . . . 122
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

GENERAL
Gearboxes 6 S 400 A O.D are made up of an On the rear cover there is the speed selection and
electronic/mechanical system controlling and managing the engagement control support.
gearbox in the different conditions of vehicle use. On a side of the main casing there is a slot where it is possible
This is the automatic version of the 6 S 400 gearbox unit. to apply a power take-off.
Driver’s intervention is just limited to using the gear Motion transmission is carried out by a set of helical-toothed
selection/engagement control lever and the accelerator constant mesh gears both for forward speeds and for reverse
pedal, so making clutch control pedal application not speed.
necessary any more. Splined or machined gears are placed on four shafts: input,
The system is equipped with: main, transmission and reverse shaft.
- Safety device preventing vehicle engine start up under Gears splined on main and on reverse shaft, idle on straight
determined situations (gearbox central unit managing roller bearings.
the ignition). Input and main shaft are supported, in the gearbox, by
- Sound and visual signalling device drawing driver’s four-contact ball bearings.
attention on system operation or faults. Transmission shaft is supported, in the gearbox, by roller
- Diagnosis device. bearings which can be adjusted, axially, by means of ring
shims.
- Provided display unit acquainting about:
Selected A/M mode; The synchronization of the speed engagement is carried out
Gear; by means of free synchronizer rings having the same
dimension for: first, fourth, and fifth speed and a greater
Faults status.
dimension for second and third speed.
The system interfaces to EDC system and ABS8/ESP8 device
Speed engagement sliding sleeve control forks, are controlled
via CAN line.
by one shaft only, the same which supports them.
Figure 1
108867
1. Production series number - 2. 1st / 6th gears ratio - 3. Dry oil quantity - 4. Oil rules - 5. Tachograph report -
6. IVECO number - 7. ZF series number.

MAIN COMPONENTS LOCATION

Figure 2
108868
1. Gears actuator - 2. Electronic central unit - 3. Gearbox cable - 4. Clutch actuator -

5. Fork - 6. Flywheel - 7. Clutch disk

MAIN SYSTEM FUNCTIONS

Startup/start procedure
Enabling on
”Brake” display unit (OK)
Gearbox
appears on Brake pedal SI for 2 sec. It is
initialisation
START display pressed? possible to start STOP
step
unit (~ 1000 rpm)
NO
NOTE In order to have correct signalling on the display unit, ”keying off” and then ”keying on” must be carried out within
a time not shorter than 4 seconds, as in the other electronic systems aboard the vehicle. If, after writing ”BRAKE” has
appeared, the brake is not pressed, the clutch remains shut.
NOTE (FOR MARKET AUSTRALIA ONLY)

The system only enables engine start up with the gearbox in neutral position. If, during engine startup, the gearbox is in 1st or
reverse gear position, then the system disables the engine from being started up but warns by an ”N” blinking on the display
unit that the gearbox has to be put into neutral position in order that start up is enabled.
Check procedures
Figure 3
107203
On starting up again the engine after switching off with the gearbox in neutral position, the system carries out above indicated
check procedure.
Figure 4
107203
On starting up again the engine after switching off with the gearbox in 1st gear position, the system carries out above indicated
check procedure.

Limp Home
Limp Home function allows to remove the vehicle when system faults are so serious that they cannot be automatically managed
by the system.
Information loss in gearbox central unit allows to drive in manual mode. Gears allowed depend on fault type:
1. driving with gears from first to fourth plus reverse gear: e.g. when B7 speed signal is lost;
2. driving with first, second and reverse gears: when accelerator pedal failure is present;
3. driving with first and second gears: when gear selector failure is present;
4. driving with first gear only: when a failure is present either in selection actuator electrical motor or in the actuator with
a gear entered;
5. locked clutch: e.g. when clutch actuator is faulty; in this case, the system remains in its current condition.
Buzzer
The buzzer is activated in following situations:
- To warn about faults such as clutch slipping. Through a calculation algorithm, threshold temperature overflow is signalled
by an intermitting Beep sound.
- To show reverse gear being entered (intermitting Beep sound) or warn about driver’s door being opened with a gear
entered and engine on (intermitting Beep sound).
- To warn about parking brake not operated with the engine off (KEY ON) and the gearbox in neutral position. It warns about
the danger that the vehicle might skid (intermitting Beep sound).
Start up with tow
- Select 1st gear (clutch is open)
- start towing the vehicle
- once a speed of 12 km/h has been reached, the clutch shuts engaging the gear and starting up the engine.
NOTE if you are towed, use neutral gear position before using accelerator pedal. On the contrary, if you are skidding on sloping
down, drive normally.
NOTE Starting up with reverse gear is not suggested.

HILL HOLDER (FUNCTION ONLY AVAILABLE TO VEHICLES WITH ESP8 BRAKING

SYSTEM)
Functional features
Figure 5
108869
- It prevents the vehicle from moving either uphill with 1st gear or downhill with reverse gear after releasing brake pedal.
- It keeps that brakes pressure which was applied by driver’s foot.
- Brakes pressure is kept up to 2 s. This time is sufficient to driver to displace his/her foot from brake pedal to accelerator
pedal in order to perform start operation in an easier way.
- 2-second safety concept is applied in order to prevent driver from going out of the vehicle as if it was parked.
- If the vehicle is skidding with its wheels locked, the brakes are released in order to maintain its stability.
Activation: Deactivation:
- Stopped uphill/downhill (>2% slope) - Start
- Press brake pedal - shifting from 1st to reverse gear (uphill) or from
reverse gear to neutral (downhill)
- 1st gear (uphill) reverse gear (downhill)
- clutch shutting
- 2 sec. after releasing brake pedal
- with hand brake engaged (signal from ESP 8 central
unit).

SYSTEM STRUCTURE
System central unit
The electronic central unit receives signals from sensors/switches; on these signals, it bases management and control of the
system in the different operation conditions of the gearbox.
It is interfaced with other electronic systems on board, such as EDC and ABS, through CAN communication lines.
A - Gearbox side connector
B - Vehicle side connector
Figure 6
90135
From the connection to EDC 16 system, gearbox central unit is able to detect accelerator pedal position and engine rpm’s.
Connection with ABS8/ESP8 central unit is used to prevent gear shift ”UP” on bending and manages the drive in low adhesion
conditions in case of drive in mode ”A” (automatic mode).
New ABS system manages ”intelligent” warning lamps integrated into board panel. Their going on shows a failure in braking
system.
NOTE Signal ”Brake”, at start up, is directly coming from EDC central unit.
Reverse gear signal is direct.
Figure 7
90136
Central unit location

Gears actuator
Figure 8
107211
Gear engagement electrical motor - 2. Gear selection electrical motor
Gears actuator has the task of continuously exchanging gears selection and engagement information with electronic central unit.
It is made up of two electrical motors, drive cylinders, and their sensors.
Clutch actuator
Figure 9
90138
1. Actuator cylinder - 2. Electrical motor - 3. Vehicle electrical wiring harness junction block
It is made up of:
- One cylinder operating on clutch engaging/disengaging lever.
- One position sensor detecting clutch lever travel and acquainting the electronic central unit of actuator cylinder position
and clutch disk wear.

Accelerator pedal
To detect engine idling position and enable clutch entering at vehicle start, N.O. switch is used with pedal released; the switch
is integrated in position sensor.
This signal comes to EDC central unit and is sent to gearbox central unit through VDB (Vehicle Data Base) CAN line.
During ride, ”kick down” function can be activated in automatic mode.
In conditions where the pedal is 98% pressed, e.g. on overtaking, the system automatically shifts down by one gear, so allowing
to best exploit the drive torque.
In practice, if accelerator pedal is fully pressed, a drive with an engine rotation speed with higher gear shift is chosen.
Display unit
Figure 10
112601
The display unit, positioned on instrument panel allows to display all information needed for system correct use, e.g.:
- Mode: manual or automated, and, in both cases, gear ratio entered;
- Reverse/neutral (R/N) position;
- Faults signalling:
- SERVICE: gearbox failure
- SERVICE: serious gearbox failure (associated to acoustic warning signal)
- SERVICE: excessive clutch temperature (associated to acoustic warning signal)
- Gearbox failure in ”SERVICE” mode (this message is displayed only at the Dealership Centres)
- Failure code at page 50 can only be displayed through diagnosis tool.
- Vehicle status: gear entered.

Gear selector
Figure 11
108873
- Capability to switch from automated to manual mode selection and from manual to automated mode selection by operating
the lever leftwards. In this way, entered gear / rpm is not lost on shifting.
- Capability to skip gears: by repeatedly operating the lever, a gear which is correct and suitable to the speed is entered (3-4
gears can be skipped, too).
- Central ”N” - Neutral - position and ”R” - reverse positions are stable.
- The gearbox shows that gear with which you stopped. Should the gear be entered, the system opens the clutch in order
to enable engine start up.
- The system optimises the performances by identifying a drive style depending on how accelerator pedal is operated. If
accelerator pedal is fully pressed, a drive with an engine rotation speed with higher gear shift (~ 3900 rpm) is chosen.
- Complete signalling on the display unit showing:
mode (manual or automated)
reverse/neutral position
failure/misuse with sound warning (e.g. clutch overheating).
- On bending, shifting ”UP” is inhibited. This function persists for some metres after the exit from the bend.
Gear shitting
- It is either in manual mode by operating on gears lever or in automated mode. Gear shifting is without releasing the
accelerator pedal. The system opens the clutch, enters the gear and shuts the clutch.
- Clutch pedal is not present.
Vehicle parking
On vehicle putting off operation, the system automatically opens the clutch, then shuts it back, without the need of positioning
the lever to neutral position. In these conditions, the clutch is shut and parking with the gear entered is enabled.


The combined action of the selector lever (2) and the engagement lever (1) cause the rotation and axial movement of the rod
(4) in two subsequent steps to engage the required gear by means of the rods (8-7-6 and 9).
The motion of speed selection/engagement levers occurs through the action of two electric motors (M) managed directly by the
gearbox electronic control unit.
Neutral arrangement and/or 3rd/4th gear 1st/3rd gear selection election and engagement
selection and engagement arrangement arrangement
Figure 12 Figure 13
SECTION A-A
SECTION A-A
101935
3rd/4th gear selection

According to the angular position of the selector lever (2),
the slider (3) turns with the rod (4) (which is integral) and the 101936
selector (5) arranges the slider on the 3rd/4th gear rod (9). At
the same time, the slider (3) moves the rod (10) to prevent
This arrangement is obtained by moving the selector lever (2)
the simultaneous engagement of two gears, to keep the 3rd anticlockwise. In this way, the selector (4) is inserted in the
and 4th gear engagement rod (9) free and to prevent
1st/2nd gear engagement rod (5).
movement of the other rods by engaging the grooves in the
rods. 1st/2nd gear engagement rod (5).
3rd/4th gear engagement
According to the movement of the engagement lever (1), the
slider (3) axial moves the rod (4) (which is integral), the
selector (5) (previously arranged) and consequently the
chosen 3rd and 4th gear engagement rod (9).
Neutral position coincides with the 3rd/4th gear selection
arrangement.
In this case, the vertical axis of the selector lever (2) is exactly
at 90° with respect to the horizontal axis of the control
corresponding to no angular variation of the rod (4).

5th/6th gear selection and engagement Reverse gear selection and engagement
arrangement arrangement
Figure 14 Figure 15
SECTION A-A
SECTION A-A
101938
101937 This arrangement is obtained by moving the selector lever (2)

anticlockwise. In this way, the selector (4) is inserted in the re-
This arrangement is obtained by moving the selector lever (2) verse gear engagement rod (5).
clockwise. In this way, the selector (4) is inserted in the 5th/6th By moving the lever (1), the slider (3) will axially move the re-
gear engagement rod (5). verse gear engagement rod (5).
Safety device
5th/6th gear engagement rod.
The transmission is equipped with a device which prevents the
simultaneous engagement of two gears.
It consists of a suitably shaped rod (6) fitted transversally in the
transmission box.
The slider (3), moves the rod (6) under the action of the lever
(2). This keeps the selected gear engagement rod free and
prevents movement of the other gears by engaging their
respective grooves.

TRANSMISSION 6 S 400 A O.D.
Type Mechanical
Input torque 400 Nm

Weight 72 kg
6 forward speeds
Speeds
1 reverse speed
Speed control Electronic
Optional
Power take-off
(HYDROCAR type only)
Speed engagement:
Forward speeds
- 5th/6th - 3rd/4th Single-cone synchronizer
- 1st/2nd Dual-cone synchronizer
Reverse speed Quick-connect (non-synchronized) type
Gear ratio
First 6.727
Second 3.947
Third 2.555
Fourth 1.776
Fifth 1.289
Fifth 1.000
Reverse 6.055
Shaft bearings:
Transmission shaft tapered roller

Transmission shaft bearing end play 0 ÷ - 0.05 mm
Shim thickness for transmission shaft bearing

-
end play adjustment
Main shaft
- hubs for sliding sleeves 80° ÷ 110oC
- 1st-R gear bushes and spacer ring 80° ÷ 110oC
- front bearing* 90° ÷ 110oC
Transmission shaft
- bearings 80°C (max 120oC)
- 5th-4th gears 170°÷160oC
Gear end float:
1st - 3rd - 4th - R - 5th gear 0.15 ÷ 0.40 mm
2nd gear 0.25 ÷ 0.5 mm

0 ÷ 0.15 mm
ring end float

-
ring thickness
Retaining ring end float:
- transmission shaft front bearing 0 ÷ 0.1 mm
- main shaft roller bearing 0 ÷ 0.1 mm
Transmission shaft rear bearing retaining
-
ring thickness
LOCTITE 510
Sealant LOCTITE 242
LOCTITE 5206

Quantity 2.7 litres
2.43 kg

TIGHTENING TORQUES
Figure 16
101948
TORQUE
DESCRIPTION
Nm kgm
1D Screw securing driver to main rod 9.5 0.9
2 Gearbox actuator support fastening screw 23 2.3
3 Clutch housing, screw to fasten clutch housing to crankcase 80 8
4 Constant mesh shaft cover fastening screw 23±15% 2.3±15%
5J Screw securing p.t.o. side cover 46±15% 4.6±15%
6 Plugs for rod preventing gear engagement 32 3.2
7 Clutch actuator fastening screws 23 2.3
8 Screw securing reverse gear shaft 23±15% 2.3 ±15%
9* Screw securing rear cover 23±15% 2.3±15%
10 Electronic control unit fastening screws 9.5 0.9
11 Side plug on rear cover 35 3.5
12 Speedometer transmitter fixing 50 5
13 Screw locking sleeve for transmission coupling on main shaft 235 23.5
14 Cap 32 3.2
15D Screw securing ball bearing retaining ring 9.5±15% 0,.±15%
16 Gearbox actuator fastening screws 23 3.2
17 Electric motor fastening screws - -
: Spread LOCTITE 5206 sealant on the contact surfaces

F Spread LOCTITE 242 on the thread
J Spread LOCTITE 510 on the thread

TOOLS
99327010 E.A.SY.
99327001 Modus station

DIAGNOSIS
Diagnosis instruments
DISPLAY
Figure 17
108872
System fault displayed with symbols indicated in figure.
MODUS
Computer-assisted diagnosis station intended for diagnosis of electronically-controlled braking systems, pneumatic suspensions,
engines and systems.
This station is equipped with auxiliary functions such as electronic control unit programming, spare part catalogue referencing,
time-charts, etc.
IT 2000
IT 2000 is a diagnosis instrument for all Electronic Systems fitted to IVECOvehicles. It allows you to promptly operate on a vehicle
by recognizing the latter by means of the chassis number.
It stores the results of the diagnostic work carried out.
It can also be used as a laptop PC and is set for remote diagnosis.
Using MODUS as a mother station allows you to update and configure IT 2000.
E.A.SY.
The E.A.SY. system allows you to easily diagnose and program the various electronic controls unit fitted to the vehicle. It is made
up of an ECI module for communication with the electronic control units and a Panasonic PC.
The ECI module allows you, by taking advantage of the Panasonic PC, to easily carry out work on the road; in particular, diagnostic
work can be assisted by a specialized remote centre, thanks to the wireless technology incorporated into the Panasonic PC (e.g.
GPRS).

MODUS - IT 2000 - E.A.SY. CONNECTION

The 38-pole connection makes it possible to perform the following operations:
- Gearbox control unit data reading
- Error (if any) detection and clearing
- Clutch engagement/release control
- Control unit configuring
Figure 18
108874
A. IT 2000 - B. E.A.SY. - C. MODUS - D. Body computer - E. Diagnosis socket.

530210 GEARBOX REMOVAL/REFITTING

Removal Figure 22
Disconnect the battery cable in engine opening.
Place the vehicle in a pit, or on an auto lift or special supporting
stands.
Figure 19
Figure 24
102137
Remove electric cable fastening strap (1) on the clutch

actuator side.
102134
Remove the straps (shown by arrows) that secure the electric

cable to the gearbox. Figure 23
Figure 20
102135 102138
Remove reverse gear light connectors (1) and revs number Press clutch actuator connector pull-back spring (1), as shown
sensor (2). by the arrow
Remove the power take-off electric connections (if any) from
the other side of the gearbox. Figure 24
Figure 21
102136
102139
Push the safety retainer downwards, then remove the

Remove connector (1) from clutch actuator (2).
connector form the control unit (see arrow).

Figure 25 Figure 28
102140
Prior to removing the actuator, verify that the clutch

is closed. This can be done either by means of the
102143
diagnosis instrument or by visually inspecting the
position of the fork which must be perpendicular to Unscrew the four screws (2) securing drive shaft (1) to the
the gearbox axis. gearbox.
In the event that the clutch has been left open, due
to a mechanic or electric fault, the fork will be loaded
by the actuator internal spring Figure 29
Therefore, avoid touching the engaging tip straight
with your hands.
Figure 26
102144
102141 Properly secure drive shaft (1) to the chassis.

Remove the four clutch actuator fastening screws (1).
Take off actuator (2).
Figure 30
Figure 27
102163
102145
Remove screws (1) securing the starting motor to the gearbox
case front cover. Then, place it carefully in the engine Remove the two hexagonal screws (1), then take off the
compartment. engine lower cover (opposite the axle).

Figure 31 Figure 34
102149
102146
Before mounting bracket 99372069, remove a number of Remove the crossbar fastening screws (1) on the left side.
screws securing gearbox to block.
Figure 32 Figure 35
102150
102147
Remove the crossbar fastening screws (1) on the right side,
Use a hydraulic jack to position bracket 99370629 (1) under then remove the crossbar, taking care not to drop it on the
the gearbox; then, put the chain onto the gearbox and place floor.
a ring of the same into the bracket slotted hole.
Screw down the nut so as to tightly secure, through the chain, Figure 36
the gearbox to the bracket.
Figure 33
102151
Remove boot (1) from its housing.

This operation is necessary to make the fork travel the full
102148 disengagement stroke when detaching the gearbox
Remove the remaining screws securing the gearbox to the
Remove screw (1) centrally securing the rear crossbar to the clutch bell.
gearbox.

Move the gearbox backwards until the motion input shaft has Refitting
come out of the clutch disc hub. Fully take out the gearbox, Figure 40
taking care not to hit it or get it caught in some component.
Figure 37
102155
Press the pressure plate bearing onto the shaft and the fork
against the bearing, as shown in the figure. Apply grease MRM2
to the fork at the bearing pressure point.
Figure 41
102152
After the detachment operation has been completed,

pressure plate bearing (1) shall remain fitted into the clutch (as
shown in the figure).
Figure 38
102156
Put rubber boot (1) into its housing.
NOTE Gearbox is provided by spares in second gear in

order to enable primary shaft rotation through
transmission shaft connection flange rotation.
102153 Figure 42
Use pliers to act on the retaining ring to disassemble bearing (1).
Figure 39
102157
Couple gearbox (2) with clutch (1).
NOTE In order to facilitate coupling, two guiding pins, fitted

onto two of the holes used to secure the gearbox
102154 to the base unit, can be used.
Remove bearing (1).

Figure 43 Figure 45
102158
Manually screw down screws (1) securing the gearbox case to 102160
the base unit prior to tightening them to torque.
Secure the cable to the gearbox by means of the special
fasteners (1).
Figure 44
Figure 46
102161
Screw down gearbox fastening screws (1) by tightening them

to torque.
Figure 47
102159
102145
NOTE Pull the fork (3) towards the control unit, so that
pressure plate bearing (2) is correctly engaged into
diaphragm spring (1). Screw down screws (1), then fit the engine lower cover.

Figure 48 Figure 51
102163
102141
Re-attach the starting motor to the gearbox case front cover
by tightening the screws (1) to the specified torque. Secure clutch actuator (1) to the gearbox by means of the four
screws (2), then tighten to the specified torque.
Figure 49 Figure 52
102149 102167
Secure crossbar (1) to the gearbox and to the chassis by Connect connector (1) to the clutch actuator.
tightening the screws to the specified torque.
Figure 50 Figure 53
102165
Fit the clutch actuator (1) engaging tip into the special fork slot, 102168
taking care not to touch it straight with your hands.

Secure the gearbox cable by means of strap (1).

Figure 54 Figure 57
102169 102172
Connect connectors (1) to the control unit. Secure the wiring to the gearbox, as shown by the arrows in
the figure.
Figure 55
Figure 58
102170
Properly secure the connector until the pull-back spring clicks

into position (see arrow). 102143
Figure 56
Secure drive shaft (1) to the gearbox by tightening fastening
screws (2) to torque.
After the gearbox has been re-attached completely, check for
correct connection of electric cables.
NOTE After re-attachment has been completed, perform

the specific calibration procedure by means of the
diagnosis instrument described on page 122/30.
102171
Connect the reverse light (1) and revs number sensor (2)
connectors.
Connect the electrical connections of the power take-off, if
present, from the other side of gearbox.

GEARBOX UNIT OVERHAULING

66136114 CONTROL UNIT
NOTE As far as gearbox unit overhauling is concerned,
follow the instructions and illustrations relative to Removal
the 6 S 400 O.D. gearbox unit. Place the vehicle in a pit or on an auto lift.
Below are the descriptions and illustrations relative Disconnect the battery cable in the engine compartment.
to the replacement of the gearbox unit
electric/electronic components supplied with spare
parts.
Figure 59
102162
Remove connector (4) from control unit (1) by pulling the safety retainer downwards, as shown by the arrow.
Remove strap (6). Unscrew screws (2, 3).
Remove screw (5) while holding the control unit and taking care to recover spacer (7) placed behind screw (3). Take off control
unit (1).

Refitting
Figure 60
102164
Screw down screw (5), yet without tightening it to torque. Connect the battery cable.
Fit spacer (7), between the control unit and the gearbox,
behind screw (3), then screw down the latter.
Screw down screws (2). the specific calibration procedure by means of the
Screw down all screws (2, 3 & 5) to the specified torque. diagnosis instrument described on page 122/30.
Insert control unit connector (4) by securing it with the safety
hook, as shown by the arrow.

505279104 CLUTCH ACTUATOR
Removal
Figure 61
102166
Place the vehicle in a pit, or on an auto lift or special supporting open, it is required that the action of the lever is
stands. forced back, since the lever is loaded by the clutch
diaphragm spring. Properly lock the motion of lever
Disconnect the battery cable in the engine compartment. (4), and avoid, during the subsequent actuator
Remove strap (1). releasing phase, getting your hands near the
engaging tip area.
Take off connector (5) by pressing onto the fastening springs,
as shown by the arrows.
Prior to removing the clutch actuator, make sure
that the clutch is closed. Remove the four fastening screws (3).
Engaging lever (4) must be in the position shown in
box A (perpendicular to the gearbox axle). Take off clutch actuator (2).
If the lever is not found in that position, the clutch
will be open. In the event that the actuator has been taken off
This condition can be inspected both visually and by with the clutch open, release lever (4), previously
getting connected to the vehicle by means of the engaged, with the utmost care.
diagnosis instrument and subsequently reading the Avoid touching the lever straight with your hands,
data memory. In the event that the clutch is owing to the lever being loaded.

Refitting 530520100 GEARBOX ACTUATOR

Figure 62 Removal
stands.
Disconnect the battery cable in the engine compartment.
Take off the clutch actuator, as described on page 119.
NOTE The actuator, positioned in the upper part of the

gearbox, cannot be accessed, owing to the very
narrow space between the cabin floor and the
actuator itself.
102173
Proceed as it follows:
Position clutch actuator tip (1) into fork aperture (3).
Tighten the four fastening screws (2) to the specified torque.
Figure 64
Figure 63
102190
Place a pit lift (2) under gearbox (1). Unscrew the gearbox
crossbar fastening screws. Lower the lift so as to obtain a
distance “A” of 12-13 cm between the actuator and the cabin
floor.
102189 NOTE This operation must be carried out with the greatest
care, avoiding hitting the front part of the power unit.
Fit connector (2) by pressing it until it gets engaged.
Secure the cable by means of strap (1).
Connect the battery cable.

diagnosis instrument described on page 125.

Figure 65 Figure 66
102192
- Apply an even coat of LOCTITE 574 sealant on the

gearbox actuator supporting surface.
- Position the actuator into its seat with the greatest care.
- Tighten the nuts or screws to the specified torque.

diagnosis instrument described on page 125.
769152104 CHASSIS WIRING

GEARBOX
Removal
102191
stands.
Take electric connectors (2) off the actuator.
Unscrew electric motor support fastening screw (4). Take off
supports (3). Figure 67
Use a suitable tool (5) to remove the eight fastening screws
(1), then take off gearbox actuator (6).
NOTE Clean the supporting surface of the actuator on the

gearbox case.
Refitting
detachment operations. Also follow the advice below:
102193
Open the engine hood.

Unscrew screw (1), disconnect the battery cables and take off
battery (2). Take connector (3) off EDC central unit.

Figure 68 769152104 GEARBOX WIRING -

GEARBOX
Removal

stands.
Disconnect the battery cable in the engine compartment.
102194
Disconnect wiring (1) from the gearbox control unit, taking Figure 70
care that it is not hit or does not get caught.
Figure 69
102196
102195 Remove the straps (shown by arrows) that secure the cable
to the gearbox.
Take full wiring (1) off the vehicle.
Refitting

detachment operations. Also tighten the nuts or screws to the
specified torque.
NOTE After the re-attachment operation has been

completed, verify, by getting connected to the
vehicle by means of the diagnosis instrument, that no
error is found in the gearbox control unit fault
memory.

Figure 71 Figure 73
102198
Remove connector (1) from control unit (2), by releasing the

pull-back spring downwards, as shown by the arrow.
Figure 72
102200
Remove the connectors (1) from the gearbox actuator

electric motors by pressing the fastening springs, as shown by
the arrows.
Refitting

detachment operations. Also follow the advice below:
- Lay the wiring onto the gearbox by fitting the same with
102199
brackets at the specified points, then place it on the engine,
taking care that it does not get pinched.
Press connector springs (2) inwards (see arrows). - Check for correct insertion of connectors, which can be felt
when the locking bracket has been closet.
Remove the connector from clutch actuator (1).
NOTE After the re-attachment operation has been

completed, verify, by getting connected to the
vehicle by means of the diagnosis instrument, that no
error is found in the gearbox control unit fault
memory.

CALIBRATION
Some modifications or repairs that affect the ESV1 system components, automatic transmission, require a calibration procedure.
The repairs that require this operation are detailed as follows:
- Replacing the gearbox kit + control unit
- Replacing the control unit only
- Replacing the clutch actuator
- Replacing the gearbox actuator
- Replacing an electric motor of the gearbox actuator
- Replacing the engaging fork
NOTE Replacing the gearbox wiring requires no calibration procedure.
Calibration in case of replacement of the gearbox kit + control unit

The control unit must be programmed (no error in the memory) by providing the same with the vehicle data, e.g. axle ratio, rolling
radius, strength curve, etc.
Get connected to the vehicle by means of the diagnosis instrument, with the vehicle stationary, engine OFF and gearshift lever
in neutral.
Carry out the operations indicated by the instrument: key ON (engine ON), then the dedicated calibration procedure will be
started → ” Adaptation of touch Point.
Message “service” will appear on the display; the system in automatic mode will carry out the following operations:
- opening the clutch;
- engaging the 5th or 6th speed;
- he clutch closes three times searching for the point of initial slip (the vehicle will pick up three times);
- putting the lever in neutral;
- closing the clutch.
The procedure is interrupted when the engine is switched off.
NOTE Wait 10 seconds prior to the next KEY ON.
When the procedure has been completed, check the control unit memory and verify that no error is found.
Calibration in case of replacement of the control unit

The control unit must be programmed by providing the same with the vehicle data, e.g. axle ratio, rolling radius, strength curve,
etc.
in neutral.
Carry out the operations indicated by the instrument: key ON (engine OFF), then the dedicated calibration procedures will be
started → Measurement of Maximum Clutch Travel
Transmission Self Adaptation
Message “service” will appear on the display; the system in automatic mode will carry out the aforesaid procedures. Upon
completion of this step, the engine will be started and the → Adaptation of touch Point calibration procedure will be started.
- he clutch closes three times searching for the point of initial slip (the vehicle will pick up three times);

Calibration in case of replacement of the clutch actuator

Clear the control unit error memory.
in neutral.
Carry out the operations indicated by the instrument: key ON (engine OFF), then the dedicated calibration procedure will be
started → Measurement of Maximum Clutch Travel.
Message “service” will appear on the display; the system in automatic mode will carry out the necessary operations. The procedure
will be interrupted when the engine is switched off.
Calibration in case of replacement of the gearbox actuator or an electric motor of the gearbox
actuator
in neutral.
Carry out the operations indicated by the instrument: key ON (engine OFF), then the dedicated calibration procedure will be
started → Transmission Self Adaptation.
Message “service” will appear on the display; the system in automatic mode will carry out the necessary operations. The procedure
will be interrupted when the engine is switched off.
Calibration in case of replacement of the clutch engaging/release fork

in neutral.
Carry out the operations indicated by the instrument: key ON (engine ON), then the dedicated calibration procedure will be
started → Adaptation of Touch Point.

- the clutch closes three times searching for the point of initial slip (the vehicle will pick up three times);


DAILY EURO 4 POWER TAKE OFF 127
TRANSMISSION
Power take off
Page
ASSEMBLY STANDARDS . . . . . . . . . . . . . . . . . 131
POWER TAKE OFF ELECTRIC ACTUATOR . . 132
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

128 POWER TAKE OFF DAILY EURO 4

TYPE Hidrocar 20Z1 Hidrocar 20 Z2

Application 5 S 300 6 S 400 A O.D.
Gear ratio I, PTO(*) output revs., normal PTO(*) input revs. 1 0.910
PTO(*) output rated torque at 1500 rpm (Nm) 120 180
Expected duration at rated torque and at 1500 rpm hours 500
Rotation direction (with respect to engine) Opposite
Control Electric
Assembly side (with respect to running direction) Left side
Torque obtainable from gearbox (Nm) 175 303
Oil capacity (litres) ~ 0.6 ÷ 0.4
(*) = Power Take Off
Drive gear taper roller bearing axial backlash 0 - 0.1 mm
Drive gear taper roller bearing axial backlash

by shims
adjustment
Drive gear taper roller bearing axial backlash

0.1 - 0.2 - 0.3 - 0.5 mm
adjusting ring thickness
Figure 1
62092
Power take offs are applied to secondary shaft on gearbox left side instead of cover (1).
NOTE Fill and check gearbox oil level.

TIGHTENING TORQUES
Figure 2
62181
TORQUE
DESCRIPTION
Nm kgm
1 M16x1.5 actuator fixing tang 50 5
2 Switch fixing 50 5
3* Flange fixing screw 25 2,5
M10 nuts for fixing PTO to gearbox 35 ÷ 39 3.5 ÷ 3.9
* Smear screw thread with LOCTITE 242

Figure 3
62093
POWER TAKE OFF COMPONENTS
Figure 4
ASSEMBLY STANDARDS
Parts (*): sealing rings and bearings shall be smeared with
grease POLIMER 400.
Adjusting ring (♦) thickness shall guarantee taper roller
bearing axial backlash equal to 0 ÷ 0.1 mm.
Screw thread (•) shall be smeared with Loctite 242.
Sealing ring (1) shall be fitted with 6 mm sinking from power
take off housing (2) surface.
62094

POWER TAKE OFF ELECTRIC ACTUATOR

Description
Figure 5
62095
The linear actuator (1) provides motion to control rod (5) Operation
controlling power takeoff connection and disconnection.
POWER TAKEOFF CONNECTION
It is fixed to power takeoff through the bottom side (2),
screwing it on the power takeoff box. PTO connection (Figure 5) is divided into two different
phases:
Control rod motion is generated by a system composed of
electric motor and worm screw (7) which, being blocked in The first phase consists in moving forward worm screw (7),
rotation, linearly moves along two directions enabling to rod (5) and sleeve (3), which, coming into contact with shaft
connect and disconnect the PTO. toothing (4), creates axial backstop of the rod and worm
screw in an intermediate position as to the whole stroke.
Axial power load is controlled by a spring, set inside actuator
(1), providing approx. 350 N force on power takeoff control The axial backstop of worm screw (7) preloads the spring
rod (5). inside the actuator and switches the electric motor off; the
pretensioned spring exerts energises control rod (5) and
keeps the axial load even after electric motor switching off.
The second phase consists in stroke continuation if sleeve (3)
toothing sustains a relative rotation as to the shaft (4)
toothing and therefore stops the axial backstop previously
set by the two toothing contrast.

Figure 6
62096
In this case, the spring inside the actuator, previously It is therefore possible to install on PTO having different
preloaded, provides a first motion to the elements (7, 5 and stroke values without modifying or adding compensation
3) and causes the electric motor, previously stopped, starting. elements.
Subsequently, the stroke starts again until it meets a new POWER TAKEOFF DISCONNECTION
obstacle, represented by rod (5) limit stop on the power
The PTO disconnection phase (Figure 6) is divided into two
takeoff box.
motions:
At this point, another axial backstop condition is created and The first motion consists in the worm screw return (7)
the above-mentioned operation is repeated: rod (5) tension through the reversal carried out on the electric motor.
and electric motor switching off.
The second motion consists in the control rod retrocession
As long as the PTO engagement toothings stay on contact (5) through spring (6) and consequent shaft (4) sleeve (3)
with each other, the electric motor is switched off because disengagement.
the pressure on the toothings (3 and 4) is kept by the spring,
inside the actuator.
NOTE The retrocession motion of the worm screw (7) do
The axial load on the engagement toothings is calibrated not depend on the movement carried out by the
(about 350 N) and gradually applied because the action control rod (5); this guarantees, if the sleeve (3)
spring (inside the actuator) carries out a determined stroke cannot be disengaged, the immediate backing of the
before being completely loaded. Toothing mouths (3 and 4) worm screw (7) without causing overloads to the
shall therefore be protected against violent impacts assuring, electric motor.
as to traditional mechanical or pneumatic system, less
The PTO will be disconnected when the backstop
engagement element wear and consequently, an higher
condition is over.
number of turns to be implemented before component
deterioration. This event can occur if during the disengagement
request the shaft (4) is still in rotation or
The functionality is more serviceable since the engagement pretensioned by a residual torque.
is softer and more silent as to the traditional systems.
Worm screw (7) limit stop is determined by axial load and
distance covered by control rod (5).


DAILY EURO 4 PROPELLER SHAFTS 1
SECTION 5
5056 Propeller shafts
Page
CHARACTERISTICS AND DATA . . . . . . . . . . . . . 3
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . 10
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PROPELLER SHAFT REMOVAL AND REFITTING . 11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CHECKING PROPELLER SHAFTS ON VEHICLE . . 11

2 PROPELLER SHAFTS DAILY EURO 4


Name mm
Complete spider assembly (radial) in the fork housings 0,03
Transmission shaft max. off-centring
- measured at centre 0,4
- measured at extremities 0,25
- measured on tang 0,15
Max. working angle 20º
4x2 Vehicles
Figure 1
62123
GKN-TYPE ARTICULATED PROPELLER SHAFT
Figure 2
50826
DANA-TYPE ARTICULATED PROPELLER SHAFT

4x2 Vehicles
Figure 3
GKN-TYPE CONNECTING SHAFT 62122
Figure 4
50827
DANA-TYPE CONNECTING SHAFT
Figure 5
75213
GKN-TYPE CONNECTING SHAFT

Propeller shaft length (mm) SENZA CODICE-2

MODEL VERSION PITCH L
(mm) L1
GKN supply DANA supply
VAN
2120 ÷ 2205
3000 813 2120 ÷ 2210 2130 ÷ 2215*
CHASSI
CAB
29L-35S 10/12
29L 35S 14
29L-35S
1134 2565 ÷ 2655 -
VAN 3450
1135 - 2580 ÷ 2665
2075 ÷ 2160
VAN 3000 763 2075 ÷ 2165
2085 ÷ 2170*
35S 10/12/15/18
CHASSI
3450 1085 2520 ÷ 2610 2520 ÷ 2605
CAB
VAN
35C - 40C 10/12 2080 ÷ 2165
35C 14 3000 652 2080 ÷ 2170 2090 ÷ 2175*
CHASSI
CAB
35C 10/12/18 VAN
3000 602 2035 ÷ 2125 2035 ÷ 2120

35C - 40C CHASSI
10/12/15/18 CAB
(*) Power trains extended by 10 mm.

Propeller shaft length (mm)

PITCH Front shaft SENZA CODICE-4 Rear shaft SENZA CODICE-2
MODEL VERSION (mm) L
L L1
VAN 3300 891 343 1540 ÷ 1630 1540 ÷ 1625
29L.10/12/14 CHASSI 1980 ÷ 2065

3750 891 666 1980 ÷ 2070
35S 10/12/14 CAB 1990 ÷ 2075*
2180 ÷ 2265
VAN 3950 891 866 2180 ÷ 2270
2190 ÷ 2275*
VAN 3300 841 343 1540 ÷ 1630 1540 ÷ 1625
CHASSI 1980 ÷ 2065

35S 10/12/14 3750 841 666 1980 ÷ 2070
CAB 1990 ÷ 2075*
/15/18
2180 ÷ 2265
VAN 3950 841 866 2180 ÷ 2270
2190 ÷ 2275*
1650 ÷ 1735
VAN 3300 730 608 1650 ÷ 1740
1660 ÷ 1745*
CHASSI
3450 730 607 1815 ÷ 1905 1815 ÷ 1900
CAB
35C - 40C 10/12 2090 ÷ 2175

CHASSI
35C 14 3750 730 652 2090 ÷ 2180
CAB 2110 ÷ 2195*
VAN 3950 730 986 2315 ÷ 2405 2315 ÷ 2400
CHASSI 2450 ÷ 2530

4100 730 1024 2450 ÷ 2540
CAB 2460 ÷ 2540*
CHASSI
3450 680 607 1800 ÷ 1905 1815 ÷ 1900
CAB
35C - 50C 15
45C - 50C 10/12 CHASSI 2090 ÷ 2175
3750 680 652 2090 ÷ 2180
14/15/18 CAB 2110 ÷ 2195*
VAN 3950 680 986 2295 ÷ 2385 2315 ÷ 2400

Propeller shaft length in mm.

PITCH Front shaft SENZA CODICE-4 (*) Rear shaft SENZA CODICE-2 - (*) 5
L L1
VAN 4100 680 1024 2450 ÷ 2540 2460 ÷ 2545

35C - 40C
10/12/14/15/18 1650 ÷ 1735
CHASSI
3300 680 607 1650 ÷ 1740
CAB 1660 ÷ 1745*
45C - 50C 15/18 VAN 3300 (*) 680 (*) 690 ÷ 790
35C - 50C
45C - 50C VAN 3950 680 986 2295 ÷ 2405 2315 ÷ 2400
10/12/15/18

Front shaft Central shaft
PITCH SENZA Rear shaft SENZA CODICE-2-(S) 5
MODEL VERSION CODIC SENZA CODICE-4-(S) 5
(mm) -4 L L
L1
L GKN supply DANA supply GKN supply DANA supply
CHASSIS (S) 755 ÷

COWL
3750 (S) 680 (S) 755 ÷ 855 - (S) 1080÷2180 (S) 1080÷1190
855
CHASSI CAB 746 722 1950÷2040 1965÷2050
CHASSIS 4350 680

(S) 755 ÷
COWL (S) (S) 755 ÷ 865 (S)440 (S) 1630÷1720 (S) 1630÷1715
855
45 - 50C 15/18
CHASSI CAB 730 1056 2380÷2470 2380÷2465
CHASSIS 4750 680

(S) 755 ÷
COWL (S) (S) 755 ÷ 865 (S)781 (S) 2100÷2190 (S) 2100÷2185
855
(S) 1120 ÷
VAN 3950 (*) 680 - (S) 900÷1000 -
1220
(S) Vehicles with Telma retarder



PITCH Front shaft SENZA CODICE-4 Rear shaft SENZA CODICE-2
L L1
VAN 3300 670 614 1630 ÷ 1720 1630 ÷ 1715
CHASSI
3450 670 626 1780 ÷ 1870 1790 ÷ 1875
CAB
60C - 65C 15/18
CHASSI
3750 670 660 2075 ÷ 2165 2085 ÷ 2170
CAB
VAN 3950 670 995 2280 ÷ 2370 2280 ÷ 2365

Front shaft Rear shaft
MODEL VERSION PITCH SENZA Central shaft
CODIC
(mm) SENZA CODICE-4 L
-4
L1
L L GKN supply DANA supply
CHASSI
4350 670 801 724 1885 ÷ 1975 1885 ÷ 1970
CAB
60C - 65C 15/18
CHASSI
4750 670 730 1065 2350 ÷ 2440 2350 ÷ 2435
CAB

Front shaft Central shaft SENZA CODICE Rear shaft Figure 5.1.2
MODEL VERSION PITCH SENZA CODIC
(mm) -4 L L
L1
L GKN supply DANA supply GKN supply DANA supply
CHASSIS
COWL
3750 670 (S) 970÷1070 - - (S) 825÷925 -
CHASSIS
60C - 65C 15/18 COWL
4350 670 (S) 970÷1070 - - (S) 1395÷1495 -
CHASSIS
COWL
4750 670 (S) 1080÷1180 - 408 - (S) 1705÷1790
(S) Vehicles with Telma retarder

DIAGNOSTICS
The main operating faults of the propeller shaft are as follows:
1. Noise and vibrations
NOISE AND VIBRATIONS

1
Deformation of shaft. Replace shaft.

YES
NO
Shaft unbalanced. Check balancing of shaft and determine the points

YES where to weld the counterweights.
NO
Excessive play between the splined profiles. Replace the shaft.

YES
NO
Nuts and bolts fastening shaft to either transmission or After a careful check, tighten up the loose screws and
rear axle sleeves loose. YES nuts, and eventually replace any damaged ones.
NO
Universal joints seized-up or excessively worn. Overhaul or replace the universal joints.
YES
NO
Insufficient lubrication of the parts. Lubricate the parts at the appropriate nipples.
YES
NO
Elastic support fixing screws loose. Tighten the screws to the required driving torque.
YES
(Continues)

Elastic dowel of central support in bad condition. Replace the support.

YES
NO
Central elastic support bearing in bad condition or Replace the support.

excessive play. YES
NO
Flange fixing screws or ring nuts on propeller shaft tang Tighten the screws or the ring nuts to required driving
loose. YES torque.
TIGHTENING TORQUES
TORQUE
PART
Nm kgm
Ring nut for fixing to connecting shaft 250 ± 25 25,4 ± 2,5
M10 x 1,5 63,5 ± 6,5 6,5 ± 0,6
Nut for screw for fixing flanges to propeller shaft
M12 x 1,25 116,5 ± 11,5 11,8 ± 1,2
Nut, linkage shaft to chassis side member fixing screw 62,5 ± 6,5 6,3 ± 0,6
TOOLS
99370618 Support for removal-refitting propeller shaft

505620 PROPELLER SHAFT REMOVAL AND REFITTING

Figure 6
52123
Removal CHECKING PROPELLER SHAFTS ON

VEHICLE
NOTE When overhauling the propeller shaft, always begin
by removing the rear shaft.
Figure 7
Arrange the support 99370618 on the hydraulic jack and
apply the support to the propeller shaft.
Remove the fixing bolts from the flange and remove the shaft;
for the intermediate and front axles, also remove the chassis
shaft support.
Refitting
Repeat the same operations for removal in the opposite
order and observe the following:
- Make sure that the arrows shown on the moving part 52124
and on the shaft are aligned.
- Make sure that the holes of the front flange are aligned
with those of the rear flange;
The plates welded to the propeller shafts are counterweights.
- the nuts for the flange coupling screws must be replaced If the plates are missing the shaft must be re-balanced.
and never reused; By operating on the propeller shaft and at the same time, in
the opposite direction, on the sliding sleeve, check that there
- the flange coupling screws must be inserted into the is not too much slack between the splines.
holes of the flange from the side of the universal joint; By operating on the sleeve forks. check that the spiders are
- the nuts and screws must be tightened to the required not worn; if they are, replace them.
driving torque;
- the flange of the moving part of the propeller shaft must
be connected to the output shaft flange.


DAILY EURO 4 REAR AXLES 1
SECTION 6
5250 Rear axles
Page
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR AXLE NDA RS . . . . . . . . . . . . . . . . . . . . . 5
REAR AXLES NDA RG . . . . . . . . . . . . . . . . . . . . 35
REAR AXLE 450511 . . . . . . . . . . . . . . . . . . . . . . 53
REAR AXLE 450517/2 . . . . . . . . . . . . . . . . . . . . 83

2 REAR AXLES DAILY EURO 4

DAILY EURO 4 REAR AXLES 3
DIAGNOSTICS
The main rear axle operating faults are as follows:
1. - Wheel hubs noise;

2. - Rear axles noise;
3. - Noise at release;
4. - Noise during acceleration;
5. - Cornering noise.
1 WHEEL HUBS NOISE
Insufficient lubrication. Check that there are no leaks from gaskets or the rear
YES axle casing and top up oil to correct level.
NO
Wheel hub bearings inefficient. Remove the hub and replace inefficient parts.
YES
NO
Wheel hub bearings out of adjustment. Adjust bearings.

YES
2 REAR AXLES NOISE
Lubricating oil level low. Check that there are no leaks from gaskets or the rear
NO
Drive shaft splines to fit the differential crown wheels Overhaul the rear axle and replace worn or damaged
damaged. YES
parts.
NO
Wheel hub bearings inefficient. Adjust the bearings clearance.

YES

4 REAR AXLES DAILY EURO 4
Bad adjustment or wear on differential gears or bearings. Locate the trouble and overhaul the unit.
YES
3 NOISE AT RELEASE
Improper fitting clearance between pinion and ring bevel Remove the gear housing inspection cover and adjust
gear. YES clearance between pinion and ring bevel gear.
4 NOISE DURING ACCELERATION
Insufficient lubrication. Check that there are no leaks from gaskets or the rear
NO
Gear housing bearings badly set or deteriorated. Overhaul the unit.

YES
NO
Bad tooth contact between pinion and ring bevel gear. Adjust the contact.
YES
5 CORNERING NOISE
Improper clearance between planetary gears and crown Overhaul or replace the unit.
wheels. YES

DAILY EURO 4 REAR AXLE NDA RS 5
Rear axle NDA RS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REAR AXLE NDA - RS REMOVAL - REFITTING 17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OVERHAULING THE REAR AXLE ASSEMBLY . 19
- Air breather disassembly - assembly . . . . . . . . 19
- Wheel hub overhaul . . . . . . . . . . . . . . . . . . . . 19
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REPAIRING THE DIFFERENTIAL . . . . . . . . . . . . 22
- Disassembling the differential unit . . . . . . . . . . 22
- Gear housing removal . . . . . . . . . . . . . . . . . . . 23
- Dismounting bevel pinion . . . . . . . . . . . . . . . . 24
- Checking the parts comprising the differential 25
- Assembly of gear housing . . . . . . . . . . . . . . . . 26
- Assembling the bevel pinion assembly . . . . . . 27
- Assembly of differential unit . . . . . . . . . . . . . . 30

6 REAR AXLE NDA RS DAILY EURO 4

DESCRIPTION The adjustment of bearing rolling torque is through adjusting

rings put in between box and stop rings.
The rear axle is the load-bearing type with a single reduction
using a hypoid crown wheel and pinion. The clearance between pinion and crown wheel is adjusted
by changing the thickness and/or position of the adjustment
The axle housing is made of pressed sheet steel with hot
rings, though the total thickness must be the same as that of
pressed arms.
the adjustment rings removed.
The bevel pinion is supported by two pre-lapped tapered
Differential wheelwork assembly is made up of two planetary
roller bearings to hold the bearing pre-load better.
and two crown wheel gears.
The bearings are factory lubricated by the manufacturer with
The drive shafts are supported inside the arms of the axle
rustproof protective oil.
housing by UNIT BEARINGS lubricated for life, which require
The rolling torque of the bearings of the bevel pinion is no adjustment.
adjusted by changing the thickness of the adjustment ring
The brakes are disc brakes with floating brake calipers.
between the two tapered roller bearings.
The disc brakes are splined onto the end of the drive shafts
In addition, it is possible to adjust the position of the bevel
and secured with pins that also serve as centring for the
pinion with respect to the ring bevel gear by changing the
wheel rims.
thickness of the ring between the axle housing and the bevel
pinion rear bearing external ring. The brake calipers are secured with flanges welded onto the
end of the arms of the axle housing.
The gear housing is supported by two tapered roller bearings,
also pre-lapped and lubricated with rustproof protective oil. The brake calipers are equipped with the parking brake
device.
Figure 1
107834

Type of rear axle:

NDA RS
Simple reduction type
DIFFERENTIAL UNIT
1/3,154 (13/41) - 1/3,416 (12/41) - 1/3,727 (11/41) - 1/3,916

Reduction bevel gear pair ratio
(12/47) - 1/4,182 (11/46) - 1/4,444 (9/40) - 1/4,889(9/44) -
(No. of teeth: pinion/crown)
1/5,111 (9/46)
Bevel pinion bearings 2 with taper rollers
Bevel pinion bearings rolling torque

(bearings lubricated and without
gasket) Nm 2.3 ÷ 3.3
New bearings
kgm 0.23 ÷ 0.33
Adjustment of pre-load of bevel
By means of adjustment rings
pinion bearings
Bevel pinion bearings pre-load 0.545 ÷ 1.070 mm

> adjustment rings with progression of 0.025 mm.
Temperature at assembly of inner
-
bearing ring on bevel pinion
Position of bevel pinion with

By means of adjustment spacers
respect to differential casing
Thickness of adjustment rings 3.585 ÷ 4.235 mm

> placed between bevel pinion and
differential casing with progression of 0.025 mm.
Bearings for gear housing 2 with taper rollers
Differential casing bearings rolling

torque (bearings lubricated and
without gasket)
- 15/44 - 13/41- 12/41
- 12/43 - 12/47 - 10/41:
Nm 2.7 ÷ 3.9
kgm 0.27 ÷ 0.39
- 11/49 - 9/40 - 9/44
- 8/41 - 8/45:
Nm 2.6 ÷ 3.7
kgm 0.26 ÷ 0.37
Adjustment of differential casing

bearings rolling torque
Thickness of adjustment rings of 1 ÷ 1,95 mm

> differential casing bearings rolling
torque with progression of 0.05 mm.

Type of rear axle:

NDA RS
Clearance between pinion and ring
bevel gear with reduction ratios
- 1/3.916 - 1/4.182 - 1/4.444 -
0.13 ÷ 0.18 mm
1/5.111:
- 1/3.154 - 1/3.416 - 1/3.727 -
0.15 ÷ 0.20 mm
1/4.889:
Adjustment of clearance between

pinion and ring bevel gear
Clearance between planetary and

0.05 ÷ 0.15 mm
crown wheels
WHEEL HUBS
Wheel hub bearings UNIT-BEARING
Wheel hub bearings end play -
Wheel hub bearings rolling torque

Nm -
kgm -
Adjustment of wheel hub bearings Not adjustable

end play Tighten fixing ring nut to torque
Rear axle oil TUTELA W90/M-DA (SAE 80 W 90)

Quantity Litres 1,35
Dry rear axle weight :
- With ABS kg 112.1
- Without ABS kg 110.6
- Max capacity (GAW) kg 2240

TIGHTENING TORQUES
Figure 2
107835
NDA RS REAR AXLE DIFFERENTIAL SECTION
PART TORQUE
Nm Kgm
1 Bevel pinion retaining nut 400 ÷ 500 40 ÷ 50
2 Screw securing half-housing and ring bevel gear 89 ÷ 108 8.9 ÷ 10.8
3** Oil filler plug 49 ÷ 62 4.9 ÷ 6.2
4 Screw securing caps to differential housing 100 ÷ 120 10 ÷ 12
5 Screw securing gearing inspection cover to the axle housing 80 ÷ 95 8 ÷ 9.5
*** Oil drainage plug 49 ÷ 62 4.9 ÷ 6.2
* = Apply LOCTITE 5910 on the housing
** = Apply LOCTITE 577 on the plug thread
*** = Apply LOCTITE 573 on both sides of the gasket

Figure 3
107836
NDA RS REAR AXLE DIFFERENTIAL SECTION

Figure 4
107837
NDA RS REAR AXLE WHEEL HUB SECTION
TORQUE
PART
Nm Kgm
1 Wheel securing screw 160 16,3
2 M8x1.25 brake disk securing screw 13 ÷ 21 1,3 ÷ 2,1
3 M52x3 half shaft bearing securing ring nut 559 ÷ 677 57,0 ÷ 69,0
4 M12 rear axle arm - bearing support securing screw 125 ÷ 135 12,7 ÷ 13,8
5 M14x1.5 brake caliper securing screw 176 ÷ 217 17,9 ÷ 22,1
- M6 metal sheet guard securing screws 10 ÷ 16 1,0 ÷ 1,6

TOOLS
99305121 Hot air drier
99322215 Front and rear axle overhaul stand
99341003 Single-acting rear axle
99341015 Clamp

TOOLS
99345057 Extractor reaction block
99355184 Shaft bearing ring nut wrench
99370006 Handle, interchangeable drift
99370007 Grip for interchangeable punches
Tool to determine thickness of adjustment of bevel pinion

99370239 (use with 99395728)

TOOLS
99370241 Tool for fitting drive shaft bearing
99370317 Reaction lever with extension for flange retaining
Universal mounting to support axles during removal and refitting

99370617
99372236 Tool to move brake caliper piston back
Key to fit differential bevel pinion gasket (use with 99370007)

99374022
Punch to fit external races of bearings (diameter 55 ÷ 69 mm use

99374091 with 99370007)

TOOLS

99374092 with 99370007)
99389819 Dynamometric wrench (0 ÷ 10 Nm) with 1/4” square connection
Dial gauge with mounting to be used with the tools to determine

99395728 the thickness of adjustment of the bevel pinion

525010 REAR AXLE NDA - RS REMOVAL - Figure 5

REFITTING
Removal
Position the vehicle on level ground and stop front wheels.
Loosen rear wheels securing screws.
Lift the vehicle from its rear side and position it on support
stands.
Position hydraulic truck under rear wheels. Remove wheels
securing screws and take them off the vehicle.
Unscrew nut (2) adjusting hand brake linkage. Release the
cables from the chassis by uncoupling check springs (1).
Unscrew screws (7) securing transmission shaft (8).
Disconnect electrical cables (15) of the sensors of brake pad
wear and phonic wheel rpm’s (6).
Unscrew nuts (12) securing shock absorbers (11).
Take hydraulic pipes (16) of brake system off the fitting on the
chassis. Such pipes will be removed together with real axle in
the end step of the disconnection from the vehicle.
In disconnecting the hydraulic pipes of brake circuit

! and vapours breather, pay attention to any oil losses.
Prearrange suitable collectors in such a way that
brake liquid is not spread out into environment.
Avoid contact of liquid with skin and eyes. In case of
contact, wash abundantly with water.
Unscrew screws (3) securing rods (4) supporting stabilising bar

(5).
Disconnect rear axle oil vapours breather pipe (20).
Properly position a hydraulic jack provided with support
99370617 under rear axle.
Unscrew nut (17) securing leaf spring (9) to rod (18).
Unscrew nuts (13) of brackets (14) securing rear axle to leaf
springs (9).
Lower hydraulic jack and take out rear axle.
Refitting
For refitting, carry out the operations described for removal in
reverse order, taking the following precautions:
- Check the thread of the brackets joining the leaf springs to
the axle. If there are any irregularities, rectify the thread
(operation 500412) or replace the brackets.
- Bleed the air from the brake hydraulic system as described
under the relevant heading (operation 784010).
- Adjust the handbrake control ties as described under the
relevant heading (operation 502710).
- Lock the nuts or screws to the required tightening torque.
- The self-locking nuts must not be reused.
108434
- The lubricating oil in the axle housing should be at the right
level.
- Check the state of the flexible pads (19) and replace them
if they have deteriorated (operation 500417).


525010 OVERHAULING THE REAR AXLE 525030 Wheel hub overhaul

ASSEMBLY Disassembly
Figure 8
The drive shafts, brake disc and calipers, air breather
! and differential can all be removed and refitted even
with the unit mounted on the vehicle.
Before positioning the rear axle assembly on the stand for

overhauling, drain off the oil by unscrewing the side plug of
the axle housing.
Figure 6
107985
Take out the screws (1) and remove the brake caliper (2)
with its brake linings from the mounting.
The caliper must not be violently knocked or

! dropped.
Prevent the rubber caps coming into contact with
sharp metal tools.
Do not dirty or wet the rubber caps with mineral grease or
oil.
107853
Do not dirty the pads with liquids or grease.
Set the entire rear axle assembly on stand 99322215.
Do not operate the parking brake lever before mounting on
the disc: this makes the piston come out, decreasing the gap
The identification data of the rear axle unit are given between the two brake linings and jeopardizing wearability on
! on the plate (1) fixed near to the leaf spring the disc.
attachment support. Should this be done unexpectedly, it is necessary to take
down the brake linings and move the piston back with tool
99372236, taking the precautions given in the BRAKES
section.
525013 Air breather disassembly - assembly

Figure 9
Figure 7
107855
Remove pin (1) centering/securing brake disk (2) to half shaft

(3). Take off brake disk (2).
107854
Check that the air breather (1) is not clogged; otherwise, NOTE Check brake disk as described in Brakes section. On
disassemble and clean it thoroughly before refitting. putting away the brake disk, do not damage phonic
wheel toothing.

Figure 10 Figure 13
107986 107989
Unscrew securing screws (2) and take out half shaft Properly arrange half shaft (1) on hydraulic press and take out
comprehensive of unit-bearing support (1), bearing, ring nut bearing (2) together with support (3). Using extractor
and metal sheet guard (3). 99348001 (4).
Figure 11 Figure 14
107987 107990
Tighten half shaft (1) in a vice. Unscrew screws (2) securing metal sheet guard (1) to
Remove denting (→) of ring (2) engaging in ring nut (3). support (3). Pull guard apart from support.
Figure 12
107988
Using wrench 99355184 (1), unscrew ring nut (2) checking

bearing (3) to half shaft (4).

Assembly Figure 17
Figure 15
108042
Put assembled half shaft into rear axle box. Tighten screws
(1), securing half shaft to rear axle arm, at prescribed torque.
108040
Arrange tool 99370241 (4) on the press and position bearing

(3) and support (2) comprehensive of metal sheet guard on
the tool.
Put in half shaft (1) and, by the press (driving load
3300÷18000 N), put it into up to ledge.
Figure 18
NOTE The bearing (3) must not be heated.
107855
Figure 16
Mount brake disk (2) on half shaft (3) and tighten securing
pin (1) at prescribed torque.
108041
Mount the assembly on a vice.

Thread washer (2) and ring nut (1).
Using wrench 99355184 (3), tighten ring nut (1) at
prescribed torque.
Dent washer (2) on milled portion of ring nut (1) as indicated
in figure.

Figure 19 Figure 21
107985
108043
NOTE The brake lining with the wear indicator must be Mark the position of the caps (1 and 2), take out the screws
mounted on the piston side of the brake caliper. (3) and remove them.
Rest the brake caliper (2) with the brake linings on the
mounting.
NOTE Should brake calliper piston be moved backward,

use tool 99372236 and follow the
recommendations set out in the BRAKES section.
Figure 22
Tighten the screws (1) securing the caliper (2) to the
required torque.
After assembly, fill the axle housing with TUTELA W90/M -
DA oil in the required quantity and grade.
526210 REPAIRING THE DIFFERENTIAL
Disassembling the differential unit
NOTE Before repairing the differential it is necessary to

drain off the oil and dismantle the drive shafts, as
described under the heading of overhauling the
wheel hub (operation 525030).
Figure 20 108044
Take differential box (1), comprehensive of ring gear,

wheelwork, bearings (2-5), adjusting shims (4) and rib rings
(3), out of rear axle box.
NOTE Write down the positions of adjusting shims, rib

rings and bearing outer rings in order to be able to
107838 arrange them according to original configuration
Unscrew screws (1) complete with safety washers and take on mounting step.
off wheelwork inspection cover (2).

Gear housing removal Figure 24

Figure 23
51818 108045
Use tool 99341003 (1), brackets 99341009 (2), clamp Unscrew screws (3) and remove bevel wheel (1) from
99341015 (3) and reaction block 99345057 (4) to remove differential box (2).
taper roller bearing inner rings (5 - 7) from gear housing (6).
Figure 25
108046
Using a proper beater, remove spring peg (1) and unthread planetary gear holder pin (9).
Rotate crown wheels (6 and 10) in such a way as to have planetary gears (3 and 7) matching the slits on differential box (4).
Remove planetary gears (3 and 7) and relating thrust blocks (2 and 8) from differential box (4).
Remove crown wheels (6 and 10) and relating rib thrust blocks (5 and 11).

Dismounting bevel pinion Figure 29

Figure 26
108050
108047 Remove the seal (1) and the internal ring (2) of the front
Lift denting (1) checking nut (2). bearing.
Using tool 99370317, stop the rotation of flange (3).
Unscrew and remove nut (2).
Figure 27 Figure 30
108048 107839
Take flange (1) out of bevel pinion (2). Use a punch to remove the external rings (3 - 4) of the
Should flange (2) be too difficult to remove, single-acting rear tapered roller bearings from the axle housing (1) and take out
axle 99341003 coupled to bracket pair 99341009 can be the adjustment shim (2).
used as an extracting assembly.
Figure 31
Figure 28
108049 74727
Using a proper beater, beat according to direction indicated With axle 99341003 (2), brackets 99341011 (1), press
by the arrow until bevel pinion (1) complete with rear 99341015 (5) extract the internal ring (3) on the bevel pinion
bearing, fixed spacer and adjusting nut is ejected from rear (4).
axle box (2).

Figure 32
107840
DIFFERENTIAL UNIT COMPONENTS

1. Nut - 2. Transmission connection flange - 3. Gasket - 4. Front bearing - 5. Bearing adjusting shim - 6. Spacer - 7. Ledge ring -
8. Rear bearing - 9. Bevel pinion - 10. Ring bevel gear - 11. Rib ring -12. Adjusting ring - 13. Taper roller bearing -
14. Differential box - 15. Crown wheel rib thrust block - 16. Crown wheel - 17. Planetary gear rib thrust block - 18. Planetary
gear - 19. Pin - 20. Screw securing ring gear / differential box
Checking the parts comprising the differential

NOTE If it is necessary to replace the ring bevel gear or
pinion, replace both parts since they are supplied
Carefully clean the single components of the differential in pairs.
locking.
Lubricate the bearings and rotate the roller cage freely;
rotation must be even and without signs of stiffness. Check Check planetary gears with relating rib thrust blocks, pin and
the support surfaces of the ring bevel gear and the striking crown wheels with rib thrust blocks.
surface of the half-casing so that the ring bevel gear fits Replace all the sealing elements, the bevel pinion retaining
perfectly. Deformations of such parts, could determine nut and the gear housing bearing adjustment ring nut with
vibration of the ring bevel gear fastening screws, thus new parts.
compromising the perfect operation of the unit.
NOTE Carefully clean all the threads in order to obtain

exact adjustments and accurate tightening torque. NOTE The tapered roller bearings are supplied as spare
parts, lubricated with rustproof oil.
They must not be washed or heated for assembly.
Check for grooved section for keying the flange on the pinion The differential housing support bearings must
not being excessively worn out. Otherwise, replace the both be from the same supplier.
pinion.

Assembly of gear housing

Figure 33
108046
Put crown wheels (6) and (10), complete with rib rings (5) and (11), into seats inside differential box (4).
Through the slits on box (4), position planetary gears (3) and (7), complete with rib thrust blocks (2) and (8), in order them
to contact crown wheels (6) and (10).
Rotate crown wheels in such a way that the holes of planetary gears are aligned to guide holes for pin (9) that are present on
the box of differential (4).
Thread pin (9) aligning the hole for spring peg (1) to the hole that is present on the box of differential (4).
Using a proper beater, put spring peg (1) into its seat.
Figure 34 Figure 35
108045 108404
Tighten screws (3), for matching between bevel wheel (1) Using a proper beater, mount inner ring (1) on wheelwork
and the box of differential (2), at prescribed torque. box (2).
Repeat operation for outer ring (3).

Assembling the bevel pinion assembly Figure 39

Figure 36
108405 101977
Using the punch 99374091 (3) and grip 99370006 (4), mount Mount provided washer (3) and inner ring (2) of taper roller
the external ring (2) of the tapered roller bearing in the axle bearing on dummy pinion 99370239 (1).
housing (1).
NOTE New bearings are lubricated with rustproof oil and

must therefore not be washed or heated for
assembly.
Figure 37
Figure 40
108406
Set adjusting ring (4), removed at disassembling, into rear axle

casing (5).
Using the punch 99374092 (2) and grip 99370007 (1), mount
the external ring (3) of the tapered roller bearing.
Figure 38
108409
Position dummy pinion 99370239 (1), assembled as in Figure

39, on the outer ring of taper roller bearing (2).
On the opposite side, fit the taper bearing internal ring (3)
on the dummy pinion (1) and the transmission shaft flange
18241 (4) .
On a surface plate (2), zero a dial gauge (1) set on the Screw nut (5) until dummy pinion is freely rotating without
mounting 99395728 (3) and pre-load it slightly. axial clearance.

.
Figure 41 Figure 42
108407 18246
Fit the mounting 99395728 (2) with the dial gauge (1) on the
dummy pinion 99370239 (3).
NOTE If the value marked on the pinion is preceded by a
Orientate the, previously zeroed, dial gauge so as to position positive sign (+), it must be subtracted from the
the rod on the lowest portion of the seat of the bearing value of the sum divided by two for both seats,
supporting the gear housing and note the difference A1. whereas it has to be added if it is preceded by a
negative sign (-).
Repeat the same operation on the seat of the other bearing
and note the difference A2.
Unscrew check nut and transmission connection flange.
Thickness S to be added to adjusting ring thickness (4, Unthread flange and bearing from dummy pinion.
Figure 43) used for measuring, for pinion positioning is Remove the dummy pinion with the mounting 99395728,
obtained by the following formula: dial gauge and rear bearing from the axle housing.
S = A1 + A2 − ( B)
2
A1 indicates the value measured on the right-hand seat.
A2 indicates the value measured on the left-hand seat. Figure 43
B indicates the value marked on the bevel pinion (see
Figure 42).
For example:
S = 1, 05 + 1, 10 − (− 0, 05) = 2, 15 + 0, 05 = 1,125
2 2
The result of the formula must be added algebraically to the

value of the adjusting ring used to make the measurements.
Example:
if the value of the adjusting ring used is 3.00 mm, replace with
one measuring 4.125 mm (3.00 + 1.125).
108406
If required, replace adjusting ring (4) with a new one having

the calculated thickness, after removing bearing outer ring (3)
from rear axle casing (5) by beater.
Then fit the new adjusting ring (4) into rear axle casing (5).
Using the punch 99374092 (2) and grip 99370007 (1), mount
the external ring (3) of the tapered roller bearing.

Figure 44 Figure 47
18251
108410
Using a suitable punch (1) and a hydraulic, press mount the
internal ring (2) of the tapered roller bearing on the bevel Mount the bevel pinion (1) in the axle housing so as to enter
pinion (3). the internal ring (2) of the tapered roller bearing.
Figure 45 Beat on the top of pinion (1) until nut securing flange (3) can
be mounted.
18252
Position fixed spacer (3) and adjusting ring (2) on bevel pinion
(1).
Figure 46
Figure 48
108408
108421
Position the axle casing as indicated in the figure.
Fit the taper bearing internal ring (1) and the transmission Use tool 99370317 (2) to prevent the flange (1) from
shaft flange (2). rotating.
Position a suitable pipe (3) on the stand so that the flange (2)
and the taper bearing internal ring (1) are correctly Tighten the bevel pinion retainer nut to the required torque
supported. with a torque wrench (3).

Figure 49 Figure 51
108423 108424
Using torque meter 99389819 (1), detect bevel pinion rolling

torque. NOTE Position the caps (2) making the marks made
during disassembly coincide.
NOTE Rolling torque must be detected at 25 ºC ambient
temperature having the pinion rotating at 50 rpm
speed, after the pinion has run 10 revolutions. Screw on the screws (1) and tighten them to the required
torque with the dynamometric wrench (3).
If the reading differs from the prescribed value, disassemble

the pinion (1, Figure 47), replace the adjuster ring (2,
Figure 45) with a ring of the correct thickness.
Refit the pinion and repeat the rolling torque check.
Assembly of differential unit

Figure 52
NOTE When fitting the differential unit, carefully comply
with the tightening torque values specified, and
make use of a torque wrench.
Figure 50
108423
Check total rolling torque using torque meter 99389819 (1).
NOTE The rolling torque must be measured at an ambient

temperature of 25°C, making the pinion turn at a
108422 speed of 50 rpm after it has made 10 turns.
Fit the differential (1) unit and support (6) bearings in the axle
casing.
Mount spacers and adjusting rings in same quantity, thickness If the value of the measurement is not as required, replace
and position as detecting on dismounting, according to the adjustment rings (3 and 5, Figure 50) with another one
following sequence: stop ring (2), adjusting rings (3 and 5) and of a suitable thickness.
stop ring (4).

Figure 53 Figure 55
Correct contact.
108427
44604
Position the dial gauge 99395728 (1) with a magnetic base
and measure the clearance between the pinion and crown
wheel on four opposite teeth of the crown wheel (2).
The average of the measurements must equal the required Figure 56
value.
If a different clearance is found, remove the caps (3) again and
swap over the assembly position of the adjustment rings (1
and 3, Figure 50).
Should this not be sufficient, replace adjusting rings by other
rings having different thickness, on condition that total
thickness must be equal to the total thickness of the adjusting
rings that were dismounted.
This is so as not to change the total rolling torque.
Excessive contact on tooth
Using a brush, apply a thin layer of Prussian blue on ring gear bottom or flank.
teeth. Move pinion away from ring
Turn the pinion and measure the impression of the contact gear, then move ring gear
of the pinion toothing on the crown wheel toothing. close to pinion in order to
adjust clearance.
Here we illustrate the possible contacts with the corrections
to obtain precise coupling of the crown wheel and pinion. 44605
Figure 54
Figure 57
44603 Excessive contact on heel

of tooth.
A = Coupling depth E = Greater base Move the ring bevel gear
B = Crest F = Heel towards the pinion and
C = Side G = Top land then move the pinion away
D = Play H = Contact surface from the ring bevel gear to
I = Lateral surface adjust clearance.
44606

Figure 58 Figure 61
Excessive contact in the

upper part or crest of the
tooth
108426
Move pinion close to ring
gear, then move ring gear Lubricate the internal lip of the seal (1).
away from pinion in order With the key 99374022 (2) and grip 99370007 (3), mount
to adjust clearance. the seal in the axle housing.
44607
Figure 62
Figure 59
Excessive contact on the

top land of the tooth
Move the ring bevel gear
108421
away from the pinion them
move the pinion towards Mount flange (1). Stop the rotation of flange (1) using tool
the ring bevel gear to adjust 99370317 (2).
44608
clearance. Using torque wrench (3), tighten nut checking bevel pinion
at prescribed torque.
Figure 60
Figure 63
108425
After prescribed coupling clearance has been completed,

stop the rotation of flange (1) using tool 99370317 (2). 108428
Deform the collar of the nut (1) as shown in the figure at the
Unscrew the retaining nut and extract the flange (1) from the
milling of the bevel pinion (2).
bevel pinion.

Figure 64 Figure 66
107856
108429
Thoroughly clean the flange of the axle housing. According to sequence indicated in figure, tighten the screws
at prescribed torque.
Apply LOCTITE 5910 sealant on the flange of the axle
housing to form a bead of approx. 5 mm diameter. Complete mounting operation observing the following:
It must be uniform (no lumps), without any air bubbles, thin - Mount the drive shafts as described under the heading:
areas or gaps. ”525030 overhauling hubs”.
Any flaws must be corrected in as short a time as possible. - Apply LOCTITE 577 thread-locking oil on the oil drain
plug thread, screw it into the axle housing, tightening it
Avoid using too much material to seal the joint. to the required torque.
Too much sealant would tend to come out on both sides of - Add lubricating oil in the required quantity and grade
the joint. through the hole.
After applying the sealant, the joints need to be assembled - Apply LOCTITE 577 thread-locking oil on the inspection
immediately (10 - 20 minutes). plug thread, screw it into the axle housing, tightening it
To seal at a later date, there is product 21623 capable of to the required torque.
softening or liquefying the above-mentioned sealant. - Take the assembly off the stand.
It is essential to clean the surface to be sealed in order to
achieve good future sealing.
NOTE The assembly should be put back on its mounting

Figure 65 to prevent the dust guards and/or brake discs from
getting damaged.
108430
Mount the cover (1) and screw on the screws (2).

- Flanged screws (for solution without gasket).
- Screws with washer (for solution with gasket).


DAILY EURO 4 REAR AXLE NDA RG 35
Rear axles NDA RG
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Air breather disassembly - assembly . . . . . . . . 48
- Replacing the wheel hub bearing . . . . . . . . . . 49
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

36 REAR AXLE NDA RG DAILY EURO 4

DESCRIPTION The clearance between pinion and crown wheel is adjusted

using a hypoid crown wheel and pinion.
The gearing of the differential is composed of two planetary
pressed arms.
gears and two crown wheels.
The wheel hubs are keyed, with UNIT BEARINGS lubricated
for life, onto the arms of the axle housing.
The rolling torque of the bearings of the bevel pinion is
The bearings UNIT BEARINGS need no adjustment.
between the two tapered roller bearings. The brakes are disc brakes with floating brake calipers.
In addition, it is possible to adjust the position of the bevel The disc brakes are keyed onto the wheel hubs.
pinion with respect to the ring bevel gear by changing the
The brake calipers are secured with flanges fixed onto the
arms of the axle housing.
pinion rear bearing external ring.
Brake caliper is equipped with parking brake device.
The gear housing is supported by two tapered roller bearings.
The rolling torque of the bearings is adjusted with adjustment
rings between the spacer rings and the external rings of the
bearings.
Figure 1
107857

Type of rear axle:

NDA RG
Simple reduction type with mech-
anical control differential locking
DIFFERENTIAL UNIT
1/4.182 (11/46) - 1/4.444 (9/40) - 1/4.889 (9/44)- 1/3.416

(12/41) - 1/3.916 (12/47) - 1/3.154 (13/41) - 1/3.615 (13/47) -
(No. of teeth: pinion/crown)
1/3.308 (13/43) - 1/3.727 (11/41)

(without seal ring) Nm 2.3 ÷ 3.3
kgm 0.23 ÷ 0.33
pinion bearings
Bevel pinion bearings pre-load ad- 0.545 ÷ 1.070 mm

> justment rings with progression of 0.025 mm.
Temperature at assembly of inner
-
Position of bevel pinion with re-

By means of adjustment spacers
spect to differential casing

> placed between bevel pinion and
differential casing with progression of 0.025 mm.

torque
Nm 2.7 ÷ 3.9
kgm 0.27 ÷ 0.39

Thickness of adjustment rings of dif- 1.00 ÷ 1.95 mm

> ferential casing bearings rolling
torque with progression of 0.05 mm.
bevel gear
- 1/3,615 - 1/3,727 - 1/3,916 -
1/4,182 - 1/4,444: 0.13 ÷ 0.18
- 1/3,154 - 1/3,308 - 1/3,417 -
1/4,889: 0.15 ÷ 0.20

Type of rear axle:

NDA RG


0.05 ÷ 0.15 mm
crown wheels
WHEEL HUBS
Wheel hub bearings end play --

Nm --
kgm --
Adjustment of wheel hub bearings By means of nut

end play Torquing the securing nut

Quantity Litres 1.35
Max capacity (GAW) kg 2240

TIGHTENING TORQUES
Figure 2
107858
NDA RG REAR AXLE DIFFERENTIAL SECTION
TORQUE
PART
Nm Kgm
1 M26x1.5 bevel pinion securing nut 400 ÷ 500 40.8 ÷ 51.0
2 M12x1.5 ring bevel gear wheelwork box securing screw 89 ÷ 108 9.0 ÷ 11.0
3 M22x1.5 oil filling plug** 49 ÷ 62 5.0 ÷ 6.32
4 Screw securing caps to differential box 100 ÷ 120 10.2 ÷ 12.2
5 M8x1.25 rear axle box rear cover securing screw 80 ÷ 95 8.2 ÷ 9.7
- M22x1.5 oil draining magnetic plug** 49 ÷ 62 5.0 ÷ 6.3
* Apply Loctite 5910 on the housing
** Apply Loctite 577 on the plug thread

Figure 3
107859
NDA RG REAR AXLE DIFFERENTIAL SECTION

Figure 4
108433
NDA RG REAR AXLE WHEEL HUB SECTION
TORQUE
PART
Nm kgm
1 Wheel securing screw -
2 M10x1.25 screw securing half shaft to wheel hub 63 ÷ 76 6.4 ÷ 7.7
3 M52x1.5 ring nut checking wheel hub bearing 545 ÷ 565 55.5 ÷ 57.6
4 M10x1.25 screw securing brake disk to wheel hub 69 ÷ 76 7.0 ÷ 7.7
5 M14x1.5 screw securing shoes support to caliper support 177 ÷ 217 18.0 ÷ 22.1
6 M10x1.5 screw securing brake caliper support to rear axle arm 85 ÷ 97 8.7 ÷ 9.8

TOOLS
99321024 Hydraulic trolley for removing and refitting wheels
99322215 Driving and steering axle overhaul stand
99341001 Double effect bridge
99341003 Single-acting rear axle
99341005 Reaction bridge

TOOLS
99341009 Pair of retainers
99341015 Clamp
99345057 Extractor reaction block
65 mm. diam. box wrench for disassembly - assembly wheel hub locking
99355087 ring

TOOLS
99370007 Grip for interchangeable punches
Tool for measuring thickness of bevel pinion adjustment rings (to

99370239 be used with 99395728)
99370317 Lever and relevant extension bar to retain flanges
99370497 Tool for assembly of wheel hub
99370498 Tool for assembly of wheel hub bearing and phonic wheel

TOOLS
Axle universal support during removal/installation

99370617
99372236 Tool to move brake caliper piston back
Keying tool for assembly of differential bevel pinion gasket (to be used
99374022 with 99370006)
Punch to fit external races of bearings

99374091 (diameter 55 ÷ 69 mm use with 99370007)
Punch to fit external races of bearings

99374092 (diameter 69 ÷ 91 mm use with 99370007)
99389819 Torque wrench (0 to 10 mm) with 1/4” square attachment

TOOLS
Dial gauge with support to be used with the tools to determine the
99395728 adjustment thickness of the bevel pinion

525010 OVERHAULING THE REAR AXLE 525030 Wheel hub overhaul

ASSEMBLYOVERHAULING THE
REAR AXLE ASSEMBLY Figure 7
NOTE For differential assembly repair operations, refer to
what described in chapter ” NDA-RS rear axle” on
pages 22 to 34.
NOTE The drive shafts, brake disc and calipers, air

breather and differential can all be removed and
refitted even with the unit mounted on the vehicle.

overhauling, drain oil by loosening rear axle casing plug.
108435
Figure 5 Take out the screws (1) and remove the brake caliper (2)
with its brake linings from the mounting.

! dropped.
sharp metal tools.
Do not dirty or wet the rubber caps with mineral grease or
oil.
Do not dirty the pads with liquids or grease.
Do not operate the parking brake lever before mounting on
107860
the disc.
Set the entire rear axle assembly on stand 99322215. This makes the piston come out, decreasing the gap between
the two brake linings and jeopardizing wearability on the disc.
Should this be done unexpectedly, it is necessary to take
NOTE The identification data of the rear axle unit are down the brake linings and move the piston back with tool
given on the plate (1) fixed near to the leaf spring 99372236, taking the precautions given in the BRAKES
attachment support. section.
525013 Air breather disassembly - assembly

Figure 8
Figure 6
107854
101967
Take out the screws (1) and remove the brake caliper with
its brake linings from the mounting. Take out the screws (1) and remove the drive shaft (2).

Figure 9 Figure 11
44613
44616
Lift up the notch (⇒) of the ring nut (1). Using the wrench The bearing (1) is removed from the wheel hub with the aid
99355087 (2) remove the ring nut (1), take out the washer of an ordinary punch.
and extract the wheel hubs (3).
Assembly
NOTE Bearing (1) driving load is 2100 ÷ 5000 kg.
NOTE In resting the hubs on the bench, pay attention that

phonic wheel is not being damaged.
Figure 12
525031 Replacing the wheel hub bearing

Disassembly
45164
The new bearing should be mounted in the wheel hub with

Figure 10 a press and tool 99370498.
Figure 13
101969
Remove bearing protection ring.

Take out the screws (2) and remove the brake disc (1) from 101970
the wheel hub. Check the brake disc as described under the
Brakes heading. Mount the brake disc (1) on the wheel hub (2) and tighten
the fixing screws (3) to the required torque.

Figure 14 Figure 16
44618
44621
If it is necessary to replace the pins of the wheel hub (1), Mount the inserter 99370497 (2) on the sleeve.
before mounting the new ones, check that the mating surface Lubricate the sleeve with TUTELA W90/M-DA oil and key
of the pin head is free from burrs, dross and blisters. the wheel hub (1).
The pins should be driven in by applying a load on their head
no greater than 2000 kg.
After driving them home, check that the pins are perfectly in
touch with the hub: maximum orthogonal tolerance 0.2 mm.
Figure 15
44619
Stand the bearing of the wheel hub (2) on a special mounting

that permits rotation. With a magnetic dial gauge (1) check
the off-centring of the brake disc on both sides.
Centering error must not exceed 0.1 mm.

Figure 17 Figure 19
44626
Apply IVECO 1905685 sealant on the contact surfaces of the

44622 drive shaft (2) with the wheel hub (1).
Mount the drive shaft (2) in the sleeve.
Mount new washer (1), ring nut (2) and, using wrench Tighten the screws (3) securing the drive shaft (2) to the hub
99355087 (3), tighten ring nut (2) at prescribed torque. (1) to the required torque.
Notch the fixing ring nut (2) on the milling of the axle housing After the assembling operation has been completed, fill the
arm.
rear axle case with TUTELA W90/M - DA oil to the
prescribed amount and grade.
Figure 18
108435
Mount brake caliper support on rear axle arm observing

prescribed tightening torques.
Thread braking gaskets.
Apply brake caliper (2) to the support and tighten securing
screws (1) at prescribed torque using a torque wrench.
Where brake caliper plunger must be withdrawn, observe
what indicated in section Brakes.
NOTE On each brake caliper remounting operation,

replace screws (1): these screws cannot be reused
once they have been unscrewed.


DAILY EURO 4 REAR AXLE 450511 53
Rear axles 450511
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REAR AXLE REMOVAL - REFITTING . . . . . . . . 65
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
- Replacing the wheel hub bearing . . . . . . . . . . 68
DIFFERENTIAL REPAIR OPERATIONS . . . . . . . 71
- Disassembly of differential locking . . . . . . . . . . 71
- Assembling the differential locking device . . . . 71
- Differential locking removal . . . . . . . . . . . . . . . 71
- Differential locking refitting . . . . . . . . . . . . . . . 71
- Adjusting the differential locking device . . . . . 72
- Disassembling the differential unit . . . . . . . . . . 72
- Disassembly of gear housing . . . . . . . . . . . . . . 73
- Assembly of gear housing . . . . . . . . . . . . . . . . 75
- Assembling bevel pinion unit . . . . . . . . . . . . . . 75
- Differential unit refitting . . . . . . . . . . . . . . . . . 79

54 REAR AXLE 450511 DAILY EURO 4


The gear housing is composed of two half-housings.
pressed arms.
It may be of two different sizes depending on the ratio of the
crown wheel and pinion.
The gearing of the differential is composed of four planetary
The rolling torque of the bearings of the bevel pinion is
between the two tapered roller bearings. The wheel hubs are keyed, with UNIT BEARINGS lubricated
for life, onto the arms of the axle housing.
In addition, it is possible to adjust the position of the bevel
pinion with respect to the ring bevel gear by changing the The bearings need no adjustment.
The brakes are disc brakes with floating brake calipers.
pinion rear bearing external ring.
The disc brakes are keyed onto the wheel hubs.
The brake calipers are secured with flanges fixed onto the
arms of the axle housing.
bearings. The parking brake is the drum type, built into the brake disc.
Figure 1
51858


Type of rear axle:
450511
Electric control mechanical differential locking on request
DIFFERENTIAL UNIT 13/41(1/3.15)
( ) - 13/43(1/3.31)
( ) - 13/47(1/3.62)
( ) - 12/47(1/3.92)
( )-
11/46(1/4 18) - 9/40(1/4.40)
11/46(1/4.18) 9/40(1/4 40) 9/44(1/4.89)
9/44(1/4 89) - 9/46(1/5.11)
9/46(1/5 11) -
Reduction bevel gear pair ratio 9/47(1/5.22) - 8/45(1/5.63) - 7/41(1/5.86)
(No. of teeth: pinion/crown) 13/47(1/3.62) - 12/47(1/3.92) - 11/46(1/4.18) - 9/40(1/4.40) -
8/45(1/5.63) - 9/47(1/5.22)

(lubricated bearings and gaskets)
Nm 1.2 ÷ 2.4
New bearings
kgm 0.12 ÷ 0.24
pinion bearings
> Bevel pinion bearing preload 1 ÷ 1.975 mm

adjusting ring thickness with progression of 0.025 mm.
Temperature of assembly of inner

80 °C ÷ 90 °C
Position of bevel pinion with

respect to differential casing
Thickness of adjusting ring placed 1 ÷ 1.975 mm

> between bevel pinion bearing and
differential carrier. with progression of 0.025 mm.

torque
Nm 2 ÷ 2.8
kgm 0.20 ÷ 0.28

Differential carrier bearing rolling 1 ÷ 1.95 mm

> torque adjusting ring thickness with progression of 0.05 mm.

0.15 ÷ 0.20 mm
bevel gear


0.12 ÷ 0.18 mm
crown wheels

Type of rear axle:

450511
WHEEL HUBS
Wheel hub bearings Unit-Bearing
Wheel hub bearings end play -

Nm -
kgm -
Adjustment of wheel hub bearings Non-adjustable

end play Tightening to fixing ring nut torque

Quantity Litres 1.9
Dry rear axle weight :
- With ABS kg 154,6
- Without ABS kgg 153
- Max capacity (GRW) kg 3700

TIGHTENING TORQUES
Figure 2
44588
REAR AXLE DIFFERENTIAL SECTION WITH DIFFERENTIAL LOCKING
TORQUE
PART
Nm kgm
1 M26x1.5 bevel pinion securing nut. 400 ÷ 500 40 ÷ 50
2 Screw securing half-housing and ring bevel gear M14 x 1.5 200 ÷ 210 20 ÷ 21
3 Screw securing mounting for differential locking to the axle housing or securing cover 21 ÷ 25 2.1 ÷ 2.5
for differential locking mounting seat cover
4 Screw securing gearing inspection cover to the axle housing 21 ÷ 26 2.1 ÷ 2.6
5 Screw securing caps to axle housing 96 ÷ 117 9.6 ÷ 11.7

Figure 3
51862
450511 REAR AXLE DIFFERENTIAL SECTION

Figure 4
87907
WHEEL HUB SECTION
TORQUE
PART
Nm kgm
1 Wheel retaining nut M18 290 ÷ 349 29 ÷ 34.9
2 Screw securing drive shaft to the wheel hub M10x1.25 63 ÷ 76 6.3 ÷ 7.6
3 Ring nut retaining wheel hub bearing M52x1.5 545 ÷ 565 54.5 ÷ 56.5
4 Screw securing brake disc to wheel hub M10x1.25 69 ÷ 76 6.9 ÷ 7.6
5 Screw securing caliper mounting to shoe mounting M14x1.5 180 ÷ 220 18 ÷ 22
6 Screw securing shoe mounting to axle housing M10x1.5 85 ÷ 97 8.5 ÷ 9.7
7 Screw securing guard 8 0.8
** Screw securing sensor mounting 5÷7 0.5 ÷ 0.7
* Spread the surface of the drive shaft - wheel hub union with B-type sealant.
** When assembling the screws securing the timing sensor mounting, apply a few drops of LOCTITE 243 thread-lock onto
the thread of the corresponding holes of the bracket welded onto the axle arm.

TOOLS
99321024 Hydraulic trolley for removing and refitting wheels
99341001 Double effect bridge
99341005 Reaction bridge

TOOLS
99345056 Counter block for pullers
65 mm. diam. box wrench for disassembly - assembly wheel hub locking
99355087 ring
Tool for measuring thickness of bevel pinion adjustment rings (to be

99370309 used with 99395728)

TOOLS
99370317 Lever and relevant extension bar to retain flanges
99370497 Tool for assembly of wheel hub
99370498 Tool for assembly of wheel hub bearing and phonic wheel
99370617 Axle universal support during removal/installation
Keying tool for assembly of differential bevel pinion gasket (to be used
99374022 with 99370006)

99374092 with 99370007)

TOOLS
99389819 Torque wrench (0 to 10 mm) with 1/4” square attachment
Dial gauge with support to be used with the tools to determine the
99395728 adjustment thickness of the bevel pinion

REAR AXLE REMOVAL - REFITTING

Removal Figure 5
Position the vehicle on level ground and lock the front wheels.
Loosen the nuts securing the rear wheels.
Lift the vehicle at the back and set it on stands.
Put the hydraulic trolley 99321024 under the rear wheels. Take out
the nuts securing the wheels.
Unscrew the handbrake adjustment nut (4). Free the cables from the
vehicle crosspiece, unhooking the retaining clamps (3).
Unscrew the screws (6) securing the propeller shaft.
Disconnect the electric cables for indicating brake lining wear (2) and
(13), for the ABS speed sensors, if present.
Disconnect the braking corrector adjustment tie (14) from the axle
housing.
Unscrew the nuts (5) securing the shock absorbers.
Disconnect the oil pipe (1) from the fitting secured to the axle
housing.
Unscrew the screws (9) securing the stabilizer bar (10) to the axle.
Disconnect the pipe (16) from the axle housing oil vapour vent.
For axles with differential locking only
Release spring (17) and unthread flexible tie rod (18) from bracket
(19).
Disconnect the electric cable of the differential locking indicator
transmitter (15).
For all vehicles
Position a hydraulic jack equipped with the mounting 99370617
under the axle.
Unscrew the nuts (7) of the brackets (8) securing the axle to the leaf
spring (11).
Lower the hydraulic jack and extract the axle.
Refitting
reverse order, observing the required tightening torques for the
screws and/or nuts.
At procedure completion:
- Check the thread of the brackets joining the leaf springs to the
axle. If there are any irregularities, rectify the thread (operation
500412) or replace the brackets.
- Bleed the air from the brake hydraulic system as described under
the relevant heading (operation 784010).
- Check for self-locking nuts having been replaced;
- Check the state of the flexible pads (12) and replace them if they
have deteriorated (operation 500417).
- Check for rear axle box lubrication oil correct level. 52121


525010 OVERHAULING THE REAR AXLE Figure 8

ASSEMBLY
Figure 6
44611
Unthread braking pads (1). Take off screws (→) and detach
support (2).
44609
Set the entire rear axle assembly on stand 99322215.

Figure 9
The identification data of the rear axle unit are given

! on the plate (1) fixed near to the leaf spring
attachment support.
525030 Wheel hub overhaul

Figure 7
44612
Take out the screws (⇒) and remove the drive shaft (1).
Figure 10
101965
Disconnect the pipe (2) from the support bracket (1).

Remove caps (3), take off screws (4), then remove brake
caliper (5) from support (6).
44613
NOTE The thread of the screws securing the brake caliper

is treated with adhesive. Therefore, they must not Lift up the notch (⇒) of the ring nut (1). Using the wrench
be reused, but replaced with new ones every time 99355087 (2) remove the ring nut (1), take out the washer
they are removed. and extract the wheel hubs (3).

525031 Replacing the wheel hub bearing Figure 14
Figure 11
45164
44614 The new bearing should be mounted in the wheel hub with
If the hub is fitted with a phonic wheel (2), take it out with a press and tool 99370498.
the extractor (1) 99341001 as shown in the figure.
Otherwise, take out the bearing guard ring. Figure 15
Figure 12
44617
Mount the brake disc (1) on the wheel hub (2) and tighten
44615 the fixing screws (⇒) to the required torque.
Take out the screws (⇒) and remove the brake disc (1) from
the wheel hub. Check the brake disc as described under the Figure 16
Brakes heading.
Figure 13
44618
44616
If it is necessary to replace the pins of the wheel hub (1),
The bearing (1) is removed from the wheel hub with the aid before mounting the new ones, check that the mating surface
of an ordinary punch. of the pin head is free from burrs, dross and blisters.
no greater than 2000 kg.
NOTE Bearing (1) driving load is 2100 ÷ 5000 kg. touch with the hub: maximum orthogonal tolerance 0.2 mm.

Figure 17 Figure 20
44619
Stand the bearing of the wheel hub (2) on a special mounting

that permits rotation. With a magnetic dial gauge (1) check
44621
the off-centring of the brake disc on both sides.
Off-centring must not exceed 0.1 mm.
NOTE Check and, if necessary, adjust the clearance
between the parking brake drum and shoes as
Figure 18
described in the Brakes section.
Mount the inserter 99370497 (2) on the sleeve.

Lubricate the sleeve with TUTELA W140/M-DA oil and key
1 the wheel hub (1).
45165
The phonic wheel (2) should be mounted in the hub with the
punch 99370498 (1), checking after assembly that the
”phonic” wheel rests perfectly in its seat in the hub.
Figure 21
Figure 19
44622
44620
Check the orthogonality of the phonic wheel (2), proceeding

as follows:
Position the feeler of the magnetic dial gauge (1) on the
phonic wheel. Mount the washer (1) and a new ring nut (2). Using the
wrench 99355087 (3), tighten the ring nut (2) to the required
Making the wheel hub (3) turn, check that the maximum torque.
error of orthogonality of the phonic wheel (2) is no greater Notch the fixing ring nut (2) on the milling of the axle housing
than 0.1 mm. arm.

Figure 22 Having to move the brake caliper piston back, keep to the
instructions given in the BRAKES section.
Mount only new screws (1, Figure 24).

! Every time they are removed, they must be replaced.
Figure 25
44623
Mount the support (2) and tighten the fixing screws (1) to
the required torque.
Figure 23
101962
Fit new protection caps (3).

Connect the pipe (2) to the support bracket (1).
44611
Mount braking pads (1).
Braking pad with wear signalling unit must be

! mounted at brake caliper plunger side.
Figure 26
Figure 24
44626
Apply IVECO 1905685 sealant on the contact surfaces of the

101971 drive shaft (2) with the wheel hub (1).
Mount the drive shaft (2) in the sleeve.
Fit brake caliper (3) to support (2), then use torque wrench
(4) to tighten fastening screws (1) to a torque of 32 to 36 Tighten the screws (3) securing the drive shaft (2) to the hub
Nm. (1) to the required torque.

526210 DIFFERENTIAL REPAIR Assembling the differential locking device

OPERATIONS
Assemble the differential locking device by following the
526260 Disassembly of differential locking removal operations in the reverse order.
Re-attach the differential locking device to the rear axle
Figure 27 casing as follows:
Differential locking refitting

Figure 29
61869
Remove the spring (1).

Unscrew and remove the 4 screws (2) including washers and
then disconnect the differential locking device (3).
If required, remove the unit as described in the following
paragraphs.
61869
Mount a new O-ring on the differential locking attachment

plane.
Position the previously assembled support (3) so as to insert
the control lever in the spline on the sliding sleeve.
Insert the 4 screws (2) complete with washers and spring
washers and tighten the screws to the driving torque of 23
Nm (2.35 kgm).
Assemble the spring (1).
Adjust the differential locking device by following the
procedures below.
Differential locking removal
Figure 28
23227
Remove gasket (4).

By means of a normal beater knock out the elastic pin (2),
remove the lever (1) complete with ring and washer.
Finally, remove the control lever (3) from the support (5).

Figure 30
107982
DIFFERENTIAL LOCKING DEVICE COMPONENTS

1. Flexible tie rod bracket (Bowden) - 2. Rear axle casing - 3. Spring - 4. Gasket - 5. Sealing ring - 6. Gasket - 7. Sleeve
control lever (9) - 8. Elastic pin to fix lever (7) to lever (12) - 9. Differential locking sliding sleeve - 10. Spring coupling
plate (11) - 11. Lever return spring (12) - 12. Transmission lever - 13. Adjusting screw nut - 14. Adjusting screw -
15. Differential locking device body.
Adjusting the differential locking device Figure 31
Engage the sliding sleeve (9). Once this has been done,
loosen the nut (13), move the adjustment screw (14) so that
it is contact with the control lever (7). After this, unscrew the
adjustment screw by 9.5 turns (corresponding to 9.5 mm.
travel of the screw) and lock it with the fastening nut (13).
Disassembling the differential unit
NOTE Before carrying out repair operations on the

differential unit you must drain off the oil and 18216
disassemble the drive shafts. For the rear axle, you
must disassemble the differential locking as Unscrew the screws (1) complete with tab washers and
described in the relevant paragraphs. spring washers and remove the gear housing inspection
cover (2) complete with gasket.

Figure 32 Disassembly of gear housing

Figure 34
44600
44598
Extract the support bearing inner rings (3 and 5) and shoulder
Mark the position of the caps (1 and 2) and remove them. ring (2) from the gear housing and, by means of the puller tool
99348001 (4), extract the counter block (1).
NOTE The thrust ring (2) is only present with rear axles
fitted with differential locking.
Figure 35
18222
Figure 33
NOTE Mark the cover (1) and the gear housing (4).
Unscrew the screws (2), remove the ring bevel gear (3) and
the gear housing (4) cover (1).
Figure 36
44599a
Take out the gear housing (1).

Note the assembly position of the adjustment rings (3) and
take them out of the housing together with the spacer rings
(2). 62099
NOTE In the case of reuse, do not swap over the assembly Remove the crown wheel (2) on the cover side with its thrust
positions of the external rings (4) of the tapered washer (3) from the gear housing (1).
roller bearings. Using a generic beater to remove the long pin (4) and the
two short pins (5) from the gearing case (1).

Figure 37 Figure 38
20378 18226
Remove the crown wheel (1) on the gear housing side with
Remove the spider (1) and the four planetary gears (2) with
the thrust washers.
their shoulder washers (3) from the gear housing.
Figure 39
51863
PARTS COMPRISING THE DIFFERENTIAL UNIT

1. Nut - 2. Transmission connection coupling - 3. Seal - 4. Front bearing - 5. Pinion shim ring - 6. Fixed
spacer - 7. Spacer ring - 8. Adjustment ring - 9. Rear bearing - 10. Bevel pinion - 11. Ring bevel gear - 12. Fixed ring -
13. Adjustment ring - 14. Bearing - 15. Thrust ring (axle with differential locking) - 16. Gear housing - 17. Crown wheel
thrust washer - 18. Spider - 19. Crown wheel - 20. Gear housing cover - 21. Screw - 22. Planetary gear thrust washer - 23.
Planetary gear - 24. Short pin - 25. Long pin.

Assembly of gear housing Figure 43

Figure 40
18237
18226 Assemble the cover and make the marks made during
disassembly coincide. Assemble the ring bevel gear and fasten
Position the crown wheel (1), gear housing side, complete this to the half-casing by means of the fixing screws.
with thrust washer, into its own housing. By means of a torque wrench (1) tighten the fixing screws (2)
to the required tightening torque.
Figure 41 Figure 44
18240
Only for axles with differential lock.

20379 Using tool 99305121, heat thrust ring (1) to a temperature
Position the two planetary gears (1) complete with thrust of 120ºC ÷ 150ºC for 15’ and fit on the gear casing (2) from
washers, spider (2) and then insert the long pin (3). the side with the differential lock.
Figure 42
Assembling bevel pinion unit
Figure 45
20380
Position the other two planetary gears (1) complete with 18241
thrust washers and then insert the two short pins (2).
Rotate the planetary gears-crown wheel unit and check that
it is free without stiffness. On a surface plate (2) zero the dial gauge (1) placed on the
Assemble the other crown wheel complete with thrust support 99395728 (3) and lightly pre-load it.
washer.

Figure 46 Figure 48
101977 51840
Fit tapered-roller bearing internal ring (2) onto false pinion Fit the mounting 99395728 (2) with the dial gauge (1) on the
99370309 (1) with the washer supplied (3). dummy pinion 99370309 (3).
Orientate the, previously zeroed, dial gauge so as to position

the rod on the lowest portion of the seat of the bearing
Figure 47 supporting the gear housing and note the difference A1.
Repeat the same operation on the seat of the other bearing

and note the difference A2.
Thickness S to be added to adjusting ring thickness (4,

Figure 50) used for measuring, for pinion positioning is
obtained by the following formula:
S = A1 + A2 − ( B)
2
A1 indicates the value measured on the right-hand seat.
A2 indicates the value measured on the left-hand seat.
B indicates the value marked on the bevel pinion (see
51839
Figure 49).
Position the dummy pinion 99370309 (1), assembled as For example:
shown in Figure 46, on the external ring (2) of the tapered
roller bearing.
On the opposite side, fit the taper bearing internal ring (3)
S = 1, 05 + 1, 10 − (− 0, 05) = 2, 15 + 0, 05 = 1,125
on the dummy pinion (1) and the transmission shaft flange
(4) . 2 2
Screw on the nut (5) so that the dummy pinion turns freely
with no end float.
The result of the formula must be added algebraically to the
value of the adjusting ring used to make the measurements.
Example:
if the value of the adjusting ring used is 3.00 mm, replace with
one measuring 4.125 mm (3.00 + 1.125).

Figure 49 Figure 51
18251
18246
Using a suitable punch (1) and a hydraulic press, mount the
internal ring (2) of the tapered roller bearing on the bevel
pinion (3).
NOTE If the value marked on the pinion is preceded by a
positive sign (+), it must be subtracted from the Figure 52
value of the sum divided by two for both seats,
whereas it has to be added if it is preceded by a
negative sign (-).
Unscrew the retaining nut, the transmission connection

flange and remove it and the bearing from the dummy pinion.
Remove the dummy pinion with the mounting 99395728,
dial gauge and rear bearing from the axle housing.
18252
Figure 50 Position the fixed spacer (3) and the adjustment ring (2), used
previously to obtain the required rolling torque, on the bevel
pinion (1).
Figure 53
51838
If required, replace adjusting ring (4) with a new one having

the calculated thickness, after removing bearing outer ring (3) 62097
from rear axle casing (5) by beater. Position the axle casing as indicated in the figure.
Then fit the new adjusting ring (4) into rear axle casing (5). Fit the taper bearing internal ring (1) and the transmission
shaft flange (2).
Using the punch 99374092 (2) and grip 99370007 (1), mount Position a suitable pipe (3) on the stand so that the flange (2)
the external ring (3) of the tapered roller bearing. and the taper bearing internal ring (1) are correctly
supported.

Figure 54 Figure 56
74728
51845
Mount the bevel pinion (1) in the axle housing so as to enter Using torque meter 99389819 (1), detect bevel pinion rolling
the internal ring (2) of the tapered roller bearing. torque.
Tap on the end of the pinion (1) so that the transmission shaft NOTE The rolling torque must be measured at an ambient
flange retaining nut (3) can be fitted. temperature of 25°C, making the pinion turn at a
speed of 50 rpm after it has made 10 turns.
If the reading differs from the prescribed value, disassemble

the pinion (1, Figure 54), replace the adjuster ring (2,
Figure 52) with a ring of the correct thickness.
Figure 55
51846
Use tool 99370317 (2) to prevent the flange (1) from

rotating.
Tighten the bevel pinion retainer nut to the required torque
with a torque wrench (3).

Differential unit refitting

Figure 59
Figure 57
107983 18252
Using a suitable punch, with a grip, drive the external ring (4) Heat the internal ring (4) of the tapered roller bearing to
for the front bearing into the axle housing (1). 80°C ÷ 90°C for approximately 15 min. and drive it, with a
Position stop ring (5) with 2 mm thickness and drive outer suitable punch, onto the bevel pinion (1).
ring (3) of rear bearing using a proper beater. Position the spacer ring (3) and adjustment ring (2),
Determine bevel pinion position adjusting shim as described calculated beforehand to obtain the required rolling torque,
above. on the bevel pinion (1).
Remove the external ring (3) of the tapered roller bearing.

Position adjusting ring (2) having the calculated thickness, on
stop ring (5).
Refit the external ring (3) of the tapered roller bearing.
Figure 58
Figure 60
51865
Lubricate the internal ring of the front bearing and position

it in the housing.
Using the key 99374022 (1) and grip 99370006 (2), mount
the pre-lubricated seal.
Determine bevel pinion rolling torque adjusting ring as
described above. 51866
Position the axle housing as shown in the figure.

NOTE The rolling torque of the bevel pinion must be On the stand, set a pipe (3) of such diameter and length as
measured with lubricated bearings and seals. to provide a solid supporting surface for the flange (2) and
the internal ring (1) of the front bearing above, already
mounted in the axle housing.

Figure 61 Figure 63
20384
4
Position the sliding sleeve in the rear axle housing for
51867
differential locking (if present). Mount the external rings (1)
Insert the bevel pinion (1), assembled as shown in the figure, for the gear housing support bearings and then position the
in the internal ring of the front bearing (2) and in the flange previously mounted gear housing in the rear axle housing.
(3).
NOTE Strike the top of the bevel pinion until it is possible Figure 64
to fit the nut (1, Figure 62) securing the flange (3).
Take out the support pipe (4).
Complete assembling the pinion by fully tightening
the nut.
Block rotation of the transmission flange with the retainer

tool 99370317.
Using a suitable Allen wrench and the torque wrench, tighten
the bevel pinion retainer nut (1, Figure 62) to the required
torque.
To be on the safe side, check the rolling torque of the bevel 44594
pinion with the dynamometer 99389819.
Mount the spacers and adjustment rings in the same number,
thickness and position found during disassembly, in the
following order: spacer (1), adjustment ring (2), adjustment
ring (3) and spacer (4).
Figure 62
* DIRECTION OF ROTATION
OF THE NUT
51868
Make a cut in the collar of the nut (1) by the milling of the
bevel pinion (2) as shown in the figure.

Figure 65
18262
Complete mounting operation by checking total rolling

torque and the clearance of ring gear and pinion coupling as
described for NDA rear axles.
Position a new seal ring over the gear housing inspection
attachment surface.
Mount the cover (3), insert the fixing screws (2) complete
with tab washers and spring washers.
Tighten the screws (2) with the torque wrench (1) to the
required tightening torque.
NOTE Do not tighten the screws to a torque greater than

the value indicated since this would impair the
sealing effect of the gasket placed between the
coupling plane and the gear housing inspection
cover.
Mount the differential locking device (if present) and adjust

it as described under the relevant heading.
Mount the drive shafts as described under heading: “525030
Overhauling the Hubs”.
Screw on the oil drainage plug and tighten it to the required
torque.
Add lubricating oil in the required quantity and grade through
the hole.
Screw on the oil filler plug and tighten it to the required
torque.
Take the assembly off the stand.
NOTE The assembly should be put back on its mounting

to prevent the dust guards and/or brake discs from
getting damaged.


DAILY EURO 4 REAR AXLE 450517/2 83
Rear axle 450517/2
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 85
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
REAR AXLE REMOVAL - REFITTING . . . . . . . . 95
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Air breather disassembly - assembly . . . . . . . . . 97
- Overhaul of wheel hubs . . . . . . . . . . . . . . . . . 97
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
- Stud replacement . . . . . . . . . . . . . . . . . . . . . . 99
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
DIFFERENTIAL REPAIR OPERATIONS . . . . . . . 102
- Differential locking . . . . . . . . . . . . . . . . . . . . . . 102
- Differential unit removal . . . . . . . . . . . . . . . . . 103
- Gearing case removal . . . . . . . . . . . . . . . . . . . 103
- Differential components check . . . . . . . . . . . . 105
- Rear axle casing check . . . . . . . . . . . . . . . . . . . 105
- Gearing case refitting . . . . . . . . . . . . . . . . . . . . 105
- Differential unit refitting . . . . . . . . . . . . . . . . . . 109

84 REAR AXLE 450517/2 DAILY EURO 4


The gear housing is composed of two half-housings.
pressed arms.
It may be of two different sizes depending on the ratio of the
The central portion, seat of the differential unit, is equipped
crown wheel and pinion.
with cooling fins.
The gearing of the differential is composed of four planetary
Wheel hubs are supported by two ”SET RIGHT” type bear-
The rolling torque of the bearings of the bevel pinion is ad-
ings set on the sleeve.
justed by changing the thickness of the adjustment ring be-
tween the two tapered roller bearings. The bearings need no adjustment.
In addition, it is possible to adjust the position of the bevel pin- The brakes are disc brakes with floating brake calipers.
ion with respect to the ring bevel gear by changing the thick-
The disc brakes are keyed onto the wheel hubs.
ness of the ring between the axle housing and the bevel pinion
rear bearing external ring. Perrot type brake callipers are supported by flanges welded
to rear axle casing arms.
The parking brake is the drum type, built into the brake disc.
bearings.
Figure 1
62983

Type of rear axle:

Bearing with single reduction and 450517/2
mechanical control differential
locking
DIFFERENTIAL UNIT

1/3,91 (11/43) - 1/4,30 (10/43) -
(tooth no.: pinion/crown wheel), on
1/4,56 (9/41) - 1/5,13 (8/41)
request
Bevel pinion bearing rolling torque

(lubricated gaskets and bearings)
Nm 2÷3
New bearings
kgm 0.20 ÷ 0.30
Bevel pinion bearing preload
through adjustment rings
adjustment
> Bevel pinion bearing preload 1 - 2 mm

adjustment ring thickness with 0.025 mm progression
Temperature for fitting inner

80 °C ÷ 90 °C
Bevel pinion position with reference

By means of shims
to differential casing

> between bevel pinion and
differential casing with 0.025 mm progression
Bearings for gearing case 2 taper rollers
Differential case bearing rolling

torque
Nm 2.6 ÷ 3.9
kgm 0.26 ÷ 0.39
Adjustment of differential case

Through adjustment rings
bearing rolling torque
Thickness of adjustment rings for 2.65 ÷ 3.20 mm

> differential case bearing rolling
torque with 0.05 mm progression
Backlash between pinion and crown

0.15 ÷ 0.20 mm
wheel
Adjustment of backlash between

Through adjustment rings
pinion and crown wheel

Type of rear axle: 450517/2
WHEEL HUBS
Wheel hub bearings Two ”SET-RIGHT” type taper rollers
Hub bearing end play 0.16 max.
Wheel hub bearing rolling torque

Nm 0÷4
kgm 0 ÷ 0.4
Adjustment of wheel hub bearings

Fastening nut tightening to torque
end play
Rear axle oil Tutela W140/M-DA (SAE 85 W140)

Amount Litres 3
kg 2.7
Max. capacity GAW kg 5000

TIGHTENING TORQUES
Figure 2
62879
450517/2 (R0537) REAR AXLE DIFFERENTIAL SECTION
TORQUE
PART
Nm kgm
1 Bevel pinion retaining nut 533 ÷ 589 53.3 ÷ 58.9
2 Screw fastening gearing inspection cover to rear axle casing* 26 ÷ 21 2.6 ÷ 2.1
Screw fastening crown gear to 12RDAC5 half casing* 309,5 ÷ 342,5 30.9 ÷ 34.2
3
Screw fastening crown gear to 10RDAC5 half casing 266 ÷ 294 26.6 ÷ 29.4
4 Screw fastening half casings 61 ÷ 74 6.1 ÷ 7.4
5 Screw fastening differential locking device or cover 23 2,3
6 Screw fastening caps to rear axle casing 102 ÷ 113 10.2 ÷ 11.3
* Before tightening the screws, smear their threaded holes with IVECO sealant 1905683.

Figure 3
74729
Figure 4
62878
ABS VERSION
TORQUE
PART
Nm kgm
1 Wheel fastening nut 238.8 ÷ 342.6 23.8 ÷ 34.2
2** Screw fastening axle shaft to wheel hub 56 ÷ 69 5.6 ÷ 6.9
3 Wheel hub bearing retaining ring nut 441 ÷ 540 44.1 ÷ 54
4 Safety screw 9.5 ÷ 11.5 0.9 ÷ 1.1
5 Screw fastening brake disc to wheel hub 54 ÷ 59 5.4 ÷ 5.9
6 Screw fastening brake calliper to rear axle 176 ÷ 194 17.9 ÷ 19.7
7 Screw fastening brake shoe support to rear axle casing 68 ÷ 75 6.9 ÷ 7.6
8*** Rpm sensor support fastening screw 5÷7 0.5 ÷ 0.7
* Apply IVECO 1905685 sealant on half shaft - wheel hub joint surface
** Apply IVECO 1905683 sealant on the threading of plugging screws
*** Apply LOCTITE 243 on the threading of holes

TOOLS
99305121 Hot air operated equipment
99306004 300 kg hydraulic crane
99306010 Equipment for bleeding air from brake and clutch system
99321024 Hydraulic truck for removing - refitting wheels
99322215 Stand to overhaul axles
99345056 Counter block for pullers

TOOLS
99348001 Puller with locking device
99357080 Wrench (91.5 mm) for wheel hub bearing adjustment nut
99370006 Handle for interchangeable beaters
99370007 Handle for interchangeable beaters
Tool to find bevel pinion shims (to be used with 99395728)

99370296
99370317 Counter lever and relevant extension to retain flanges

TOOLS
99370617 Universal support to hold axles during removal/refitting
Beater to fit in place bearing outer races (91-134) (to be used with
99374093 99370007)
Element to fit in place wheel hub internal gasket (to be used with
99374132 99370006)
99374201 Element to fit in place differential bevel pinion gasket
99389819 Dynamometric wrench (0-10 Nm) connection 1/4”
Tool to check hub rolling torque (to be used with dynamometric

99395026 wrench)

TOOLS
99395684 Dial gauge with magnetic base
Dial gauge with support to be used with the tools for finding proper
99395728 bevel pinion shims


REAR AXLE REMOVAL - REFITTING

Removal Figure 5
Position the vehicle on level ground and lock the front
wheels.
Loosen rear wheel fastening nuts.
Lift the rear part of the vehicle and position it on proper
stands.
Fit hydraulic truck 99321024 under the rear wheels, remove
wheel fastening nuts and then remove wheels.
Loosen handbrake lever adjustment nut (4). Release cables
(2) from vehicle cross member by releasing the retaining clips
(5), and from the side member brackets by loosening clamp
fastening screws (3).
Loosen propeller shaft fastening screws (6).
Release cables from clamps and disconnect the brake lining
(1) and (7) wear indication electrical cables of ABS sensors,
if any.
Loosen shock absorber (14) fastening nuts (16).
Loosen the screws (17) fastening the stabilizer bar (10) to the
rear axle.
Disconnect brake oil pipes from connection (13) and secure
them to the chassis to prevent oil draining from system.
Disconnect pipe (15) from rear axle casing oil vapour bleed.
Position the hydraulic jack fitted with support 99370617
under the rear axle.
Loosen the nuts (8) of the brackets (9) fastening the rear axle
to the leaf spring (10).
Lower the hydraulic jack and remove the rear axle.
Refitting
reverse order, observing the required tightening torques for the
screws and/or nuts.
Afterwards, check that:
- Check the thread of the brackets joining the leaf springs to the
axle. If there are any irregularities, rectify the thread (operation
500412) or replace the brackets.
- Bleed the air from the brake hydraulic system as described under
the relevant heading (operation 784010).
- The self-locking nuts must not be reused.
- Check the state of the flexible pads (12) and replace them if they
have deteriorated (operation 500417).
- The lubricating oil in the axle housing should be at the right level. 61988


525010 OVERHAUL OF REAR AXLE 525013 Air breather disassembly - assembly

Figure 8
The drive shafts, brake disc and calipers, air breather

! and differential can all be removed and refitted even
with the unit mounted on the vehicle.
Figure 6
62882
Take out the screws (1) and remove the brake caliper with its
brake linings from the mounting.
525030 Overhaul of wheel hubs

62880 Disassembly
overhauling, drain oil by loosening rear axle casing plug. Dis- Figure 9
connect brake fluid pipes (2) from brake callipers (1) and from
rear axle casing and pipes (3) from rear axle casing.
Figure 7
62883
Take out the screws (1) and remove the brake caliper (2) with
its brake linings from the mounting.

! dropped.
62881
Set the entire rear axle assembly on stand 99322215. sharp metal tools.
Do not dirty or wet the rubber caps with mineral
grease or oil.
NOTE The identification data of the rear axle unit are given
on the plate (1) fixed near to the leaf spring attach- Do not dirty the pads with liquids or grease.
ment support. Check proper brake calliper and brake lining
conditions as described in ”Brake” section.

Figure 10 Figure 13
62889
62892
Rotate the wheel hub (1) to set downward one of the two
screws (2) located between hub reliefs; remove the screws Loosen bearing retaining ring nut (2, Figure 12) using wrench
and drain oil completely from wheel side. Remove the other 99357080 (1).
screws fastening the axle shaft (3) to the wheel hub (1).
Figure 14
Figure 11
62893
62890 Remove the safety washer (1).
Remove the axle shaft (2) from the wheel hub (1).
Figure 15
Figure 12
62891 62894
Remove ring nut (1) safety screw (2). Sling brake disk (1) with rope and hoist, take off wheel hub (2)
complete with brake disk (1), front (3) and rear bearings, seal
ring and spacer.

Stud replacement
Figure 16 Figure 19
62884
62887
Remove front bearing (1) inner ring and spacer (2).
Remove screws (4) and disconnect the brake disc (5) from the Where the studs of wheel hub (1) must be replaced, before
wheel hub (3). mounting the new studs, make sure that studs head rest plane
is free from slag, burr and blisters.
NOTE Check the brake disc as described in the ”Brake” no greater than 2000 kg.
section.
touch with the hub: maximum orthogonal tolerance 0.2 mm.
Figure 17
Figure 20
62885
Remove phonic wheel (1), if any, using suitable equipment.

Remove sealing ring (2) and the rear bearing inner ring (4) set
below from the wheel hub (3).
Figure 18
62888
Use handle 99370007 (1) and beater 99374093 (2) to fit

taper roller bearing outer rings into the wheel hub.
32445
NOTE This operation shall be performed using a press until
Use a suitable punch to remove the rear taper roller bearing positioning the rings at 5 mm from their abutting
outer ring (1). Repeat this operation to remove the front end, their fitting shall be then completed by hand.
taper roller bearing outer ring.

Figure 21 Figure 23
62932
62938
Lubricate rear taper roller bearing inner ring (4) with SAE W
140 M-DA oil and fit it to wheel hub (5).
Use tool 99374132 (2) provided with proper handle NOTE Check and, if necessary, adjust the clearance
99370006 (1) to fit sealing ring (3). between the parking brake drum and shoes as
described in the Brakes section.
NOTE Use tool 99374132 (2) side to position the sealing

ring (3) at 1.5 mm from wheel hub side surface. Lubricate the sleeve and the sealing ring supporting ring (1)
with TUTELA W140/M-DA (SAE 85W140) oil.
Fit the phonic wheel, if any, on the wheel hub.
NOTE Phonic wheel fitting shall be performed after heating

it at 150ºC.
When fitting is over, check whether the phonic
wheel is resting perfectly on the hub seat. Figure 24
Check whether phonic wheel squareness and
oscillation is lower than 0.2 mm.
Figure 22
62897
Use suitable rope and hoist to fit wheel hub (1) on sleeve (4).
Lubricate spacer (2) and outer bearing inner ring (3) with
Tutela W140/M-DA and fit them on sleeve (4).
62896
Fit the brake disc (3) on the wheel hub (1) and tighten the
fastening screws (2) to the specified torque.

Figure 25 Figure 28
62891
62898 After checking the end play and the rolling torque, check
whether one of the adjustment nut (1) holes is coinciding with
Fit the safety washer (3) so that the clip is guided properly into one of the safety washer holes otherwise loosen the
rear axle casing sleeve groove. adjustment nut (1) until it is possible to fit the fastening screw
Tighten ring nut (4) with wrench 99357080 (1) and (2). Tighten the fastening screw (2) and the adjustment nut to
dynamometric wrench (2), tighten the new ring nut (4) to the the specified torque.
specified torque.
Figure 29
Figure 26
62902
Smear the contact surface between axle shaft (3) and wheel
hub (1) with IVECO sealing compound 1905685.
62899 Fit axle shaft (3), tighten the fastening screws (2), excluding
those set between the two wheel hub marks (see Figure 30)
Position the dial gauge 99395684 (1) with a magnetic base with tool 99370317 (4) lock wheel hub (1) rotation.
on the wheel hub (3) and rest the rod on the sleeve (2).
Check whether wheel hub end play is falling between 0 and Figure 30
0.16 mm.
Figure 27
62903
Set horizontally to ground the two holes (1) located between

62900 the wheel hub marks and pour through 0.2 l of W140 M-DA
Use tool 99395026 (2) and the dynamometric wrench oil on each wheel side.
99389819 (1) to check whether the wheel hub rolling torque Smear the threaded section of the screws acting as plug with
is falling between 0 and 4 Nm (0 - 0.4 kgm). IVECO sealant 1905683 and tighten to the specified torque.

526210 DIFFERENTIAL REPAIR OPER-

Figure 31 ATIONS
526260 Differential locking
Figure 33
62904
Position brake calliper (1) including the brake lining on the 62906
supporting flange (2).
Tighten the fastening screws to the specified torque. Remove the 4 screws (1) including washers and disconnect the
differential locking device (2).
When refitting, replace the gasket located between differential
locking device and rear axle casing.
NOTE The brake lining with the wear sensor shall be fitted
Tighten screws (1) to the specified torque.
on brake calliper piston side.
Comply with BRAKE section requirements to move
back the brake calliper piston.
Figure 34
Figure 32
62907
DIFFERENTIAL LOCKING DEVICE SECTION
62880 Differential locking device engagement/disengagement lever

stroke shall be equal to 5 mm.
Remove the rear axle assembly from the overhaul stand. Refit
brake fluid pipes (2 and 3) to rear axle casing and brake
callipers (1).
Fill rear axle casing with oil in the specified amount and quality.

Differential unit removal Gearing case removal
NOTE Before performing differential repair, drain oil and Figure 38

remove axle shafts as described previously.
Figure 35
33081
Remove gearing case supporting bearings (1 and 2) using

puller 99348001 (3) and counter block 99345056 (4).
Figure 39
33077
Remove gearing (1) inspection cover including the gasket.
Figure 36
33082
Clamp the gearing case (2) in a vice and remove the ring bevel
gear (1) from the gearing case (2).
33078
Remove caps (1) after marking them. Figure 40
Figure 37
33079
33083
Remove the spacer (1) and remove the gearing case (3) in- Mark gearing half-boxes (1 and 2), loosen the fastening
cluding the crown wheel (4) and the outer rings (2) for sup- screws, position the gearing case on a bench and remove the
porting bearings. Remove the other spacer and the adjust- two half-boxes.
ment rings. Do not reverse the outer races of the gearing case
supporting bearings.

Figure 41 Figure 44
33088
33084
Use a bronze beater in arrow direction to remove the bevel
Remove sun gears (5) and planetary gears (2) including the spi- pinion (1) including the rear bearing, the fixed spacer and the
der (6) from the gearing half-box (4). Recover the shoulder adjustment rings from the rear axle casing (2).
washers (1 and 3).
Figure 42 Figure 45
33089
33086
Remove the sealing ring (1) and the front taper roller bearing
Remove bevel pinion retaining nut safety crimp and loosen from the rear axle casing (2). Use a bronze beater to remove
the nut using the counter lever 99370317 (1). the front taper roller bearing outer ring.
Figure 43 Figure 46
33090
33087
Use a bronze beater to remove the rear taper roller bearing
Remove transmission connection flange (1). outer ring (1) from the rear axle casing (2).

Gearing case refitting

Figure 47 Figure 48
33092
33091
Fit in place the sun gear (2) with the shoulder washer set
Use puller 99348001 (3) to remove the rear taper roller below in gearing half-box (1).
bearing (2) from the bevel pinion (1).
Differential components check Figure 49
Carefully clean each differential component.

Lubricate the bearings and rotate the roller cage freely. The
rotation must be even and without sign of stiffness. Check the
ring bevel gear contact surfaces and the half-box striker plate
to ensure that the crown wheel adheres perfectly. Deforma-
tions on these surfaces cause the crown wheel fastening
screws to vibrate, thus jeopardizing the correct operation of
the unit.
NOTE Carefully clean all threads in order to obtain exact 33084

adjustments and accurate tightening torque. Fit in place the planetary gears (2) with shoulder washers (3),
the spider (6) and the sun gear (5) with shoulder washer (1)
in the gearing half-box (4).
Check that the splined section for flange-pinion connection is

not badly worn, otherwise replace the pinion.
Figure 50
NOTE When replacing the crown wheel or pinion it is

necessary to replace both parts since they are
supplied in pairs.
Check the planetary gears and the relevant shoulder

washers, the spider and the crown wheels with the relevant
shoulder washers.
Replace all sealing elements, the bevel pinion retaining nut
and gearing case bearing adjustment nut with new parts.
33094
Rear axle casing check
Fit between them the half-boxes (1 and 2) and tighten the
Check whether rear axle casing is not deformed. fastening screws to the specified torque.

Figure 51 Figure 54
33095 33098
Mount the outer ring of front taper roller bearing into rear axle
Heat in air-circulation furnace at 100ºC for approx. 15’ the box using beater 99374093 (1).
taper roller supporting bearing (1) on toothing side and fit it
down onto the gearing case (2) completely.
Figure 52 Figure 55
33096
33099
Heat in air-circulation furnace at 100ºC for approx. 15’ the Use beater 99374093 (1) to fit in place rear taper roller
taper roller supporting bearing (1) on toothing opposite side bearing outer ring on rear axle casing (2) without adjustment
and fit it down onto the gearing case (2) completely. ring.
Figure 53 Figure 56
33097
33100
Pour few drops of LOCTITE 270 into crown wheel (1) holes, On surface plate (2), set to zero dial gauge 99395728 (1) on
fit the crown wheel (1) on the gearing case (2) and tighten the support (3) and slightly preload it.
fastening screws to the specified torque.

Figure 57 Figure 59
33101
33103
Fit the rear bearing (2) on the false pinion 99370296 (1). Set dial gauge 99395728 (1) including support (3) on false
pinion 99370296 (2).
Direct suitably the dial gauge previously set to zero (see
Figure 56) to position the rod to the bottom of the gearing
case supporting bearing housing.
Figure 58 Repeat this operation for the other bearing and take note of
both found values.
Pinion adjustment ring thickness is obtained through the
following formula:
A1 + A2
S= -(±B)
2
”S” = thickness of the adjustment rings to be positioned

between bevel pinion rear bearing outer ring and rear axle
casing.
”A1” = value found on right housing
”A2” = value found on left housing
33102
”B” = reference value marked on bevel pinion (see Figure 60)
Example:
3,90 + 4,10
Position the false pinion 99370296 (1) including the rear bear- S= - ( ± 0,05)
ing (2) into its seat on rear axle casing (3). 2
Fit the front bearing, the transmission connecting flange and
the bevel pinion retaining nut and tighten so as to remove end 8,00
S= - 0,05
play and to enable false pinion rotation. 2
S = 4,00 - 0,05
S = 3,95
Adjustment ring thickness shall therefore be: 3.95 mm.

Figure 60 Figure 62
33104
32481
Heat the rear bearing (1) to 100°C for approx. 15’ into an
NOTE If the value marked on the pinion is preceded by air-circulation furnace and then fit it down onto the bevel
positive sign (+), it shall be subtracted from the pinion (2).
value obtained by the sum divided by two of the
housings, whereas it shall be added if preceded by
negative sign (-).
Figure 63
32482
Figure 61
Position the fixed spacer (2) and the adjustment ring (3),
previously used to obtain the specified rolling torque, on the
bevel pinion (1).
Figure 64
33099
Choose an adjustment ring having the same thickness ob-

tained by using the formula shown in SENZA CODICE and
fit it into the rear axle casing after removing rear taper roller
bearing outer ring previously mounted.
Use beater 99374093 (1) to fit definitely the rear taper roller 33111
bearing outer ring into rear axle casing (2).
Position the complete bevel pinion into the rear axle casing.
Heat the front bearing (1) to 100°C for approx. 15’ into an
air-circulation furnace and then fit it down onto the bevel
pinion (2).

Figure 65 Figure 68
32480
Using the torque wrench 99389819 (1), measure the rolling

74730
torque of the bevel pinion.
Fit the seal ring (2) in the axle casing with tool 99374201 (1).
Figure 66
If the value is incorrect disassemble the pinion (2, Figure 64),

and replace the adjuster ring (3, Figure 63) with a suitable ring.
33113
Fit the transmission connecting flange (1) and the bevel pinion
retaining nut (2).
Differential unit refitting
Figure 67 Figure 69
33116
74731
Assemble the flange (3) and prevent rotation with tool Fit gearing case supporting bearing outer rings (2) and then
99370317 (1). position the gearing case (1), previously fitted, in the rear axle
Using the torque wrench (2), tighten the bevel pinion flange casing.
(3) retaining nut to the correct torque value.

Figure 70 Figure 72
33107
Use dynamometric wrench 99389819 (1) to check total

33117
rolling torque:
Cd
Insert the spacer (2), adjuster ring (1), adjuster ring (4) and Ct = Cp + ( x 0.99)
then spacer (3). R
Ct = total rolling torque
Cp = bevel pinion bearing rolling torque
Figure 71 Cd = 2 ÷ 2.8 Nm (0.2 ÷ 0.29 kgm)
R = Rear axle reduction ratio
Example:
2,8
Ct = 2.5 + ( x 0.99)
3,91
Ct = 2.5 + 0.71
Ct = 3.21 Nm (0.33 kgm)
If the value is incorrect, replace the adjuster rings (1 and 4,
Figure 70) with rings of the correct thickness.
Figure 73
33119
Refit caps (1) taking into account the marks made at removal.
Use dynamometric wrench 99389827 (2) to tighten the
Set gearing case supporting bearings and check total rolling
torque.

33121
Position magnetic dial gauge 99395684 (1) and check the

clearance between the pinion and crown on four equidistant
teeth on the crown. The average of the measurements must
equal the required value. If a different clearance is found, remove
the caps (3) again and swap over the assembly position of the
adjustment rings (1 and 4, Figure 70).
If this is not sufficient, replace the adjustment rings with ones
of a different thickness, but the total thickness must still be the
same as that of the adjustment rings removed.
This is so as not to change the total rolling torque.
Apply a thin layer of Prussian blue on ring gear teeth by brush.
Turn the pinion and measure the impression of the contact of
the pinion toothing on the crown wheel toothing.
Here we illustrate the possible contacts with the corrections
to obtain precise coupling of the crown wheel and pinion.

Figure 74 Figure 77
44603
Excessive contact on heel
E = Greater base of tooth.
A = Coupling depth Move the ring bevel gear to-
F = Heel
B = Crest wards the pinion and then
G = Top land
C = Side move the pinion away from
H = Contact surface
D = Play the ring bevel gear to adjust
I = Lateral surface
44606
clearance.
Figure 75 Figure 78
Excessive contact in the

upper part or crest of the
tooth.
Correct contact. Move the pinion towards
the ring bevel gear and then
move the ring bevel gear
44604
away from the pinion to ad-
44607
just clearance.
Figure 76 Figure 79
Excessive contact on side Excessive contact on the

of tooth. top land of the tooth.
Move the pinion away from Move the ring bevel gear
the ring bevel gear and then away from the pinion them
move the ring bevel gear to- move the pinion towards
wards the pinion to adjust the ring bevel gear to adjust
clearance. 44605 clearance. 44608

Figure 80 Figure 82
33122 33123
Fit a new sealing gasket on gearing inspection cover connec-

tion surface. Apply Loctite 270 on the thread of the holes for Fit oil drain plug (2). Pour 3 litres of W140/M-DA oil through
screws to secure cover (1). Fit cover (1) and use dynamomet- the proper hole and fit inspection and filling plug (1).
ric wrench to tighten the fastening screws to the specified
torque.
NOTE Do not tighten screws at higher torque value since

this shall jeopardize the effect of the sealing gasket
located between the connection surface and the
gearing inspection cover.
Figure 81
* NUT ROTATION
DIRECTION
51853
Crimp nut (1) collar on bevel pinion (2) milling as shown in the
figure.

DAILY EURO 4 AXLES 1
SECTION 7
5206 Axles
Page
This section contains:
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 3
AXLE 5817 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AXLE 5818 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AXLE 5819 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
AXLE 5823 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
WHEEL GEOMETRY . . . . . . . . . . . . . . . . . . . . . 49

2 AXLES DAILY EURO 4

AXLES
DIAGNOSTICS
Front axle main working faults:
1 - Stiff steering;
2 - Wobble;
3 - Noise.
1 STIFF STEERING
Front wheels not aligned. Align front wheels.

YES
NO
Irregular wheel toe-in. Adjust front wheel toe-in.

YES
NO
Irregular tyre pressure. Inflate tyres to prescribed pressure.

YES
NO
Elements involved in the stub axle rotation on the pin Check and replace the elements deteriorated.
inefficient. YES

2 WOBBLE
Irregular wheel camber. Check the tie rod assembly, adjust or repair the
YES deformed parts.
NO
Front wheels not aligned. Align front wheels.

YES
NO
Irregular wheel toe-in. Correctly adjust toe-in.

YES
NO
Steering gear tie rod king-pins inefficient. Replace defective parts.

YES
NO
Irregular play of wheel hub bearings. Replace the wheel hubs.

YES
NO
Eccentric wheels: Replace the wrong rim.

eccentric, deformed rim YES Deflate and centre the tyre on the rim.
tyre assembled on wrong rim.
NO
Unbalanced wheels. Balance the wheels.

YES

3 NOISE
Wheel hub bearings worn. Replace worn bearings and adjust end play.
YES
NO
Stabiliser bar elastic inserts worn or relevant fixing Replace elastic inserts, tighten fixing nuts.
brackets loosen. YES
NO
Play between torsion bar-suspension arm splines. Replace worn parts and adjust torsion bar pre-loading.
YES
NO
Suspension arm bushes and/or articulation pins worn. Replace worn parts.
YES


DAILY EURO 4 AXLE 5817 7
Axle 5817
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVING AND REFITTING AXLE 5817 . . . . 13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OVERHAULING AXLE 5817 . . . . . . . . . . . . . . . 15
- Wheel hub removal and refitting . . . . . . . . . . 15
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Replacing phonic wheel . . . . . . . . . . . . . . . . . . 16
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STUB AXLE REMOVAL-REFITTING . . . . . . . . . 17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8 AXLE 5817 DAILY EURO 4

DESCRIPTION
Print 603.43.351
The front axle 5817 is composed of a load-bearing cross The wheel hubs are supported on the pins of the stub axles
member on which are mounted the suspensions and power by UNIT - BEARINGS that need neither lubrication nor
steering. adjustment.
The stub axles turn, by means of swivel heads, on the ends The wheel rims are secured onto the wheel hubs by five
of the suspensions. screws.
The steering levers are cast on the king-pin of the stub axles
to which are secured the brake calipers.
Figure 1
108374

Axle type 5817
WHEEL HUBS
Wheel hubs bearings UNIT BEARING
Hub bearings end play -
Wheel hub bearings Not Adjustable

play adjustment Fixing nut torque tightening
WHEEL GEOMETRY
Wheel camber angle

0º ± 20’
(vehicle at static load)
Wheel caster angle

3º ± 20’
Wheel toe-in
2 ± 1 mm

TIGHTENING TORQUES
Figure 2
108351
AXLE 5817
TORQUE
PART
Nm kgm
Screw securing caliper mounting to stub axle 176 ÷ 217 18 ÷ 22
1 Nut securing the upper swinging arm jointed head to the stub axle 125 ÷ 140 12.5 ÷ 14
2 Nut securing the steering rod jointed head to the lever 68 ÷ 83 6.8 ÷ 8.3
3 Nut securing the lower swinging arm jointed head to the stub axle 160 ÷ 180 16 ÷ 18
4 Screw securing stub axle guard 6 ÷ 7.5 0.6 ÷ 0.7
5 Screw securing brake disc to wheel hub 19.5 ÷ 24.9 2 ÷ 2,5
6 Screw securing wheel 180 ÷ 200 18 ÷ 20
7 Nut securing wheel hub 320 ÷ 420 32 ÷ 42

TOOLS
99305354 Portable optical reading tool for checking wheel trim
99306010 Apparatus to purge air from brakes and clutch
99321024 Hydraulic trolley for removing/refitting wheels
99322215 Guide to wheel hub assembly
99347074 Puller for steering tie rod king-pins

Print 603.43.351
REMOVING AND REFITTING AXLE 5817 Figure 3

Removal
Set the vehicle on solid, level ground.

Lock the rear wheels with scotches, remove the wheel rim
guards and loosen the screws or nuts fixing the wheel.
Lift the front of the vehicle and rest the chassis frame on
supports.
Take out the screws or nuts fixing the wheel and remove them
with tool 99321024.
From underneath the vehicle:
- remove the central guard (15) under the engine by taking
out the screws securing it to the side guards and to the
front cross member of the chassis frame;
- remove the engine side guards (6) and (19) by taking out
the screws securing them to the chassis frame;
- remove the gearbox side guards (5) and (20) by taking out
the screws securing them to the chassis frame and the nuts
securing them to the cross member under the gearbox
(23);
- disconnect the brake fluid pipe (21) from the retaining
blocks on the axle (22);
- drain off the power-steering fluid and disconnect the pipes
(11) and (12) in correspondence with the fittings on the
hydraulic power steering (13);
- disconnect the power steering column in correspondence
with the coupling (14).
If it is decided to leave the brake callipers on the axle, proceed
to:
- disconnect the electrical connection (1) signalling brake
lining wear and the ABS sensor (4) if there is one;
- disconnect the brake fluid pipes in correspondence with
the fittings (7) and (18) after draining the system.
If it is decided to leave the brake callipers on the vehicle,
proceed to:
- disconnect the brake fluid pipes from the axle (22) in
correspondence with the brackets (8, 10, 16, 17);
- then disconnect the brake callipers (3) from their
respective stub axles by taking out the screws (2) and
supporting the callipers to prevent any strain on the pipes.
To complete removing the axle:
- unscrew five of the six fixing screws (9) on both sides of
the chassis frame;
- put a hydraulic lift under the axle and take out the last two
screws;
- lower the hydraulic jack and extract the axle.
Refitting
Reverse the steps described for removal tightening the screws
or nuts to the prescribed torque.
Adjust the load of the torsion bar as illustrated under the
specific heading.
Top up the power-steering fluid.
If the brake callipers have been left on the axle, restore the
brake fluid level and bleed off any air.
Check and adjust the front wheel geometry.
75583


Print 603.43.351/D
REPAIRS
520610 OVERHAULING AXLE 5817 Figure 6
Figure 4
108366
108364
Remove centring pin (2), then take brake disc (1) off wheel
Free the screws (1) securing the wheel rim. hub (4).
Lift the vehicle and put the stands (2) under the structural Remove the cup (3) from the wheel hub (4).
members in a forward position.
Undo screws (1), remove screw guard (1) and remove the
entire wheel. NOTE Check the conditions of the brake disc and the
braking gaskets, as described in the ”BRAKING
SYSTEM” section.
520620 Wheel hub removal and refitting

Removal
Figure 5
Figure 7
108365
Remove the braking gaskets as described in the ”Brake” 108367

section, or remove screws (1) and take the support together
with brake caliper (2) off the stub axle.
Lift the deformation (⇒) of the nut (1) and unscrew this with
Support the brake caliper suitably to prevent strain on the oil a suitable wrench.
pipe.
Print 603.43.351
Figure 8 Refitting
Figure 10
61668
Extract the wheel hub (1) from the pin of the stub axle (2). 61668
Lubricate the surface of the stub axle pin (2) with TUTELA
NOTE If any trouble is found with the wheel hub or MR3 grease and key the wheel hub (1).
bearing, the assembly needs to be replaced since
the parts are not supplied as single spares.
NOTE The wheel hub must be keyed without forcing.. If
When repairing the wheel hub (1), take care not there are difficulties, do not assemble since the
to damage the phonic wheel (3). bearing may be damaged.
Extract the wheel hub, check the cause of the
difficulties and eliminate them.
526712 Replacing phonic wheel
Figure 9
Figure 11
109050
After hub (1) is force-fitted, screw down nut (3).

Tighten the nut (3) to the required torque with the Allen
wrench (2).
109048
Phonic wheel (2) can be taken off wheel hub (1) by using
generic tools. Pull-in load: 500 ÷ 900 kg.
NOTE Nut (3) is equipped with a fixed washer (4).
On completing assembly, make sure the phonic wheel sits in
its seat in the hub properly.
Check that the orthogonality and oscillation of the phonic
wheel is no greater than 0.1 mm.

Figure 12
NOTE The brake lining with its wear indicator must be
mounted from the piston side of the brake caliper.
If it is necessary to move the brake caliper piston
back, use tool 99372236, taking the precautions
given in the BRAKES section.
Tighten brake calliper (2) fixing screws to the prescribed

torque.
Figure 15
108368
Deform the collar of the nut (1) by the milling (⇒) of the pin
(2).
Figure 13
108370
Fit the wheel onto the brake disc, then place the screw guard
into position. Tighten the wheel fastening screws to the
specified torque, in accordance with the diagram illustrated
in the figure.
108366
Mount the cup (3) in the wheel hub (4).

Mount the brake disc (1) and secure it to the wheel hub (4)
with the two centring pins (2).
Figure 14
522820 STUB AXLE REMOVAL-REFIT-

TING
Removal
Remove the wheel hubs as described under the relevant

heading (operation 520620).
108369
Rest the brake caliper (2) with the brake linings on the stub
axle (1).

Figure 16 Figure 18
52259 61670
Remove screws (5) and remove protection (4) from stub With the hydraulic jack under the bottom suspension arm (3)
axle (6). oppose the action of the transverse leaf spring.
Remove nut (2) fixing kingpin (1) to lever (3). Remove the nuts (2 - 6) securing the swivel head pin (1 - 5)
to the stub axle (4).
NOTE Fit the proper setscrew wrench into kingpin (1) to

stop its rotation, if required. NOTE To block rotation of the swivel head pins (1 - 5),
insert a suitable Allen wrench into the hexagon
sunk into them.
Figure 19
Figure 17
61669
52260
Using the extractor 99347074 (2), remove the link pins (1 -

3) of the stub axle (4) and put this aside.
Using the extractor 99347074 (1), remove the pin (2) of the
swivel head from the steering lever of the stub axle (3).

Refitting
Figure 20
61671
Insert the pins of the swivel heads (1 - 2) of the top and

bottom suspension arms into the seats of the stub axle (3).
Then screw on the self-locking nuts (5) and lock them at the
required torque.
NOTE Once removed, self-locking nuts (5) must not be

reused.
To block rotation of the swivel head pins (1 - 2),
insert a suitable Allen wrench (4) into the hexagon
sunk into them.
Figure 21
52259
Connect the pin of the swivel head (1) of the power steering
tie to the lever (3) of the stub axle (6) and tighten the fixing
nut (2) to the required torque.
NOTE Once removed, self-locking nuts (2) must not be

reused.
To block rotation of the swivel head pin (1), insert
a suitable Allen wrench into the hexagon sunk into
them.
Mount the guard (4) on the stub axle and secure it, tightening
the screws (5) to the required torque.
Refit the wheel hub as described in the relevant chapter
(operation 520620).


Axle 5818
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIFICATION AND DATA . . . . . . . . . . . . . . 23
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OVERHAULING AXLE 5818 . . . . . . . . . . . . . . . 26
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STUB AXLE REMOVAL AND REFITTING . . . . 28


DESCRIPTION
Axle 5818 differs from axle 5817 for wheel hub, brake disc and wheel rim fixing to brake disc that is implemented by nut studs
without stabiliser bar.
Figure 1
108375
SPECIFICATION AND DATA
Axle type 5818
WHEEL HUBS
Wheel hub bearings Not Adjustable

play adjustment Fixing nut torque tightening
WHEEL GEOMETRY
Wheel camber angle

0º ± 20’
Wheel caster angle

3º ± 20’
Wheel toe-in
2 ± 1 mm

TIGHTENING TORQUES
Figure 2
108352
AXLE 5818
PART TORQUE
Nm kgm
4 Screw securing guard to stub axle 6 ÷ 7.5 0.6 ÷ 0.7
5 Nut securing wheel 180 ÷ 200 18 ÷ 20
7 Screw securing the brake disc and flange to the wheel hub. 98.1 ÷ 107.9 9.8 ÷ 10.7

TOOLS
99322215 Guide to wheel hub assembly
99347074 Puller for steering tie rod king-pins

520610 OVERHAULING AXLE 5818

The overhauling operation different from the ones Figure 5
concerning the axle 5817 are described below.
To remove and refit axle 5818, proceed in a similar manner
as for axle 5817.
Adjustment values, tightening torque values and equipment
are those specified in this chapter.

Removal
Figure 3
108367
Lift the deformation (⇒) of the nut (1) and unscrew this with
a suitable wrench.
19603 Figure 6
Free the screws (1) securing the wheel rim.
Lift the vehicle and put the stands (3) under the structural
members in a forward position.
Unscrew the nuts (1), take off the protection (2) and remove
the entire wheel.
Remove the braking gaskets as described in the ”Brake”
section, or remove the mounting with the brake caliper as
described for axle 5817.
Figure 4
109052
Extract the wheel hub (1) from the pin of the stub axle (2).
109051
Stop flange (2) rotation by means of a proper lever (3), then

remove screws (4) and take flange (3) and brake disc (1) off NOTE If any trouble is found with the wheel hub or
the wheel hub. bearing, the assembly needs to be replaced since
the parts are not supplied as single spares.
NOTE Check the conditions of the brake disc and the When putting aside the wheel hub, take care not
braking gaskets, as described in the ”BRAKING to damage the phonic wheel.
SYSTEM” section.

526712 Replacing phonic wheel Figure 9

Figure 7
109050
After hub (1) is force-fitted, screw down nut (3).

Tighten the nut (3) to the required torque with the Allen
wrench (2).

109053
Phonic wheel (2) can be taken off wheel hub (1) by using
generic tools. Pull-in load: 500 ÷ 900 kg.
The phonic wheel should be mounted on the wheel hub after
heating it to a temperature of 150°C.
On completing assembly, make sure the ”phonic” wheel sits
in its seat in the hub properly and is positioned at the distance
shown in the figure.
Check the oscillation of the phonic wheel (2). Tolerance
must be no greater than 0.1 mm.
Refitting Figure 10
Figure 8
108368
109052
MR3 grease and key the wheel hub (1).
Deform the collar of the nut (1) by the milling (⇒) of the pin
NOTE The wheel hub must be keyed without forcing.. If (2).
there are difficulties, do not assemble since the
bearing may be damaged.

Figure 11 522820 STUB AXLE REMOVAL AND RE-

FITTING
Perform stub axle removal and refitting as described for axle
5817, without considering the points concerning the
stabiliser bar since the latter is lacking on axle 5818.
109055
Fit brake disc (1) and flange (2) onto the wheel hub. Stop
flange (2) rotation by means of a proper lever (3), then
tighten fastening screws (4) to the specified torque.
Using a magnetic dial gauge, check the eccentricity of the
brake disc: it must not exceed 0.125 mm.
Fit the support, together with the brake caliper and braking
gaskets, into place back to the stub axle, by tightening the
Figure 12
Assemble:
- the wheel on the brake drum;
- the nut protection and screw the fixing nuts.
Tighten the nuts fixing the wheel to the prescribed torque
according to the diagram shown in figure.

Axle 5819
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 35
AXLE 5819 OVERHAUL . . . . . . . . . . . . . . . . . . 35
- Stub axle removal and refitting . . . . . . . . . . . . 35
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35


DESCRIPTION
The front axle 5819 has independent wheels. The brake calipers and steering levers are secured on the
king-pin of the stub axles.
It is basically composed of:
The hubs are supported on the stub axle pins by
- stub axles; Unit-Bearings, which need no adjustment or lubrication.
- wheel hubs;
- suspension arms.
The stub axles are also the end elements of the suspension.
They are connected to the top and bottom suspension arms
by swivel heads that allow turning the stub axle.
Figure 1
30772

Axle type 5819
WHEEL HUBS
Wheel hub bearings play Not Adjustable

adjustment Fixing nut torque tightening
WHEEL GEOMETRY
Wheel camber angle

0o 30’ ± 20’
Wheel caster angle

1o 35’ ± 20’
Wheel toe-in
2.5 ± 1

TIGHTENING TORQUES
Figure 2
108353
AXLE 5819
TORQUE
PART
Nm kgm
1 Nut securing the upper swinging arm jointed head to the stub axle 157 ÷ 177 15.7 ÷ 17.7
3 Nut securing the lower swinging arm jointed head to the stub axle 157 ÷ 177 15.7 ÷ 17.7
5 Screw securing plate and brake disc to wheel hub 98 ÷ 108 9.8 ÷ 10.8
Screw securing guards to stub axle 7 ÷ 10 0.7 ÷ 1

TOOLS
99347074 Tool for extracting steering tie rod king-pins
Wrench for spindle pin ring nut

99357144

REPAIR OPERATIONS Refitting

520610 AXLE 5819 OVERHAUL
Figure 5
The following paragraphs describe the overhaul operations
that differ from axle 5818 operations.
To remove and refit axle 5819, proceed in a similar manner
as for axle 5823.
Adjustment values, tightening torque values and equipment
are those specified in this chapter.
520611 Stub axle removal and refitting
Removal
Figure 3
19028
Set upper and lower lever kingpins (6 and 8) into stub axle
seat (4) then tighten self-locking nuts (1 and 5) to the
prescribed torque.
Refit steering lever (3) on stub axle by tightening the relevant
fixing screw and nut (7) to the prescribed torque.
Refit dust cover (2) to stub axle by means of the proper
screws indicated with arrows.
19026
NOTE Self-locking nuts (1 and 5) cannot be reused after

Remove wheel hub as described in the relevant chapter removing.
(operation 520620) concerning axle 5817.
Refit wheel hub as described in the relevant
Remove from stub axle (5): chapter (operation 520620) concerning axle 5818.
- dust cover (2) by loosening screw (7);
- steering lever (3) by loosening screw (8);
Loosen kingpin (1 and 6) fixing nuts from stub axle (5).
Figure 4
19027
Use tool 99347074 (3) to remove kingpin (1) from stub axle
(2) then remove the latter.


5206 Axle 5823
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVING AND REFITTING AXLE 5823 . . . . 43
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
AXLE 5823 OVERHAUL . . . . . . . . . . . . . . . . . . 45
- Wheel hub removal and refitting . . . . . . . . . . 45
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
- Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46


DESCRIPTION
The front axle 5823 has independent wheels. The brake calipers and steering levers are secured on the
king-pin of the stub axles.
It is basically composed of:
The hubs are supported on the stub axle pins by
- stub axles; Unit-Bearings, which need no adjustment or lubrication.
- wheel hubs;
- suspension arms.
The stub axles are also the end elements of the suspension.
They are connected to the top and bottom suspension arms
by swivel heads that allow turning the stub axle.
Figure 1
62909

Axle type 5823
WHEEL HUBS
Hub bearings end play 0.11 ÷ 0.14
Wheel hub bearings play Not Adjustable

adjustment Fixing nut torque tightening
WHEEL GEOMETRY
Wheel camber angle

1o ± 20’
Wheel caster angle

2o 30’ ± 20’
Wheel toe-in
2.5 ± 1 mm

TIGHTENING TORQUES
Figure 2
108354
AXLE 5823
TORQUE
COMPONENT
Nm kgm
5 Nut securing wheel hub
- torque 50 ÷ 60 5÷6
- angle 30.1˚ ÷ 34.1˚
6 Screw securing the brake disc and flange to the wheel hub.
- torque 43 ÷ 53 4.3 ÷ 5.3
- angle 28.4˚ ÷ 30.4˚
4 Nut securing wheel 284.5÷ 343.3 28.4 ÷ 34.3
Screw securing caliper to stub axle 7 ÷ 10 0.7 ÷ 1
Screw securing caliper mounting to stub axle 110 ÷ 140 11.2 ÷ 14.3

TOOLS
TOOL No. DESCRIPTION
99321024 Hydraulic truck for removing - refitting operations
99322215 Stand to overhaul axles
99347074 Tool to remove drag link joints and wishbones

REMOVING AND REFITTING AXLE 5823 Figure 3

Removal
Set the vehicle on solid, level ground.

supports.
Take out the screws or nuts fixing the wheel and remove them
with tool 99321024.
Remove the front right and left mudguard (1).
Remove the right and left mudguards under the bumpers (17).
To help remove the front suspension mounting (2), free the top
screw stay (14) in correspondence with the screw (15) fixing
to the suspension arm (13).
Remove the front suspension mounting (2) by taking out the
chassis frame fasteners (16).
Fit the top screw stay (14) back onto the suspension arm (13).
The same steps must be performed on both left and right.
Adjust the load on the right and left torsion bars (9).
Undo the nut (11) and unscrew the threaded pin (12) until the
torsion bar (9) is entirely ”discharged”.
Remove the fasteners (10) fixing the mounting (8) to the
chassis frame.
Extract the mounting (8) from the torsion bar (9).
If it is decided to leave the brake callipers on the axle, proceed
to:
- disconnect the electrical connection (3) signalling brake
lining wear and the ABS sensor (5) if there is one;
- disconnect the brake fluid pipes in correspondence with
the fittings (7) after draining the system;
- if it is decided to leave the brake callipers on the vehicle,
proceed to:
- disconnect the brake callipers (4) from their respective
stub axles by taking out the screws (6) and supporting the
callipers to prevent any strain on the pipes.
75581

From underneath the vehicle: Figure 4

- remove the central guard (7) under the engine by taking
out the screws securing it to the side guards (8) and to the
front cross member of the chassis frame;
- remove the right and left side guards (8) of the engine by
taking out the screws securing them to the chassis frame;
- remove the right and left side guards (9) of the gearbox by
taking out the screws securing them to the axle (11) and
to the cross member (12) under the gearbox;
- disconnect the brake fluid pipe (10) from the retaining
blocks on the axle;
- drain off the power-steering fluid and disconnect the pipes
(4) and (5);
- disconnect the power steering column (3) in
correspondence with the coupling (6);
- place the removal bracket on the hydraulic jack and put it
all under the axle;
- undo the chassis frame bottom fixing screws (2) and the
top fixing nuts (1);
- lower the hydraulic jack and extract the axle (11).
Refitting
Reverse the steps described for removal tightening the screws
or nuts to the prescribed torque.
Adjust the load of the torsion bar as illustrated under the
specific heading.
Top up the power-steering fluid.
If the brake callipers have been left on the axle, restore the
brake fluid level and bleed off any air.
Check and adjust the front wheel geometry.
75582

520610 AXLE 5823 OVERHAUL

Overhaul operations described in this sections are those Figure 7
differing from axle 5819.
Figure 5
109057
62911 Remove screws (3), then take the support, together with
brake caliper (1), off stub axle (2).
Loosen wheel rim fastening nuts (1).

Lift the vehicle and set the supporting stands under the side NOTE Suitably support the brake calliper (1) to prevent
members in forward position. oil pipe tensioning.
Loosen nuts (1), remove protection (2) and remove the
entire wheel.
Figure 8
Removal
Figure 6
109051
109056 Stop flange (2) rotation by means of a proper lever (3), then
remove screws (4) and take flange (3) and brake disc (1) off
Remove safety springs (2) from pins (3). the wheel hub.
Take pins (3) out of brake caliper (6), then recover braking
gasket (1) retaining clips (4).
NOTE Check brake disc and lining conditions as described
Disconnect gasket wear indicator electric connection (5).
in the BRAKE SYSTEM section.
Take braking gaskets (1) out of brake caliper (6).

Figure 9 526712 Replacing phonic wheel

Figure 11
108367
Lift nut (1) countersink (⇒).

109059
The possible extraction of the phonic wheel (2) can be taken

off wheel hub (1) by using generic tools. Pull-in load: 500 ÷
900 kg.
Figure 10 When the assembly is ended, make sure that the “phonic”
wheel perfectly rests on the hub housing and that is
positioned at the dimension shown in figure.
Check that the orthogonality and oscillation of the phonic (2)
wheel is no greater than 0.1 mm.
Refitting
Figure 12
109058
Use a box wrench (2) to remove nut (5) securing wheel hub
(3) to stub axle (1) pin.
Take wheel hub (3) and washer (4) out of stub axle (1) pin.
109052

MR3 grease and key the wheel hub (1).
NOTE The wheel hub must be keyed without forcing.. If

there are difficulties, do not assemble since the
bearing may be damaged.
NOTE If any trouble is found with the wheel hub or
bearing, the assembly needs to be replaced since See Figure 10.
the parts are not supplied as single spares. Fit washer (4) into place, then screw down nut (6).
When repairing the wheel hub, take care not to
damage the phonic wheel. NOTE Nut (6) is equipped with a fixed washer (5).

Figure 13 Figure 15
109057
Place brake caliper (1) onto stub axle (2).

109060
Screw down screws (3) and tighten them to the specified
torque.
Use a torque wrench and a box wrench (3) to tighten nut
(1) in two separate phases: Figure 16
phase 1: torque tightening to 50 ÷ 60 Nm (5 ÷ 6 kgm)
phase 2: angle tightening (30.1˚ ÷ 34.1˚).
Countersink nut (1) collar at pin (2) milled portion (⇒).
Figure 14
109056
Fit braking gaskets (1) into place. Position springs (4), then fit
pins (3) into brake caliper (6).
Fit safety springs (2) into pins (3).
Connect braking gaskets wear indicator electric connection
(5).
α
Figure 17
109055
Fit brake disc (1) and flange (2) onto the wheel hub.
Screw down screws (4).
Stop flange (2) rotation. Tighten screws (4) in two separate
89007
phases:
phase 1: torque tightening to 43 ÷ 53 Nm (4.3 ÷ 5.3 kgm)
phase 1: angle tightening (28.4˚ ÷ 30.4˚).
Fit the wheel onto the flange, then position the nut
protection. Tighten the wheel fastening nuts to the specified
torque, in accordance with the diagram illustrated in the
figure.


DAILY EURO 4 WHEEL GEOMETRY 49
Wheel geometry
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 51
WHEEL GEOMETRY . . . . . . . . . . . . . . . . . . . . . 53
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CHECKING CHARACTERISTIC ANGLES . . . . . 55
- Positioning jaws and projectors . . . . . . . . . . . . 55
- Electronic balancing of rim eccentricity . . . . . . 56
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . 56
- Checking toe-in . . . . . . . . . . . . . . . . . . . . . . . . 57
- Front wheel deviation test

(vehicle wheelbase check) . . . . . . . . . . . . . . . . 57
- Checking camber . . . . . . . . . . . . . . . . . . . . . . . 58
- Checking king-pin angle and caster angle . . . . . 58
- Checking steering angles . . . . . . . . . . . . . . . . . 59
- Checking rear axle alignment . . . . . . . . . . . . . . 59
- Calculating thickness of spacers to be fitted

between tie rod mountings and
chassis side members (with the exception of
vehicles equipped with 5-mm thick chassis or
with transverse leaf-spring suspension) . . . . . . 60

50 WHEEL GEOMETRY DAILY EURO 4

Print 603.93.281
DESCRIPTION
In order to have a good vehicle ground holding, a low Camber angle
consumption of tyre and to enable the driving wheels to return
to straight running after steering, the front wheels are adjusted Figure 2
at defined assembly angles: ß
- wheel camber angle;
- king-pin camber angle;
- caster angle;
- wheel toe-in.
These angles, accurately calculated, enable the correct balancing
of the forces created when the vehicle is moving, in the different
load conditions, tending to change the position of the wheels
on the ground.
32957
The king-pin camber angle (β) is the angle formed by the axis
passing through the king-pin and the vertical to the ground,
looking at the vehicle from the front.
When the projection of the king-pin axis is near to the contact
point of the wheel with the ground (opposite tendency to the
wheel camber) the angle is positive, it is difficult to say that it
is impossible to have the king-pin camber angle negative.
The wheel camber angle (α) and the king-pin camber angle (β)
enable wheel axis and the king-pin axis to come nearer as much
as possible to the contact centre of the tyre on the ground.
In this way, reduced tyre wear and lower steering torque are
obtained.
Wheel camber angle
Figure 1
Caster angle
Figure 3
a a
γ + γ _
A B
A B
32958
32956
The caster angle (γ) is the angle formed by the king-pin axis with
the vertical to the ground, looking at the vehicle from one side.
The camber angle (α) is the angle formed by the axis passing
If the projection formed by the king-pin axis falls in front of the
through the wheel centre line and the vertical to the ground,
wheel contact point with the ground, in the direction of travel
looking at the vehicle from the front.
of the vehicle, the caster angle is by convention positive (A); it
The camber angle is positive (A) when the upper part of the is negative (B) if it falls behind the wheel contact point with the
wheel tends toward the outside; it is negative (B) when the ground; it is equal to zero if it is perfectly vertical to the contact
wheel upper part tend toward the inside. point.

This angle makes it possible to keep the front wheels straight Figure 5
when the vehicle is running straight and allows the wheels to
return spontaneously to running straight from the position
taken in the bend, as soon as the steering wheel is released by
the driver. A
32960
The toe-in is negative if B is lower than A.
Wheel toe-in Figure 6

Figure 4
A
A
B
B
32961
32359
The toe-in is equal to zero if B is equal to A.
The wheel toe-in results from the difference between the

distances A and B (value expressed in mm) measured on the
horizontal axis of the rims, looking at the vehicle from the top.
In this way a light drive and a low tyre consumption is obtained.
The toe-in is positive if B is higher than A.

WHEEL GEOMETRY
MODELS
29L - 35S 35 (1) 35 (2).40 - 45. - 50. 60C - 65C
WHEEL GEOMETRY - - - -
Wheel camber angle

0o ± 20’ 0º 30’ ± 20’ 1º ± 20’
(vehicle at static load) (± 20’)
Wheel caster angle 1º 35’ ± 20’ 2º 30’ ± 20’

3o ± 20’
Wheel toe-in 2.5 ± 1

(vehicle at static load) mm 2±1
Steering angle:
b
a Internal a 47o 30’ ± 30’ 43º 37º 7’
External b 39o ± 30’ 36º 30’ 45º 6’
a
Stub axle king-pin camber α 13.38° 7°
(1) Front suspension with transverse leaf spring

(2) Front suspension with torsion bar
TIGHTENING TORQUES
TORQUE
PART
Nm kgm
Nut fixing king-pin to the side tie rod of the steering box 15 ÷ 20 1.5 ÷ 2

TOOLS
99305354 Tool for checking wheel geometry
99347074 Puller for king-pins

Print 603.93.281/A
CHECKING CHARACTERISTIC ANGLES

Before proceeding with the checks, it is necessary to perform Figure 9
a preliminary inspection at some of the vehicle members, which
can affect the geometry: if malfunctions are found, it is necessary
to eliminate them in order to avoid wrong detection.
The check to be performed are the following:
- tyre pressure;
- wheel hub bearing play
- play between steering tie rod pins and stub axle levers;
- shock absorber efficiency;
- unallowed deformation of the wheel rims.
Figure 7
23311
Lift the vehicle front part and position the floating wheels (1)
locking them with the locks (2).
33137 Figure 10
- Ensure the presence of spacers (1) between side
members (2) and tie rod (4) attachment mountings (3)
(with the exception of vehicles equipped with 5 mm thick
side members). If not, proceed as described on page 60.
NOTE The checks and possible operations on the wheel

geometry must be carried out with the vehicle at
static load. Make sure, periodically, that the optical
unit are perfectly calibrated.
For modification of the characteristic angles of the

! wheels, in vehicles with ESP, follow the calibrating
procedure of the steering angle sensor assembled in
the flywheel as described on page 63 of the Brake
Section.
25114
Perform the geometry check using the tool 99305354. Position the clutch jaw (1) fitted with fixing pins (2). Operating
the handgrip (3), lock the jaw on the wheel, making sure that
Positioning jaws and projectors it is perfectly secured.
Figure 8
Figure 11
1
2
1
2
3
33137
Place the vehicle with the wheel in straight running position on 32818
a level surface. Lift the rear of the vehicle and position the Assemble the detecting unit (1) on the jaws (3) and constrain
board (3). Lower the vehicle, brake the rear wheels and apply it with the screw (2). Repeat the operation on the other
the hook (1) with the slide rule (2). wheel.

Revi - February 2005
Print 603.93.281
Electronic balancing of rim eccentricity Figure 13
Figure 12
25120
Press the brake pedal locking it with the suitable tool (1)
positioned against the seat.
NOTE The wheels must be braked during the whole

measuring cycle.
32819
Connect the detectors plugs (7) to the transformer (6) and

switch on the switch (8); loosen the locking screw (2) of the
detector and lift the detector lens guard (7).
Make sure that the laser beam does not hit the eyes
of people, it will severely damage their sight.
Press the push-button ”out of centre” (1) for at least two Wheel alignment
seconds, the display (3) shows nine lines.
Manually rotate the wheel slowly in the running direction and Figure 14
project the light signal on the slide rule scale (5).
Stop the wheel when the signal read on the slide rule (5) has
reached the maximum value and note down the value (e.g. 12).
Rotate the wheel again until the minimum value is reached and
note it down (e.g. 8).
Calculate the mean value of the amplitude: 12 + 8 = 20 : 2 =
10 and position the wheel on the mean value calculated
marking its position.
Press the push-button ”out of centre ” again (1) until the LED
(4) of the wheel camber is lighted and on the display (3) a
fictitious value is shown.
52269
Repeat the operations on the other wheel.
Lower the vehicle so that the wheels, in the position previously Using the level (4) arrange horizontally the detectors (3) and
marked, completely rest at the centre of the floating discs (9). fix them to their position with the screw (2).
Loosen the floating discs (9) from their bases extracting the Move the slide rules (1) until they are centred by the light signal
pins (10). transmitted by the detector (3) and note down the values.

Figure 15 Figure 17
13952
If the values are different, steer the wheels until the light signal
indexes are set to two values equal (A) and exactly the mean 52270
value of the two previous readings. Repeat the same operations on the opposite detector and
In this way a perfect wheel alignment is obtained. read the toe-in value on the scales (in millimetres): the result
of the algebraic sum of the two values must be the prescribed
value.
Figure 18
32295
The positive or negative toe-in adjustment is carried out as

Checking toe-in follows:
Loosen the nuts (3) on the joint heads (2, right and left).
Figure 16 Turn tie rods (1) up to obtain the toe-in of each wheel equal
to half of the prescribed value.
Then tighten the nuts (3) to the prescribed torque.
Front wheel deviation test (vehicle wheelbase

check)
The front wheel deviation test and toe-in reading are carried
out at the same time.
The partial toe-in values, to be detected on the proper
straightedges divided into millimetres, must have the same
value and their sum must correspond to the whole toe-in
value.
25122
If between the readings there is a difference (e.g.: -2 and + 3),
it means that there is a deviation between the two wheels: a
Keeping the detectors in horizontal position and the wheels wheel onward as to the other wheel, equal to 5 lines of the
perfectly aligned, move the lens guard (2) using the lever (1) toe-in scale.
The number of lines is calculated by the algebraic sum
Operate the lever (3) and direct the light signal index on the
[+3-2(-1)=5] or counting the lines included between the two
slide rule scale (4) corresponding to the rim diameter.
values.

Each line corresponds to a deviation of 2 mm, so the deviation Checking king-pin angle and caster angle
between the two wheels is equal to 10 mm (5 x2).
For vehicles with torsion bar suspension: Figure 20
After determining which is the defective wheel, check its
conditions and the exact assembly dimension of the upper and
lower tie rods of the wheel suspension.
If the tie rods have been subject to deformations, replace
them; if the assembly dimension is wrong, screw or unscrew
the tie rod on the king-pin so that the vehicle wheel base is
adjusted and the wheel are on the same axis.
NOTE In order not to change wheel caster angle, a

lengthening or shortening of the lower tie rod must
correspond to a lengthening or shortening of the
upper tie rod.
32823
When the front wheels are aligned to the rear ones, loosen
the knurled knobs (3) and zero the graduated sector (2) on
For vehicles with transverse leaf spring the index (1) of the floating disc.
suspension:
The deviation error may be due to deformation of the frame
or of the assemblies connected to the wheels. Figure 21
32824
Steer the wheel 20° toward the inside; press twice the king-pin
camber push-button (2), the LED lights up and the display (1)
Checking camber shows 9 horizontal lines.
Figure 19 Figure 22
32821 32825
When the front wheels are aligned to the rear ones and the
detectors are on an horizontal plane, press the key wheel Steer the wheels 20° toward the outside, press the king-pin
camber (2) the LED lights up and the display (1) shows the camber push-button (2) and the display (1) shows the king-pin
camber angle value. camber angle.

Figure 23 - Steer the wheels until the floating disc index of the wheel
inside the bend in correspondence with the prescribed
steering angle.
NOTE For steering angles higher than 30°, it is necessary to

consider as reference index the mark 20° (1).
- under the above conditions, check on the other wheel

that the steering angle value is as expected;
- reverse steering and check again.
If different values are found, possible causes can be:
32826 - wrong centering of the steering box;
Without moving the wheel, press the caster angle - deformations caused by impacts;
push-button (2), the LED lights up and the display (1) shows
- deviation error between axles (front and rear axles)
the caster angle value.
higher than 20 mm.
Repeat these operations on the other wheel.
NOTE The king-pin camber angle and the wheel caster

angle are stored, after detection, by the instrument
and can be recalled when necessary pressing the
push-button relevant to the concerned angle.
For regulating the caster angle proceed as follows:

- set wheels in a straight running condition;
- press the kingping angle button until its relevant LED starts
blinking;
- screw and unscrew, as required, lower tie rod joint head, Checking rear axle alignment
considering that the joint head can’t carry out more than
one turn. Figure 25
Checking steering angles

Figure 24
44933
Apply the slide rule (1) to the front wheels checking that the
33134
cursor (2) is exactly in the middle of the two ring splines of the
shaft (3)
This check is carried out during the king-pin camber check of Apply the detectors to the rear wheels and proceed as already
during the caster angle check, making the following operations: described for the front axle wheels.
- if the prescribed steering angles exceed 30°, the mark
20°(1) on the floating disc (2) and the mark 30° (3) on
the graduated selector (4) mast be considered as initial
reference values.

Figure 26 Proceed as follows.

Measure external chassis width A1 at the axle.
If chassis width is not 864 mm (reference value A), subtract
your reading (for example, A1 = 859 mm) from the reference
value: 864 - 859 = 5 mm.
Divide this figure by 2 (5 : 2 = 2.5 mm).
2.5 mm is therefore the thickness of the compensating spacers
that should be fitted to each side member.
Spacers are supplied as spare parts in the following
thicknesses: 1 - 1.5 - 2 mm.
44934
Project the light signal on the slide rule (1) and mark the value
shown.
Repeat the measure on the other wheel and check that the
value is equal to the noted down value, otherwise carefully
check the vehicle rear axle assembly
If no malfunctions are detected, check that the frame is not
deformed, sticking to the procedures described in the section
”Body and frame”.
Figure 28
Calculating thickness of spacers to be fitted

between tie rod mountings and chassis side
members (with the exception of vehicles
equipped with 5-mm thick chassis or with
transverse leaf-spring suspension)
Figure 27
46952
Proceed as follows to install compensating spacers (1).

Dismantle:
- Rh and lh front engine guard (5 and 6).
- Engine oil sump guard (3).
- Rh and lh wheel guard (4 and 7).
46951
Introduction - Rh and lh side engine guard (2 and 8).

The external width of the chassis with reference to tie rod Position spacers (1) of the thickness calculated before, fit
mountings attachment point can vary from vehicle to vehicle mounting (10), screw in screws (11) and lock them to a torque
depending on chassis assembling tolerances and side member of 14.25 kgm (142.5 Nm).
thickness.
Reassemble all previously dismantled guards.
Therefore, width A (864 mm) is considered as an acceptable
reference value on which to base correct wheel geometry. When assembly is completed, check and adjust wheel
The above value results from the sum of chassis internal width geometry as required following directions provided in the
B (854 ± 2 mm) plus thickness D1 - D2 of a 4 mm thick chassis. relevant chapters.

DAILY EURO 4 SUSPENSIONS 1
SUSPENSIONS
SECTION 8
Suspensions
Page
FRONT AND REAR MECHANICAL

SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR AIR SUSPENSIONS . . . . . . . . . . . . . . . . . 81

2 SUSPENSIONS DAILY EURO 4

DAILY EURO 4 FRONT AND REAR MECHANICAL SUSPENSIONS 3
FRONT AND REAR MECHANICAL SUSPENSIONS
Front and rear

mechanical suspensions
Page
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT MECHANICAL SUSPENSIONS . . . . . . 9
REAR MECHANICAL SUSPENSIONS . . . . . . . . 51

4 FRONT AND REAR MECHANICAL SUSPENSIONS DAILY EURO 4

DIAGNOSTICS
FRONT AND REAR MECHANICAL SUSPENSIONS
Main possible suspension defects
1 - noisy suspension;
2 - the vehicle tends to drift to one side;
3 - excessive suspension flexibility;
4 - excessive suspension stiffness.
1 NOISY SUSPENSION
Insufficient lubrication. Lubricate carefully.

YES
NO
Shock absorbers noisy or inefficient. Check and if necessary replace shock absorbers.
YES
NO
Wheel bearings worn and with excessive backlash. Replace bearings or adjust backlash.
YES
NO
Wishbone spring bushes worn. Detach wishbones and replace bushes.

YES
NO
Wishbone articulated heads worn. Replace wishbone articulated heads.

YES
NO
Tie-rod articulated heads worn Replace tie-rod articulated heads.

YES
(vehicles with torsion bar suspension).
(Continues)

Steering knuckle nuts or fastening ring nuts loose Check and tighten nuts and fastening ring nuts to driving
YES torque.
(vehicles with torsion bar suspension).
NO
Stabilizer bar spring bushes worn. Replace spring bushes.

YES
NO
Stabilizer bar fastening screw nuts loose. Check and tighten to torque.
YES
NO
Suspension fastening nuts and screws loose. Check and tighten suspension fastening nuts and screws
YES to torque.
NO
Torsion bar toothing worn. Detach torsion bars and replace them and adjust
YES pre-loading.
NO
Toothing of torsion bar rear supports or of wishbones Replace rear support or upper wishbones and adjust
worn. YES torsion bar pre-loadings.
NO
Leaf spring supports loose. Check the supports and replace chassis fastening
YES screws or rivets if they are loose.
NO
Leaf spring pack loose for central fastening pin failure. Overhaul leaf springs and replace central pin and its
YES self-locking nut.
(Continues)

Leaf spring pack loose for spring fixing brackets Check leaf spring fixing brackets and replace fastening
fastening rivets failure. YES rivets.
2 THE VEHICLE TENDS TO DRIFT

TO ONE SIDE
Tyre pressure low or incorrect. Check and accurately inflate tyres to the prescribed
YES pressure.
NO
Incorrect front wheel geometry. Check and correct wheel geometry.

YES
NO
Too much front wheel bearing play. Replace the wheel hubs.
YES
NO
Inefficient hydraulic shock absorbers. Remove shock absorbers and replace them.
YES
NO
Torsion bar broken. Replace torsion bar and adjust pre-loading.

YES
NO
Incorrect torsion bar pre-loading adjustment. Check and adjust torsion pre-loading.
YES
NO
Leaf spring broken. Overhaul the leaf spring and replace if necessary.
YES
(Continues)

Incorrect vehicle loading. Check the load and arrange it evenly over the loading
YES area.
3 EXCESSIVE SUSPENSION
FLEXIBILITY
Torsion bars yielded. Replace torsion bars and adjust pre-loading.

YES
NO
Incorrect torsion bar pre-loading adjustment. Check and adjust torsion bar pre-loading.
YES
NO
Shock absorbers inefficient. Check and replace the shock absorbers if necessary.
YES
NO
Leaf spring central pin broken. Replace the component.

YES
NO
Leaf spring leaves yielded or broken. Overhaul the spring and replace the unusable
YES components or, if necessary, the entire spring.
4 EXCESSIVE SUSPENSION STIFFNESS
Incorrect torsion bar pre-loading adjustment. Check and adjust torsion bar pre-loading.
YES

DAILY EURO 4 FRONT MECHANICAL SUSPENSIONS 9
PRINT 603.43.351/D
Front mechanical suspensions

Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ARTICULATED QUADRILATERAL SUSPENSION
WITH TRANSVERSE LEAF SPRING . . . . . . . 11
- Front leaf spring . . . . . . . . . . . . . . . . . . . . . . . . 12
- Front shock absorbers . . . . . . . . . . . . . . . . . . . 14
- Front stabilizer bar . . . . . . . . . . . . . . . . . . . . . . 14
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Vehicles 29 L - 35 S . . . . . . . . . . . . . . . . . . . . . 15
- Vehicles 35 C . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Vehicles 29 L - 35 S - 35C . . . . . . . . . . . . . . . . 17
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Check the clearance of upper swinging arm
articulated head . . . . . . . . . . . . . . . . . . . . . . . . 18
- Check the clearance of lower swinging arm
OVERHAULING THE SUSPENSION . . . . . . . . . 19
- Suspension arms . . . . . . . . . . . . . . . . . . . . . . . 19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Replacing suspension arm bushings . . . . . . . . . 19
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . 21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

10 FRONT MECHANICAL SUSPENSIONS DAILY EURO 4
Print 603.43.351
Page Page
LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . 39
TORSION BAR SUSPENSION - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Axle 5819 - vehicles 35C - 40C - 45C - 50C . 25
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TORSION BAR SUSPENSION
SPECIFICATIONS AND DATA . . . . . . . . . . . . . 26 Axle 5823 - vehicles 60C - 65C . . . . . . . . . . . 41
- Front shock absorbers . . . . . . . . . . . . . . . . . . . 26 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
- Stabilizer bar diameter . . . . . . . . . . . . . . . . . . . 26 SPECIFICATIONS AND DATA . . . . . . . . . . . . . 42
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - Front shock absorbers . . . . . . . . . . . . . . . . . . . 42
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 29 - Stabilizer bar . . . . . . . . . . . . . . . . . . . . . . . . . . 42

- Vehicles 35 C - 40 C - 45 C - 50 C . . . . . . . . 29
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 46
- Check the clearance of upper swinging arm
articulated head . . . . . . . . . . . . . . . . . . . . . . . . 31 SUSPENSION OVERHAUL . . . . . . . . . . . . . . . . 46
- Check the clearance of lower swinging arm - Lower tie rod articulated heads replacement . 46
TORSION BARS . . . . . . . . . . . . . . . . . . . . . . . . . 46
OVERHAULING THE SUSPENSION . . . . . . . . . 33
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TIE RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Rubber bush replacement . . . . . . . . . . . . . . . . 47
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Replacing swivel heads . . . . . . . . . . . . . . . . . . . 33
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - Torsion bar preload adjustment . . . . . . . . . . . . 50
TORSION BARS . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Replacing silentbloc and limit stops . . . . . . . . . 35
- Replacing link pins . . . . . . . . . . . . . . . . . . . . . . 35
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Adjusting torsion bar pre-load . . . . . . . . . . . . . 38
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 39

MECHANICAL FRONT SUSPENSIONS

DESCRIPTION
The front suspension has independent wheels of the type:

- with an articulated quadrilateral with a transverse leaf spring for axles 5817 and 5818;
- with longitudinal torsion bars for axle 5819 and 5823.
ARTICULATED QUADRILATERAL SUSPENSION WITH TRANSVERSE LEAF SPRING

(vehicles 29l - 35s - 35c)
The suspension comprises:
- two top triangular suspension arms, composed of a sheet-metal shell, connected by elastic bushings to the crosspiece by pins
articulated to the stub axle;
- two bottom triangular suspension arms, composed of two sheet-metal half-shells welded together, connected by elastic
bushings with metal reinforcement to the crosspiece and pins articulated to the stub axle.
The bottom suspension arms have reaction points for the leaf spring and the bottom mountings of the shock absorbers;
- a single-blade leaf spring, made of composite material for axles 5817 mounted on vehicles 29 L and 35 S, steel for axles 5818
mounted on vehicles 35 C; the spring is kept inside the crosspiece by two top reaction plugs fitted on the ends of the spring
housed in the seats in the bottom suspension arms.
The steel leaf spring, due to the resistance it provides for the rolling movements of the vehicle, makes mounting the front
stabilizer bar superfluous;
- two double-acting hydraulic shock absorbers with integrated limit stops.
Figure 1
62102


Front leaf spring
Models: 29 L - 35 S
Transverse Nº 1
Spring length (mm) 1313.2

Sheet thickness
measured at (mm) A 39.92 ± 0.50
Sheet width
B 56.0 ± 0.5
measured at (mm)
C
81.0 ± 0.5
Figure 2
SECT. A-A
52322
COMPOSITE LEAF SPRING
NEW LEAF SPRING CHECK DATA

29 L 35 S
STATIC LOAD (N) 19865 21040
SAG WITH STATIC LOAD (mm) 71.7 68.4
DYNAMIC LOAD (N) 34270 37005
SAG WITH DYNAMIC LOAD (mm) 123.7 120.4
FLEXIBILITY ± 5%1 (mm/kN) 277 307.0
DISTANCE BETWEEN SUPPORT PLUGS (mm) 540 600

Front leaf spring
Models: 35 C
Transverse Nº 1
Spring length (mm) 1365 ± 3
Sheet thickness (mm) 20 ± 0.2
Sheet width (mm) 80 ± 0.5
Figure 3
50824
STEEL LEAF SPRING
NEW LEAF SPRING CHECK DATA

LOAD CAMBER FLEXIBILITY
POSITION (mm)
daN kg mm/100 daN mm/100 kg
STATIC LOAD 845.1 861.5 70.25
8 31
8.31 8 15
8.15
DYNAMIC LOAD 1453.3 1481.4 120.8

Front shock absorbers

Models: 29 L - 35 S - 35 C
Mannesmann - Sachs Arvin Meritor
Distance between centre of eyes:
Open (mm) 405  3
Closed (mm) 320  3
Stroke (mm) 85
Front stabilizer bar

Models: 35C - 40C - 45C - 60C* - 65C* 60C - 65C dual cab
Stabilizer bar diameter 24 22
* except for dual cab
NOTE The torsion bar is not provided for the COMBI version.
TOOLS
99321024 Hydraulic trolley for wheel removal and refitting
99347074 Extractor to take out link pins
99374179 Tool for disassembling and reassembling suspension arm flexible bushings

TIGHTENING TORQUES
Vehicles 29 L - 35 S
Figure 4
85873
TORQUE
COMPONENT
Nm kgm
1 Screw for nut securing steering gear housing 50 ÷ 61 5 ÷ 6.1
2 M12 screw for nut securing leaf spring mounting to the cross member 100 ÷ 124 10 ÷ 12.4
3 M10 screw for nut securing leaf spring mounting to the cross member 39 ÷ 48 3.9 ÷ 4.8
4 Nut for screw securing shock absorber top and bottom 124 ÷ 152 12.4 ÷ 15.2
5 Screw for nut securing shock absorber mounting to bottom suspension arm 39 ÷ 48 3.9 ÷ 4.8
6 Nut securing bottom suspension arm ball joint to the stub axle 160 ÷ 180 16 ÷ 18
7 Nut securing steering gear housing tie rod ball joint to the stub axle 68 ÷ 83 6.8 ÷ 8.3
8 Screw securing wheel 180 ÷ 200 18 ÷ 20
9 Nut securing hub to stub axle 256 ÷ 314 25.6 ÷ 31.4
10 Screw securing brake disc to wheel hub 19.5 ÷ 24 1.9 ÷ 2.4
11 Nut securing top suspension arm ball joint to the stub axle 125 ÷ 140 12.5 ÷ 14
12 Nut securing ball joint to the steering gear housing tie rod 70 ÷ 100 7 ÷ 10

TIGHTENING TORQUES
Vehicles 35 C
Figure 5
SECTION B-B
SECTION D-D
SECTION M-M
SECTION E-E
49351
TORQUE
COMPONENT
Nm kgm
1 Screw for nut securing steering gear housing 50 ÷ 61 5 ÷ 6.1
2 M12 screw for nut securing leaf spring mounting to the cross member 100 ÷ 124 10 ÷ 12.4
3 M10 screw for nut securing leaf spring mounting to the cross member 39 ÷ 48 3.9 ÷ 4.8
4 Nut for screw securing shock absorber top and bottom 124 ÷ 152 12.4 ÷ 15.2
5 Screw for nut securing shock absorber mounting to bottom suspension arm 39 ÷ 48 3.9 ÷ 4.8
6 Nut securing bottom suspension arm ball joint to the stub axle 160 ÷ 180 16 ÷ 18
7 Nut securing steering gear housing tie rod ball joint to the stub axle 68 ÷ 83 6.8 ÷ 8.3
9 Screw securing cover and brake disc to wheel hub 98.1 ÷ 107.9 9.8 ÷ 10.7
10 Screw retaining ring nut securing hub to stub axle 20 ÷ 24 2 ÷ 2.4
11 Ghiera fissaggio mozzo al fuso snodo 257 ÷ 314 25.7 ÷ 31.4
12 Stud to brake disc (apply LOCTITE 242 or 270 sealant to the thread) 85 ÷ 104 8.5 ÷ 10.4
13 Nut securing ball joint to the steering gear housing tie rod 70 ÷ 100 7 ÷ 10
14 Nut securing top suspension arm ball joint to the stub axle 125 ÷ 140 12.5 ÷ 14

TIGHTENING TORQUES
Vehicles 29 L - 35 S - 35C
Figure 6
SECTION H-H SECTION N-N
7
3
4 5
SECTION L-L SECTION F-F SECTION G-G
49352
TORQUE
COMPONENT
Nm kgm
Screw for nut securing suspension arm to the top cross member and bottom to 170 ÷ 280 17 ÷ 28
1-2
the cross member
3 Screw securing disc guard to the axle stub 6 ÷ 7.5 0.6 ÷ 0.7
4 Nut for screw securing cross member to chassis frame 83 ÷ 101 8.3 ÷ 10.1
5 Nut for screw securing cross member to chassis frame 83 ÷ 101 8.4 ÷ 10.1
6 Screw securing caliper mounting to the axle stub 170 ÷ 196 17.0 ÷ 19.6
7 M14 screw securing covers to the cross member 151 ÷ 184 15.1 ÷ 18.4

REPAIRS
Check the clearance of upper swinging arm Figure 9
articulated head
Figure 7
88673
By suitable lever (3) resting on articulated spindle (4), lift

swinging arm (2) as much as possible and reset comparator
88671
(1).
Adjust vehicle on flat ground and lock rear wheels.
Unloosen rear wheels securing nuts.
By a hydraulic jack, lift the vehicle on front side and rest it on
two supporting stands.
Unscrew wheels securing nuts and detach wheels again by NOTE In operation, take care not to damage the
hydraulic truck 99321024. protection cowling of articulated head .
Check that protection cowlings (1 and 2) of articulated heads
are not damaged.
Figure 8 Figure 10
88674
88672
By suitable pliers (2) applied on articulated head (1) and on
articulated spindle (4), apply strong pressure on head and
Apply the magnetic base of comparator 99395684 (1) to spindle and check comparator (3) hand displacement
brake disk (4) and position comparator tracer point on the corresponding to articulated head clearance.
top of the articulated head (2) of upper swinging arm (3). If detected value is between 1.5 and 2.0 mm, the swinging arm
Pre-load comparator by approximately 4 mm. needs to be replaced, as described in relating chapter.

Check the clearance of lower swinging arm

articulated head Figure 13
Figure 11
61665
Take out the nut (6) and remove the shock absorber (5) from
the mounting (8) of the bottom suspension arm, extracting
the screw (7).
88692 Take out the nuts (2), extract the screws (3) and remove the
bottom suspension arm (4) from the mountings of the cross
The check of the clearance of the articulated head (2) of
member (1).
lower swinging arm (1) is similar to the one of upper swinging
arm.
If detected value is between 1.5 and 2.0 mm, the swinging arm
needs to be replaced, as described in relating chapter.
500760 OVERHAULING THE SUSPEN- Replacing suspension arm bushings

SION Disassembly
Suspension arms
Removal
Figure 12 Figure 14
52325
61664
Remove the stub axle as described under the relevant NOTE If there is damage to the caps (3) protecting the link
heading (operation 520611 including removal of the wheel pins (2) or if these have too much play, replace the
hubs operation 520620). suspension arm (1).
Take out the nuts (2), extract the screws (3) and remove the
top suspension arm (4) from the mountings of the cross
member (1). Using general tools, extract the flexible bushings (4) from the
suspension arms (1).

Assembly
Figure 17
NOTE The flexible bushings of the bottom suspension arms

are equipped with metal reinforcement.
Figure 15
52328
Insert the spacer (2) into the bushing (1).

Apply the parts (3 - 4 - 5) of the tool 99374179, as shown
in the figure.
Screw on the nut (5) to fully insert the spacer (2) into the
flexible bushings (1).
52326
Insert the bushing (2) into the suspension arm (1).

Apply the parts (3 - 4 - 5 - 6) of the tool 99374179, as shown
in the figure.
Screw on the nut (6) to make the bushing (2) flush with the
suspension arm (1).
Remove the parts of tool 99374179.
Refitting
Figure 16 Figure 18
52327 74994
Insert the bushing (7) into the suspension arm (1). To refit the bottom (5) and top (1) suspension arms to the
Apply the parts (2 - 3 - 5 - 6) of the tool 99374179, as shown crosspiece (2), reverse the steps described for removal
in the figure. tightening the nuts (6 - 3) for the fixing screws (4 - 7) to the
prescribed torque.
Screw on the nut (6) to make the bushing (7) flush with the
suspension arm (1).
Remove the parts of tool 99374179. NOTE Self-locking nuts, once removed, must be replaced
with new ones.

500910 FRONT SHOCK ABSORBERS

Removal
Figure 19
74996
FRONT SHOCK ABSORBER

VEHICLES 29 L - 35S
Set the vehicle on level ground. Lock the rear wheels with a
scotch, remove the wheel rim guards and loosen the screws
or nuts fixing the wheel.
Lift the front of the vehicle and rest the chassis frame on sup-
ports.
Take out the screws or nuts fixing the wheel and remove
them with tool 99321024.
Unscrew the top and bottom bolts (2) and remove the shock
absorbers (1) from the vehicle.
Check that the bushings and/or elastic elements are

not worn or deteriorated; if they are, replace the rel-
evant part.
Check the efficiency of the shock absorbers with a suitable

instrument.
Refitting
For refitting, carry out the removal operations in re-
verse order and keep to the required tightening tor-
ques.


PRINT 603.43.351
LEAF SPRING Figure 20

Removal
Set the vehicle on level ground.
Lock the rear wheels with chocks. Take off the wheel rim
guards and loosen the screws or nuts securing the wheel.
stands.
Take out the screws or nuts securing the wheel with tool
99321024.
On the right-hand side:
- using a hydraulic jack, slightly lift the stub axle so as to
limit the load of the leaf spring;
- disconnect the electrical connection (1) for indicating
brake lining wear;
- disconnect the ABS speed sensor (4) (if there is one);
- take out the screws (2) securing the brake caliper to
the axle stub and remove it. Remove the brake linings
from the brake caliper (3) and support this adequately
to prevent strain on the brake pipes;
NOTE Check the state of the brake linings and brake disc
as described in the BRAKES section.
- take out the nut locking the link pin of the tie rod (20)
and, with tool 99347074 (19), remove the link pin (20)
of the steering tie rod from the stub axle;
- take out the nut (21) and, with tool 99347074 (19),
remove the link pin (22) of the top suspension arm
from the stub axle;
- take out the nuts (16) and screws (18) securing the
shock absorber mounting (15) to the bottom
suspension arm;
- lower the hydraulic jack;
Repeat the similar operations on the left-hand side;
- take out the nuts (6 and 5) and screws (10 and 11) and
remove the covers (8, 9 and 12) from the cross
member (7).
NOTE Note the assembly position of the bottom flexible

plugs (13) on the cover (8).
Remove the leaf spring (17).
NOTE Note the assembly position of the top flexible plugs

(14) in the cross member (7).
112173

Refitting Figure 21
Carry out the operations described for removal in reverse

order, but you must take the following precautions:
- fit the top flexible plugs (2) in the cross member (1) at
the position found during disassembly;
- fit the flexible plugs (4) onto the ends of the new leaf
spring (3);
- fit the leaf spring (3) into the cross member and
support it with a hydraulic lift;
- with two lifts arranged under the stub axles, lift them
together, checking that the flexible plugs (4) of the leaf
spring (3) get correctly positioned in the honeycomb
of the bottom suspension arms (5 and 8) and the
centre line (⇒) of the leaf spring is aligned with the
central holes (⇒) della traversa (1), of the cross
member (1), max. error ±2 mm;
- then complete refitting by tightening the screws or
nuts to the required torque;
- position the bottom flexible plugs (6) on the cover (7)
at the position found during disassembly;
- mount the cover (7) and tighten the screws and nuts
to the required torque.
NOTE The nylon self-locking nuts must be replaced with

new ones every time they are taken down.
NOTE To block rotation of the pins of the swivel heads

(9 - 10), insert a suitable Allen wrench into the
hexagon sunk in it.
61663

Print 603.43.351

(Axle 5819 - vehicles 35C - 40C - 45C - 50C)
Description The hydraulic shock absorbers are the double-acting
telescopic type.
The torsion bar suspension is composed of:
The side tie rods are mounted at the front to the chassis
- two bottom suspension arms.
frame mounting by means of adjustable link pins, and at the
- two top suspension arms; rear to the transverse levers.
- two longitudinal torsion bars; The purpose of the stabilizer bar, mounted on the bottom
reaction screw stays, is to maintain the parallelism between
- two hydraulic shock absorbers;
the axis of the wheels and the chassis frame, cancelling any
- two bottom reaction tie rods; load unbalance on the wheels mounted on the same axle.
- two top reaction tie rods; The purpose of the rubber pads fixed on the top mounting
of the shock absorbers is to limit the upward movement of
- a stabilizer bar; the suspension.
- two rubber pads.
The longitudinal torsion bars are anchored at the front to the
top suspension arms and at the rear to a mounting secured
to the chassis frame.
Figure 22
112216
ASSEMBLY DRAWING OF FRONT TORSION BAR SUSPENSION

Torsion bar suspension with independent wheels, stabilizer bar Models

and hydraulic shock absorbers 35 C 40 C 45 C 50 C
Torsion bar diameter mm 29
378 ± 0.15 mm
Top tie rod adjustment distance
220.4 ± 0.15 mm
364.5 ± 0.15 mm
Bottom tie rod adjustment distance
300.4 ± 0.15 mm
Models: 35 C - 40 C - 45 C - 50 C
Mannesmann - Sachs Arvin Meritor
Open mm 430  3 444  3 mm
Closed mm 280  3 286  3 mm
Stroke mm 150 158 mm
Stabilizer bar diameter
Models: 35 C - 40 C - 45 C - 50 C
Stabilizer bar diameter mm 20
NOTE The torsion bar is not provided for the COMBI version.

TOOLS
99321024 Hydraulic trolley for wheel removal - refitting
99347060 Extractor to take out tie rod link pins
99347074 Extractor to take out steering tie rod link pins and suspension arms
99357144 Wrench for ring nut securing link pins
Tool for disassembling and reassembling front suspension flexible

99374241 bushings


PRINT 603.43.351
TIGHTENING TORQUES
Vehicles 35 C - 40 C - 45 C - 50 C
Figure 23
62103
TORQUE TORQUE
DESCRIPTION DESCRIPTION
Nm kgm Nm kgm
1 Nut, reaction rod mounting upper fastening to chassis fixing screw 126 ÷ 154 12.8 ÷ 15.7 13 Ring nut, ball joint to upper/lower arms 83 ÷ 152 8.5 ÷ 15.5
2 Nut, reaction rod ball joint to mounting 98 ÷ 137 10 ÷ 14 14 Nut, ball joint to steering knuckle 157 ÷ 177 16 ÷ 18
3 Nut, reaction rod and knckle joint stiffener to chassis fixing screw 33 ÷ 49 3.4 ÷ 5.0 15 Nut, fixing will 180 ÷ 200 18 ÷ 20
4 Nut for screw fixing cross member to reaction rod support 126 ÷ 154 12.8 ÷ 15.7 16 Nut fixing steering box rod ball joint to stub axle lever 68 ÷ 83 6.8 ÷ 8.3
5 Nut, ball joint to upper tie rod 98 ÷ 137 10 ÷ 14 17 Hexagonal-head slotted nut, torsion bar to supension arm 84 ÷ 103 8.5÷10.5
6 Nut, upper tie rod to upper arm fastening screw 150 ÷ 183 15.3 ÷ 18.7 18 Nut, cross member upper fastening to bracket on chassis side member upper wing fixing 47 ÷ 58 4.8 ÷ 5.9
7 Nut, shock absorber upper and lower fastening screw 116 ÷ 142 11.8 ÷ 14.5 screw
8 Nut, lower bracket fastening screw suspension adjustment unit 151 ÷ 184 15.4 ÷ 18.8 19 Nut, cross member upper anchoring bracket to chassis side member upper wing fixing screw 18 ÷ 22 1.8 ÷ 2.2
9 Nut, torsion bar adjusting lever pin 254 ÷ 311 25.9 ÷ 31.7 20 Nut, upper and intermediate bracket fastening screw (suspension adjustment unit) 94 ÷ 115 9.6 ÷ 11.7
10 Nut, cross member to chassis side member lower wing fixing screw 72 ÷ 88 7.3 ÷ 9 - Screw for nut fixing front tubular cross member to side members 42 ÷ 51 4.2 ÷ 5.2
11 Nut for steering box fixing screw 50 ÷ 61 5 ÷ 6.1 - Nut, stabilizer bar clamps fixing screw 18 ÷ 22 1.8 ÷ 2.2
12 Nut, lower arms to cross member anchoring screw 206 ÷ 252 21.0 ÷ 25.7 - Rubber plug nut 68 ÷ 83 6.9 ÷ 8.5


REPAIRS
Check the clearance of upper swinging arm Figure 26
articulated head
Figure 24
88677
Remove screw (3) and detach tie rod (2) from lower
88675 swinging arm (1).
Adjust vehicle on flat ground and lock rear wheels.
Unloosen rear wheels securing nuts.
Figure 27
By a hydraulic jack, lift the vehicle on front side and rest it on
two supporting stands.
Unscrew wheels securing nuts and detach wheels again by
hydraulic truck 99321024.
Check that protection cowlings (1) of articulated heads are
not damaged.
Figure 25
88678
By suitable jack (2), positioned under wheel hub (1), load

suspension.
Figure 28
88676
Remove nut (5) and dismount shock absorber (1) from lower
swinging arm (2).
Unloosen nut (4) for the screw to secure lower swinging arm
(2) to cross member (3).
88679
Apply the magnetic base of comparator 99395684 (1) to

brake disk (2) and position comparator tracer point on the
top of the articulated head (4) of upper swinging arm (3).

Figure 29 Figure 31
88680 88682
Pre-load comparator (1) by approximately 4 mm and reset By suitable pliers (2) applied on articulated head (3) and on
it by suitable lever (4), lift upper swinging arm (3) as much lower swinging arm (1), apply strong pressure on head and
as possible and detect the displacement of comparator (1) arm and write down comparator (4) hand displacement
hand corresponding to the clearance of articulated head (2). corresponding to articulated head clearance.
If detected value is between 1.5 and 2.0 mm, the articulated If detected value is between 1.5 and 2.0 mm, the swinging arm
head (2) needs to be replaced, as described in relating needs to be replaced, as described in relating chapter.
chapter. Remount dismounted parts in order to make checks.
NOTE See Figure 26: the nut for screw (3) to secure tie rod
(2) to lower swinging arm (1) and see Figure 25: the
nut (4) for the screw to secure lower swinging arm
(2) to cross member (3): they must be tightened at
prescribed torque with the vehicle lowered and
vehicle empty weight weighing down on suspension.
Check the clearance of lower swinging arm

articulated head
Figure 30
88681
Position comparator (1) tracer point with magnetic base

99395684 on the top of the articulated head of lower
swinging arm (2).
By suitable lever, lower swinging arm (2) and reset
comparator (1).

PRINT 603.43.351
500760 OVERHAULING THE SUSPENSION

Figure 34
TIE RODS
Removal
Figure 32
75360
Take out the nut (3) for the screw (4) securing the tie rod
(1) to the top suspension arm (2) and remove the screw (4)
from this. Take out the nut securing the link pin (5) to the
44664 mounting (7). Using the extractor 99347074 (6), remove the
Remove the stabilizer bar as described under the relevant swivel head (5) from the mounting (7). Remove the screw
heading (operation 528030). stay (1) from the vehicle.
Take out the nut for the screw (2) securing the tie rod (3) NOTE If removing the mounting (7), so as not to change the
to the bottom suspension arm (1) and remove the screw (2) wheel geometry, not the number and thickness of
from this. the spacers (if there are any) under the mounting to
Take out the nut securing the link pin (5) to the mounting (4). mount them in the same way when refitting the
Using the extractor 99347060, remove the swivel head (5) mounting (7).
from the mounting (4).
500764 Replacing swivel heads
Figure 35
220 ± 0.5
2
378 ± 0.8
44666
Loosen the nut (2) and unscrew the swivel head (1) from the
top tie rod (3).
Screw the new swivel head (1) onto the tie rod (3)
Figure 33 positioning it at the values shown in the figure.
Figure 36
1
300.4 ± 0,.6
3
364.5 ± 0.7
19056
75359 Loosen the nut (2) and unscrew the swivel head (1) from the
bottom tie rod (3).
Using the extractor 99347060 (1), detach the stub axle (2) Screw the new swivel head (1) onto the tie rod (3)
from the mounting (4) Figure 22. positioning it at the values shown in the figure.
Remove the screw stay (3) from the vehicle. Tighten the nut (2) to the prescribed torque.

500666 TORSION BARS

Refitting
Removal
Figure 37 Remove the lower and upper tie-rods as described in the
relevant paragraph (operation 500761) and go on as follows:
Figure 39
44668
Refit the top tie rod (5) to the top suspension arm (3) and 44935
to the mounting (6). Remove the nut which fastens the articulated head (2) of the
Tighten the nut securing the link pin (1) to the required gearbox tie-rod to the steering knuckle; with the puller No.
torque. 99347074 (1) remove the articulated head (2).
Figure 40
NOTE The nut (4) for the screw securing the tie rod (5) to
the lever (3) must be tightened when the load of the
empty vehicle weighs on the suspension.
Figure 38
74997
Loosen the nut (2) and unscrew the threaded pin (1) until
the torsion bar (3) is fully ”unloaded”.
Take out the nuts (4) for the screws securing the mounting
(5) to the chassis frame.
Remove the mounting (5) from the torsion bar (3).
Figure 41
44664
Refit the bottom tie rod (3) to the bottom suspension arm
(1) and to the mounting (4).
Tighten the nut securing the link pin (5) to the required
torque.
NOTE The nut (2) for the screw securing the tie rod (3) to
the bottom lever must be tightened when the load
of the empty vehicle weighs on the suspension.
Re-fit the stabilizer bar. 44671

Remove the nuts securing the link pins (1) from the top (4)
and bottom (6) suspension arms to the stub axle (5).
NOTE At the end of the re-fitting check the wheels Support in an appropriate way the steering knuckle (5)
geometry as described in the relevant paragraph. together with brake caliper and wheel hub and with the tool
Then tighten the nuts, which fasten the articulated No. 99347074 (2) remove the steering knuckle (5) from the
head to the relevant tie-rods, to the prescribed levers (4 and 6).
torque. Place the steering knuckle (5) on a support without straining
the brake fluid hose and the electrical wires.

Figure 42 Replacing link pins

Figure 45
44672
19602
Take out the nut (5), remove the screw (4) and recover the Using tool 99357151 (1) loosen the ring nut and extract the
two washers. link pin (2) from the suspension arm.
Disconnect the bottom suspension arm (3) from the cross
member (1) extracting the bushing (2).
Figure 43
4
5
1 6
44673
Remove the split pin (6), the nut (5) and the washer (4).
Disconnect the top suspension arm (2) from the cross
member (3) extracting the torsion bar (1).
Replacing silentbloc and limit stops Figure 46
Figure 44
19603
19045
Fit the new knuckle pin (3) on upper and lower swinging arm
Silentbloc is replaced using tool 99374241 (1); the limit stops (1).
(2) are replaced with general tools. Loosen ring (2).

Figure 47 Figure 49
52370
19604
Position the top suspension arm (2) in the cross member.
With the tool No. 99357151 (1) fasten the ring nut (3,
Then insert the torsion bar (1), with the washer (3), in the
Figure 46) to the prescribed torque.
cross member and in the suspension arm.
Figure 50
Refitting 44674
Place the washer (1) and screw the nut (2) without tightening
it.
Figure 48
1 Figure 51
1
2
19046
NOTE The letters AD - AS, printed in the back of torsion

bars, indicate respectively the right bar and the left
19052
one.
Moreover the splined part has a double tooth (1) which, at Position the bottom suspension arm in the cross member
the reassembly, must correspond to the double spline (2) of and insert the bushing (1).
the upper lever. Insert the screw with its washers and screw the nut without
tightening it.

Figure 52 Figure 55
44675
Connect the stub axle (3) to the link pins of the top (1) and 44697
bottom (4) suspension arms. Tighten the fixing nuts (2) to
the required torque. Fit the stabilizer bar (1) back onto the bottom screw stays (2)
with the clamps (3), taking care that the screws (4) go into
Figure 53 the slots in the stabilizer bar.
Complete fitting the suspension back on by mounting the
shock absorber.
74998
Lubricate the grooved portion of the torsion bar (3).
Assemble the torsion bar (3) and the support (1) so that the
splines (2) of the toothed bush and of the torsion bar coincide.
Fix the support (1) to the chassis tightening the fastening
screw nuts to the prescribed torque.
Figure 56
Figure 54
7768
Refit the wheels, mount the nut guard and screw on the fixing
nuts; lower the vehicle, removing the stands..
Following the order shown in the figure, tighten the fixing
nuts to the required torque.
44676
Then tighten the torsion bar fixing nuts to the required
Refit the tie rods (4 and 7) to the suspension arms (1 and 6) torque and mount the safety split pins on them.
without tightening the nuts for the screws (3 and 5) to their
torque; connect the link pin (2) of the steering gear housing Tighten the nuts for the screws securing the top and bottom
tie rod to the lever of the stub axle and tighten the nut to the tie rods to their respective levers to the required torque.
required torque.

Adjusting torsion bar pre-load

Figure 57 Figure 58
20986
74999
TORSION BAR PRE-LOADING CONTROL DIAGRAM If the value is different, act on the adjusting screw (1) as much
H = mm, distance from ground of the side frame upper as you need it, but remember that, before acting on the
thread, measured as near as possible the suspension screw, it is necessary, to lift the vehicle with the hydraulic jack,
connecting area so that the wheels are lifted from the ground. This is
RSC = mm, loaded wheel radius necessary if you do not want to damage the screw.
Ensure that the wheel pressure complies with the prescribed Once the vehicle has reached the right position, lock the
one and check, with the suitable gauge, that the thread depth screw with the lock nut (2).
of tyres is more or less the same on both wheels.
Measure on both sides of the vehicle, the distance from
ground (H) of the side frame upper thread, measured as near
as possible the suspension connecting area.
The height H must correspond to the value given in the table
below.
HEIGHT OFF GROUND (H in millimetres) OF THE TOP EDGE OF THE CHASSIS FRAME IN RELATION TO THE
WEIGHT FOR MODELS 35C/40C/45C/50C WITH TORSION BAR DIAMETER 29 mm.
Tyres
Weight on the front wheels
(Kg)
195/75 R 16 6. 50 R 16
1200 610 629
1220 608 627
1240 606 625
1260 604 623
1280 603 622
1300 601 620
1320 599 618
1340 597 616
1360 596 615
1380 594 613
1400 592 611
1450 588 607
1500 584 602
1550 579 598
1600 575 593
1650 571 589
1700 566 585
1750 562 580
1800 558 576
1850 553 571
1900 549 567

528030 STABILIZER BAR 500910 FRONT SHOCK ABSORBERS

Removal Removal
Figure 59 Figure 60
75001
FRONT SHOCK ABSORBER

Vehicles 35C - 40C - 45C - 50C
Set the vehicle on level ground.
75000
FRONT STABILISER BAR supports.
Vehicles 35C - 40C - 45C - 50C Take out the screws or nuts fixing the wheel and remove
them with tool 99321024.
Unscrew the screws (2) fixing the half-brackets (3) and Unscrew the top and bottom bolts (2), then remove the
remove the stabilizer bar (1) from the vehicle, recovering the shock absorbers (1) from the vehicle.
rubber plugs (4).
Check that the bushings and/or elastic elements are Check that the bushings and/or elastic elements are
not worn or deteriorated; if they are, replace the not worn or deteriorated; if they are, replace the
relevant part. relevant part.
Refitting Using a suitable instrument, check the efficiency of the shock

absorbers.
To fit it back on, perform the steps carried out for
removal in reverse order, keeping to the prescribed Refitting
tightening torques.
To fit it back on, perform the steps carried out for
removal in reverse order, keeping to the prescribed
tightening torques.


PRINT 603.43.351

(Axle 5823 - vehicles 60C - 65C)
Description The hydraulic shock absorbers are the double-acting
telescopic type.
The torsion bar suspension is composed of:
The side tie rods are mounted at the front to the chassis
- two bottom suspension arms;
frame mounting by means of adjustable link pins, and at the
- two top suspension arms; rear to the transverse levers.
- two longitudinal torsion bars; The purpose of the stabilizer bar, mounted on the bottom
reaction screw stays, is to maintain the parallelism between
- two hydraulic shock absorbers;
the axis of the wheels and the chassis frame, cancelling any
- two bottom reaction tie rods; load unbalance on the wheels mounted on the same axle.
- two top reaction tie rods; The purpose of the rubber pads fixed on the top mounting
of the shock absorbers is to limit the upward movement of
- a stabilizer bar; the suspension.
- two rubber pads.
The longitudinal torsion bars are anchored at the front to the
top suspension arms and at the rear to a mounting secured
to the chassis frame.
Figure 61
ASSEMBLY DRAWING OF FRONT TORSION BAR SUSPENSION

PRINT 603.43.351/D
Torsion bar suspension with independent wheels, stabilizer bar Models

and hydraulic shock absorbers 60 C - 65 C
Torsion bar diameter mm 33
378 ± 0.8 mm
Top tie rod adjustment distance
220 ± 0.5 mm
369 ± 0.5 mm
Bottom tie rod adjustment distance
300.4 ± 0.5 mm
363.5 ± 0.5 mm
Lower linkage adjustment (for recently manufactured vehicles)
299 ± +0.3
0 mm
377 ± 0.15 mm
219 ± 0.15 mm
Models: 60 C - 65 C
Mannesmann - Sachs ARVIN
Open mm 430  3 400  3
Closed mm 280  3 280  3
Stroke mm 150 120
Stabilizer bar
60 C - 65 C
Models: Truck Cut Chassis
Twin cab Vans Semi-Glazed
Chassis Cabs Away Cowls
Stabilizer bar diameter mm 20 22
NOTE The torsion bar is not provided for the Combi version.

PRINT 603.43.351
TIGHTENING TORQUES
Figure 62
62103
TORQUE TORQUE
DESCRIPTION DESCRIPTION
Nm kgm Nm kgm
1
Nut, reaction rod mounting upper fastening to 13 Ring nut, ball joint to upper/lower arms 83 ÷ 152 8.5 ÷ 15.5
140 14
chassis fixing screw 14 Nut, ball joint to steering knuckle 157 ÷ 177 16 ÷ 18
2 Nut, reaction rod ball joint to mounting 98 ÷ 137 10 ÷ 14 15 Nut, fixing will 284.5 ÷ 343.3 28.4 ÷ 34.3
3 Nut, reaction rod and knckle joint stiffener to chassis fixing screw 41 4.1 16 Nut fixing steering box rod ball joint to stub axle lever 83 ÷ 68 8.4 ÷ 6.9
4 Nut for screw fixing cross member to reaction rod support 140 14 17 Hexagonal-head slotted nut, torsion bar to supension arm 84 ÷ 103 8.6÷10.5
5 Nut, ball joint to upper tie rod 98 ÷ 137 10 ÷ 14 18 Nut, cross member upper fastening to bracket on chassis side member upper wing fixing
52.5 5.2
6 Nut, upper tie rod to upper arm fastening screw 150 ÷ 183 15.3 ÷ 18.7 screw
7 Nut, shock absorber upper and lower fastening screw 116 ÷ 142 11.8 ÷ 14.5 19 Nut, cross member upper anchoring bracket to chassis side member upper wing fixing screw 20 2
8 Nut, lower bracket fastening screw suspension adjustment unit 151 ÷ 184 15.4 ÷ 18.8 20 Nut, upper and intermediate bracket fastening screw (suspension adjustment unit) 104 10.4
9 Nut, torsion bar adjusting lever pin 197 ÷ 241 20 ÷ 24 - Screw for nut fixing front tubular cross member to side members 42 ÷ 51 4.2 ÷ 5.2
10 Nut, cross member to chassis side member lower wing fixing screw 80 8 - Nut, stabilizer bar clamps fixing screw 24.5 2.4
11 Nut for steering box fixing screw 50 ÷ 61 5.1 ÷ 6.2 - Rubber plug nut 68 ÷ 83 6.9 ÷ 8.5
12 Nut, lower arms to cross member anchoring screw 206 ÷ 252 21.0 ÷ 25.7


PRINT 603.43.351
TOOLS
TOOL No. DESCRIPTION
99347027 Tool for removing front suspension rubber bushes
99347060 Extractor to take out link pins
99347074 Extractor to take out link pins and suspension arms
99357144 Tool for link pins fixing screw
99374166 Tool for refitting front suspension rubber bushes

REPAIR OPERATIONS
500760 SUSPENSION OVERHAUL Figure 65
NOTE It differs from suspension overhaul with torsion bars

for vehicles: 35C, 40C, 45C, 50C for the following
points.
500764 Lower tie rod articulated heads

replacement
Figure 63
61984
Loosen the nut (3) and loosen the threaded pin (2) until the
torsion bar (1) is completely ”released”.
NOTE Take note of the number of pin (2) threads above

nut (3); these data shall provide the starting point to
adjust the torsion bar after assembling..
NOTE For left torsion bar disconnect the fuel tank.

62926
Loosen the nut (2) and unscrew the articulated head (1)
from the upper tie rod (3).
Screw the new articulated head (1) on the tie rod (3).
Position it according to the values show in the above figure.
Figure 66
500666 TORSION BARS
Removal
Figure 64
62925
Remove the nut (2), withdraw the screw (3) and disconnect
the shock absorber (4) from the upper support (1).
Remove the nut (7) fastening the articulated head (6) from
the upper lever (5) to stub axle (8).
62924
Suitably support the stub axle (8) including the brake calliper
Remove the nut fastening the steering box tie rod kingpin (4) and the wheel hub and using tool 99347074 remove the
from stub axle lever; use puller 99347074 (2) to remove the lever (5) from the stub axle (8).
kingpin (4). Rest the stub axle (8) on a proper stand to prevent brake fluid
Remove suspension lever (1) upper tie rod (3). pipes and electric cables tensioning.

Figure 67 Rubber bush replacement

Removal
Figure 70
62931
Remove the circlip (1) from the sleeve (2) and remove it.
62929
Apply tool 99347027 (5) as shown in the figure.

Figure 68
Hold the screw (6), tighten the nut (4) and remove the
rubber bushes (3 and 7) from the cross member (1).
NOTE The rubber stop plug (2) is pressure-fitted to cross

member (1) and no tool is required for its
replacement.
Refitting
62927
Figure 71
Remove the lock nut (6), the nut (7) and withdraw the
washer (5).
Remove the torsion bar (2) with the washer (1) from the
upper lever (3) and remove it from the bracket (4).
Figure 69
62930
Position rubber bushes (2-5) in cross member (1).

Apply tool 99374166 (4) to bushes (2-5) as shown in the
figure.
62928 Hold the screw (6) and tighten the nut (3) until fitting in place
Remove the torsion bar (2) including the circlip (3) and the the rubber bushes (2-5).
washer (4) from the adjustment lever (5) and remove it from
the bracket (1).

Figure 72 Figure 75
62928
Set the adjustment lever (5) in the bracket (1) and insert the
torsion bar (2) including the washer (4) and the circlip (3). 44674
Set the washer (1) and screw the nut (2) without locking it.
Figure 73
Figure 76
3
19046
NOTE The rear part of the torsion bars is marked with

AD-AS to identify respectively the right bar and
the left bar.
44675
The splined part is provided with a double tooth (1), that shall
coincide at refitting with the double space (2) of the upper Connect the stub axle (3) to the upper lever (1) ball joint;
lever. tighten the fastening nut (2) to the specified torque.
Figure 74 Figure 77
52370 62931
Set the upper lever (2) in the cross member, then insert the Fit the sleeve (3) on the torsion bar (1) and in the adjustment
torsion bar (1), including the washer (3), into cross member lever (2) so that the marks on these components coincide as
and lever, making the double tooth coinciding with the shown in the following figure.
double space of the lever.

Figure 78
62934
AD. Right torsion bar AS. Left torsion bar
1. Bracket - 2. Adjustment lever - 3. Sleeve - 4. Torsion bar - 5. Washer - 6. Circlip - A. Front reference mark on sleeve (3)
- B. Front reference mark on adjustment lever (2) - C. Rear reference mark on sleeve (3) - D. Reference mark on torsion
bar (4) - E. Reference mark on left torsion bar - F. Reference mark on right torsion bar.
After refitting torsion bar (4)/ sleeve (3)/ adjustment lever (2), secure the sleeve (3) to the bracket with the circlip (6). Refit
the fuel tank (if removed).

Figure 79 Check whether tyre pressure is the specified one and then
using the proper gauge, check whether tyre tread depth is
almost the same on both wheels.
Measure on both vehicle sides the height (H) from ground
of side member upper edge - measured as close as possible
to suspension connection area
Height (H) shall correspond to the value specified in the
following table.
Figure 81
62935
Refit the tie rod (6) to the lever (3) without tightening to
torque the nut for screw (7); connect the articulated head
(4) of the steering box tie rod to the stub axle lever and
tighten the nut to the specified torque.
Connect the shock absorber with the screw (5) and the nut
(1) and tighten the latter to the specified torque.
Refit wheels, fit nut protection and tighten the fastening nuts;
remove stands and lower the vehicle.
Then tighten to the specified torque the following 62936
components:
- wheel fastening nuts;
- nut and lock nut fastening the torsion bars to the If a different value is found, operate on the adjustment screw
relevant levers; (1) as required, taking into account that before performing
- nuts for screws fastening the upper tie rods to the this operation the vehicle shall always be lifted from ground
relevant levers. with hydraulic jack to prevent screw damaging.
Adjust torsion bar preload as described in the following Once proper vehicle setup is obtained, lock the screw with
paragraph. the lock nut (2).
Torsion bar preload adjustment

Figure 80
Load on front Tyres

wheels
(Kg) 225/75 R 16 7.00 R 16
1400 672,0 691,0
1500 665.6 684.6
1700 652.6 671.6
1800 646,0 665,0
1900 639.4 658.4
2100 626.1 645.1
2300 612.8 631.8
2400 606.1 625.1
20986
2500 599.5 618.5
TORSION BAR PRELOAD CHECK DIAGRAM

H = mm, height from ground of side member upper edge
measured as close as possible to suspension connection area
RSC (Loaded radius):
- with 225/75R16 tyres, 345 mm with 2500 kg load
- with 7.00R16 tyres, 364 mm with 2000 kg load

DAILY EURO 4 REAR MECHANICAL SUSPENSIONS 51
Rear mechanical suspensions

Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 53
- Rear leaf spring . . . . . . . . . . . . . . . . . . . . . . . . 54
- Rear shock absorbers . . . . . . . . . . . . . . . . . . . . 71
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
- Vehicles 29 L - 35 S . . . . . . . . . . . . . . . . . . . . . 73
- Vehicles 35 C - 40 C - 45 C- 50 C . . . . . . . . . 74
- Vehicles 60 C - 65 C . . . . . . . . . . . . . . . . . . . . 75
REAR LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . 76
- Vehicles: 29 L - 35 S . . . . . . . . . . . . . . . . . . . . 76
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
- Vehicles: 35 C - 40 C - 45 C - 50 C -
60 C - 65 C . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
- Disassembling the leaf spring . . . . . . . . . . . . . . 78
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
- Assembling the leaf spring . . . . . . . . . . . . . . . . 78
- Replacing the bushings . . . . . . . . . . . . . . . . . . . 78
REAR SHOCK ABSORBERS . . . . . . . . . . . . . . . . 79
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 80
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

52 REAR MECHANICAL SUSPENSIONS DAILY EURO 4

DESCRIPTION
The rear suspension is composed of: The parabolic leaf spring is formed by leaves which have a
greater thickness in the middle than at the two ends.
- two leaf springs which, according to the vehicle, can be of
a semi-elliptic type with double flexibility or of a parabolic Leaves are spaced by means of shims and this reduces much
type with simple flexibility.; of the internal friction.
- two stop bumpers; The low internal friction and the particular form of the leaves
make the parabolic leaf spring more ”soft”, this makes driving
- two hydraulic double acting shock absorbers; easier.
- stabilizer bar. Hydraulic double-acting telescopic shock absorbers, hinder
The semi-elliptic leaf spring is very stiff because all leaves the wheel movement both upwards and downwards, allowing
forming the leaf spring have the same thickness from one end a great driving stability.
to the other. The stabilizer bar must keep the geometry between the wheel
Moreover, leaves are placed one against the other and this axle and the chassis and arrange the load evenly over the
causes a great internal friction which limits the movements of wheels on the same axle.
the leaf spring.
Figure 82
52371
REAR SUSPENSION


Rear leaf spring
Vehicles: 29 L - 35 S
mm
Parabolic springs No 2
L
Spring length 1500 ± 3
(measured at eye centres)
S
Leaf thickness (measured at centre) 24 (22)*
S Gap between leaves -
Leaf width 80 ± 0.5
L
CONTROL DATA WITH NEW SPRING:
Spring flexibility with static load 8.6 mm/kN
D Main leaf eye inner diameter

40 ± 0.5
(Bush seat)
D = bush outer diameter 40 +0

−0.1
D d
d = bush inner diameter 16.5 +0.2

−0
(*) Alternatively

Rear leaf spring

Vehicles: 35 C - Camper version
mm
L
S
Leaf thickness (measured at centre) -
S Gap between leaves 15
L
D Main leaf eye inner diameter 40 ± 0.5

(Bush seat)

−0.1
D d

−0

Rear leaf spring

Vehicles: 35 C
mm
L
S
Leaf thickness (measured at centre) 19
S 3
Gap between leaves
(1 x 3 + 1 x 25)*
L

(Bush seat)

−0.1
D d

−0
(*) For versions with maximum front load = 1900 kg

Rear leaf spring

Vehicles: 40 C chassis cowls
mm
L
S
L
Main spring flexibility with static load 7.6 mm/kN

(Bush seat)

−0.1
D d

−0

Rear leaf spring

Vehicles: 40 C
mm
L
S Leaf thickness (measured at the centre) 18

thickness of the auxiliary leaf (measured at the centre) 18
L

40 ± 0.5
(Bush seat)

−0.1
D d

−0

Rear leaf spring

Vehicles: 45 C
mm
L
S
Leaf thickness (measured at centre) 22 (23)*
L

40 ± 0.5
(Bush seat)

−0.1
D d

−0
(*) Alternatively

Rear leaf spring

Vehicles: 50 C
mm
L
S
L
Main spring deflection with static load
Auxiliary spring deflection with static load

40 ± 0.5
(Bush seat)

−0.1
D d

−0

Rear leaf spring

Vehicles: 60 C - 65 C
mm
L
S Thickness of the main leaves (measured at the centre) 18 (19)*

thickness of the auxiliary leaf (measured at the centre) 28
L
Main spring deflection with static load 9.3 mm/kN
Flexibility with static load after aux. spring action 3.4 mm/kN

40 +0.5
−0.2
(Bush seat)
D = bush outer diameter 40 +0.02

−0.07
D d

−0
(*) Alternatively

Rear leaf spring

Vehicles: 35 C
mm
Semi-elliptical springs No 2
L
(measured at centre of eyes)
Leaf thickness (measured at the centre),

S main leaf (1st - 4th) 9
auxiliary leaf (1st - 2nd) 15
S Gap between leaves --
L

(Bush seat)

−0.1
D d

−0

Rear leaf spring

mm
L

S main leaf (1st - 4th) 9
auxiliary leaf (1st - 3rd) 15
L

(Bush seat)

−0.1
D d

−0

Rear leaf spring

Vehicles: 45 C - 50 C (semi-elliptical with leaf spring)
mm
L

S master leaf (1st - 7th) 9
additional leaf (1st - 6th) 8
L
Main spring flexibility with static load 15 mm/kN

(Bush seat)

−0.1
D d

−0

Rear leaf spring

Vehicles: 45 C
mm
L

additional leaf (5th - 7th) 15
S Gap between leaves -
L

(Bush seat)

−0.1
D d

−0

Rear leaf spring

mm
L

L

(Bush seat)

−0.1
D d

−0

Rear leaf spring

Vehicles: 50 C
mm
L

L

(Bush seat)

−0.1
D d

−0

Rear leaf spring

Vehicles: 50 C
mm
L
S Leaf thickness (measured at the centre)

22 (24)*
master leaf
S Gap between leaves 3 (10)*
L

40 ± 0.5
(Bush seat)

−0.1
D d

−0
(*) Alternatively

Rear leaf spring

mm
L

additional leaf (1st - 2nd) 22
L

(Bush seat) 40 +0.5
−0.2

−0.07
D d

−0

Rear leaf spring

mm
L
Spring length 1415

auxiliary leaf thickness (1st - 10th) 7
L

(Bush seat) 40 +0.5
−0.2

−0.07
D d

−0
(*) Alternatively

Rear shock absorbers
Models: 29 L - 35 S
Arvin Meritor Sachs
Open 505 ± 3 mm 507 ± 3 mm
Closed 318 ± 3 mm 317 ± 3 mm
Stroke 187 mm 180 mm
Models: 35 C - 40 C - 45 C - 50 C
Arvin Meritor Sachs
Open 571 ± 3 mm 565 ± 3 mm
Closed 350 ± 3 mm 345 ± 3 mm
Models: 60 C - 65 C
Arvin Meritor Sachs
Open 564 ± 3 mm 565 ± 3 mm
Closed 347 ± 3 mm 345 ± 3 mm
Rear stabilizer bar

45 C - 50 C *
Models: 29 L - 35 S 35 C - 40 C * 45 C - 50 C *
Truck 60 C - 65 C *
Vans
Chassis Cabs
Stabilizer bar diameter (mm) 20 20 22 28
* The torsion bar is not provided for the COMBI version.

TOOLS
99306064 Hydraulic trolley to support leaf spring during removal and refitting
99370617 Bracket for removal - refitting and/or support of rear axle

TIGHTENING TORQUES
Vehicles 29 L - 35 S
Figure 83
C
A B
A--A C
B--B 112213
TORQUE
COMPONENT
Nm kgm
1 M10 nuts for screws securing leaf spring rear support to chassis 47 ÷ 58 4,7 ÷ 5,8
2 Securing leaf spring and shackle:
- M16 screw 160 ÷ 196 16,0 ÷ 19,6
- M16 nut 146 ÷ 178 14,6 ÷ 17,8
3 M16 nut securing shock absorber to chassis 124 ÷ 152 12,4 ÷ 15,2
4 M16 nut securing shock absorber to rear axle 124 ÷ 152 12,4 ÷ 15,2
5 M14 nuts for U bolts securing leaf spring to rear axle 118 ÷ 144 11,8 ÷ 14,4
6 M10 nut securing spring buffer support bracket 47 ÷ 58 4,7 ÷ 5,8
7 Securing articulated connecting rod to upper bracket:
- M16x2 screw 137 ÷ 167 13,7 ÷ 16,7
- M16x2 nut 124 ÷ 152 12,4 ÷ 15,2
8 M10x1.5 nut securing bracket for stabiliser bar to rear axle 32 ÷ 39 3,2 ÷ 3,9
9 M10 nut securing bracket for stabiliser bar support shackle 32 ÷ 39 3,2 ÷ 3,9
10 M8 nut securing spring buffer to bracket 16 ÷ 24 1,6 ÷ 2,4

TIGHTENING TORQUES
Vehicles 35 C - 40 C - 45 C- 50 C
Figure 84
SECTION A-A SEEN FROM B
50814
TORQUE
COMPONENT
Nm kgm
1 M16 nut for screw securing front leaf spring 139 ÷ 170 13.9 ÷ 17
Nuts for stands securing leaf spring to the rear axle M 14 74.5 ÷ 91.2 7.4 ÷ 9.1
2 M16 113 ÷ 170 11.3 ÷ 17
3 M16 nut for screw securing top and bottom shock absorber 124 ÷ 152 12.4 ÷ 15.2
4 M10 nut for screw securing stabilizer bar support cap 26.4 ÷ 35.3 2.6 ÷ 3.5
5 M10 nut for screw joining stabilizer bar anchoring connecting rods 26.4 ÷ 35.3 2.6 ÷ 3.5
6 M16 screw for nut securing connecting rod to mounting 179.4 ÷ 220.6 17.9 ÷ 22
7 M16 screw for nut securing rear leaf spring 139 ÷ 170 13.9 ÷ 17
8 M16 screw for nut securing shackle to rear mounting 139 ÷ 170 13.9 ÷ 17
9 M10 screw for nut securing connecting rod mounting to the chassis frame 43 ÷ 53 4.3 ÷ 5.3
10 M8 screw for nut securing buffer to the chassis frame 26.4 ÷ 35.3 2.6 ÷ 3.5

TIGHTENING TORQUES
Vehicles 60C - 65C
Figure 85
62937
TORQUE
COMPONENT
Nm kgm
1 Screw for front leaf spring fastening nut 186 ÷ 152 18.6 ÷ 15.2
2 M16 nut for upper and lower shock absorber fastening screw 92 ÷ 74 9.2 ÷ 7.4
3 Nut for stands fastening leaf spring to rear axle 150 ÷ 190 15.3 ÷ 19.3
4 Nut for screw fastening brackets and spacers to stabilizer bar supporting rod
5 Screw for rear leaf spring fastening nut 186 ÷ 152 18.6 ÷ 15.2
6 Screw for nut fastening connecting rods to support 186 ÷ 152 18.6 ÷ 15.2
7 Nut for screw fastening stabilizer bar spacer and rod to support 109.9 ÷ 137.7 11.2 ÷ 14
8 M10 screw for nut fastening support to chassis 26.4 ÷ 32.3 2.7 ÷ 3.3
9 Screw for nut fastening cross member to chassis 71.7 ÷ 87.7 7.3 ÷ 8.9
10 Nut fastening bumper to chassis 49 ÷ 40 4.9 ÷ 4

REAR LEAF SPRING

Figure 86
112177
REAR SUSPENSION WITH SINGLE-BLADE PARABOLIC LEAF SPRING
Removal Refitting
To re-fit, carry out the removal operations in reverse, taking

Set the vehicle on level ground. Lock the front wheels with the following precautions.
chocks. Loosen the screws securing the rear wheels.
Put the bracket 99370617 on a hydraulic lift, position it under
the rear axle and lift the vehicle. Check the threads of brackets which fasten the leaf
Rest the chassis frame on stands, keeping the bracket in springs to the axle; if they are damaged, re-machine
contact with the rear axle. the threads (operation 500412) or replace the
Take out the nuts securing the wheels with tool 99321024. brackets.
Check the conditions of bumpers (6), if they are damaged,
Take out the nuts (4) and remove the brackets (5) joining the replace them (operation 500417).
leaf springs (2) to the rear axle.
Position the trolley 99306064 under the leaf spring (2) and
fasten this to the trolley support with the brackets.
Take out the nuts and remove the screw (3) securing the leaf Tighten the nuts to the prescribed driving torque.
spring (2) to the front mounting (1). Following the order shown in the figure.
Take out the nut and remove the screw (7) securing the leaf
spring (2) to the shackle (8) of the rear mounting (9). After replacing the leaf springs and the hydraulic shock
Lower the trolley 99306064 and extract the leaf spring. absorbers, it is necessary to check the efficiency of the braking
control and, if necessary, carry out its adjustment (operation
796910. See Braking System Section).

Vehicles: 35 C - 40 C - 45 C - 50 C - 60 C - 65 C
Figure 87
50973
REAR SUSPENSION WITH SEMI-ELLIPTICAL LEAF SPRING

Removal Refitting
Set the vehicle on level ground. Lock the front wheels with To re-fit, carry out the removal operations in reverse, taking
chocks. Loosen the screws securing the rear wheels. the following precautions.
Put the bracket 99370617 on a hydraulic lift, position it under
the rear axle and lift the vehicle rest the chassis frame on
stands, keeping the bracket in contact with the rear axle.
Take out the nuts securing the wheels with tool 99321024. Check the threads of brackets which fasten the leaf
springs to the axle; if they are damaged, re-machine
Take out the nuts (5) and remove the brackets (4) joining the the threads (operation 500412) or replace the
leaf springs (3) to the rear axle. brackets.
Position the trolley 99306064 under the leaf spring and fasten
Check the conditions of bumpers (9), if they are
this to the trolley support with the brackets.
damaged, replace them.
spring (3) to the front mounting (1).
spring (3) to the shackle (7) of the rear mounting (6).
Operating the hydraulic lift, lower the rear axle to be able to
remove the centring setscrew of the leaf spring from it and
extract the leaf spring. Tighten the nuts to the prescribed driving torque.
Following the order shown in the figure.
After replacing the leaf springs and the hydraulic shock

When lowering the rear axle, make sure the brake absorbers, it is necessary to check the efficiency of the braking
control and, if necessary, carry out its adjustment (operation
! system pipes are not put under strain.
796910. See Braking System Section).

REPAIRS
Disassembling the leaf spring Assembling the leaf spring
Ensure that the leaf contact surfaces are perfectly smooth and
NOTE Leaf springs must be disassembled only Figure 88 if clean.
it is necessary to replace the main leaf (1) or the first Before re-assembling the leaves, grease contact surfaces with
leaf (4), in this case go on as follows. a little of CA IG Grease.
Re-assemble the pack as follows (see Figure 88):
In case other leaves are broken or yielded, replace
the whole leaf spring. - place the main leaf (1) with the end eyes in the end pin
of the 1st leaf (4);
- place the other leaves, included the one with the clip (5),
near the former ones, rest them on one side and align
them in the bench vice;
- insert through the central hole of the leaves, the central
Figure 88
pin (7), then lock the pack in the vice;
- insert the nut (2) on the central pin (7) and lock;
1
3 Figure 89
2
4
6
7
19075
19074
Place the leaf spring in the vice of the suitable bench, clamping - close the two side retaining clamps (5) by folding the ends
it near the central pin; remove the relevant nut and extract the back as shown in the figure.
central coupling pin.
Unscrew the fastening nut (2) of the central pin (7) and
extract the pin. Open the pack side clips (5), lifting the two
ends that are bent on the main leaf. Open the vice and
disassemble the leaf spring. 500454 Replacing the bushings
The leaf spring bushings (3) are replaced with the hydraulic
press and a suitable punch.
Side clips (5) fastened with a rivet (6) to the leaf, can
! be re-used, provided that they do not show signs of
breakage when they are re-bent to hold the pack. In
this case, it is necessary to replace them with new
ones to be fixed to the leaf with new rivets.
Checks
Carefully clean, with diesel oil or solvent, all

components; ensure that the bushes are firmly driven
in the spring eyes and shackles.
Check that the internal surface is not ovalized and that
the pins are not worn or strained, in case they are,
replace them.

500940 REAR SHOCK ABSORBERS

Removal Refitting
Remove the shock absorber (1) extracting the upper To re-fit shock absorbers carry out the removal
and lower fastening nuts or bolts (⇐) of the shock operations in reverse and comply with the prescribed
absorber. torques.
Figure 90
112214
REAR AXLE SHOCK ABSORBERS VEHICLES 29 L - 35 S

Figure 91
50977
REAR AXLE SHOCK ABSORBERS VEHICLES 35 C - 65 C

528960 STABILIZER BAR

Removal Refitting
Remove stabilizer bar (3) from its attachment points For refitting, carry out the removal operations in
by removing nuts (4) and screws (1) together with reverse and comply with the prescribed torques.
the fastening nuts, then release the bar from
articulated rod (2).
NOTE Check that the bushings and/or flexible parts are not
worn or deteriorated, if they are, replace them.
Figure 92
112215
REAR STABILIZER BAR VEHICLES 29 L - 35 S
Figure 93
50978
REAR STABILIZER BAR VEHICLES 35 C - 65 C

DAILY EURO 4 REAR AIR SUSPENSIONS 81
Rear air suspensions
Page
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . 83
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PNEUMATIC SUSPENSIONS - WABCO TYPE
(for R 29L - 35S vehicles) . . . . . . . . . . . . . . . . 84
- Air system components . . . . . . . . . . . . . . . . . 85
- Rear leaf spring . . . . . . . . . . . . . . . . . . . . . . . . 86
- Rear shock absorbers . . . . . . . . . . . . . . . . . . . 86
- Stabilizer bar . . . . . . . . . . . . . . . . . . . . . . . . . . 86
- Levelling and height values . . . . . . . . . . . . . . . 86
ELECTRIC SYSTEM WABCO (ECAS) . . . . . . . . 87
PNEUMATIC SYSTEM WABCO (ECAS) . . . . . . 88
PNEUMATIC SYSTEM ON VEHICLE . . . . . . . . 89
- Vehicles without ABS . . . . . . . . . . . . . . . . . . . 89
- Vehicles with ABS . . . . . . . . . . . . . . . . . . . . . . 90

CHASSIS SELF-LEVELLING, LIFTING AND
LOWERING . . . . . . . . . . . . . . . . . . . . . . . . . . 91
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
MAIN SYSTEM COMPONENTS . . . . . . . . . . . . 91
PNEUMATIC SUPPLY UNIT . . . . . . . . . . . . . . . 91
- Specifications and data . . . . . . . . . . . . . . . . . . 91
ELECTRONIC CONTROL UNIT . . . . . . . . . . . . 91
- ECU programming/setting . . . . . . . . . . . . . . . . 92
LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 92
- Level sensor replacement . . . . . . . . . . . . . . . . 92
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
- Level sensor adjustment . . . . . . . . . . . . . . . . . 92
AIR SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
- Air spring replacement . . . . . . . . . . . . . . . . . . 93
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

82 REAR AIR SUSPENSIONS DAILY EURO 4
Page
LOAD SENSING VALVE . . . . . . . . . . . . . . . . . . 93

- Load sensing valve replacement . . . . . . . . . . . . 94
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
- Load sensing valve adjustment on vehicle . . . . 94
REAR SUSPENSION OVERHAUL . . . . . . . . . . . 95
LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
REAR SHOCK ABSORBERS . . . . . . . . . . . . . . . . 95
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
REAR STABILIZER BAR . . . . . . . . . . . . . . . . . . . 95
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
PANHARD REACTION BAR . . . . . . . . . . . . . . . 96
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

DIAGNOSTIC
Print 603.93.281
Pneumatic suspension main failures:

1 - Poor or irregular pneumatic system supply;
2 - Vehicle irregular conditions.
1 POOR OR IRREGULAR PNEUMATIC

SYSTEM SUPPLY
Pneumatic system pipe leaks or breakage. Tighten or replace loosen or damaged connections.
YES Replace broken or damaged pipes.
NO
Electrocompressor malfunctioning. Overhaul or replace.

YES
2 VEHICLE IRREGULAR CONDITIONS
Pneumatic system pipe leaks or breakage. Tighten or replace loosen or damaged connections.
YES Replace broken or damaged pipes.
NO
Faulty pneumatic and/or electric connections. Find and reset faulty connections.
YES
NO
Level sensor malfunctioning. Adjust levers and replace level sensor if required.
YES
NO
ECU malfunctioning. Replace ECU.

YES

GENERAL
These pneumatic suspensions show high flexibility and significant Electronic-control pneumatic suspensions enable, through the
vibration damping. Their main characteristic is that the distance proper push buttons located in the cab, to change manually the
between chassis and road level, irrespectively of vehicle load, distance between chassis and road level and therefore the
remains constant due to the effect of the automatic adjustment height of the vehicle load bed.
of the system. The following two types of pneumatic suspensions are
currently adopted:
Electronic-control pneumatic suspensions are activated
automatically when starting the vehicle. - WABCO pneumatic suspensions for 29L - 35S vehicles
- Streparava pneumatic suspensions for 35C - 40C - 45C -
50C - 60C - 65C vehicles.
PNEUMATIC SUSPENSIONS - WABCO TYPE (for 29L - 35S vehicles)
WABCO system in addition to known advantages offered by The above mentioned operations are bound to preset
pneumatic suspension, enables the following: operating conditions and to the relevant system safety
requirements.
- significant air consumption reduction; The ECU controls automatically the chassis level (distance from
- ready response to the different adjustment processes; road level), through the real values provided by sensors and
compares these values to the rated ones stored in its memory.
- friendly systems;
If the driving position is changed, the electronic control unit
- high safety performance; governs the electro-pneumatic assemblies, by means of which
- complete system diagnostic. the actual level is corrected in relation to the nominal level set
or saved by the driver.
The WABCO system controls automatically the rated level of
vehicle pneumatic suspensions.
Figure 94
62350

Figure 95
62349

Air system components
COMPONENT
Pneumatic supply unit
- Type: WABCO 415 403 402 0
Operating temperature - 30ºC to 65ºC
Max. operating pressure 12.7 bar
Rated voltage 12V DC
Pressure control 14 to 17.1 bar
Level sensors
- Type: WABCO 441 050 012 0
ECU
- Type: WABCO 446 055 450 0
Rated voltage 12V
Double circuit load sensing valve (vehicles without ABS)
- Type : BOSCH NM/FV/98-347 (ref. 796803)
Ratio 0.15
Pneumatic actuator
- Type : ELLENA EE6492
Operating temperature - 20ºC to 80ºC
Operating pressure max 8 bar
Air tank (litres) 31
Rear air spring (Mod. 29 L - 35 S)
Max. diameter 171 mm
Min. length 350 mm
Max. length 150 mm

Rear leaf spring
mm
No 2
Spring length
(measured between eye centre and air spring 1073 ± 6
connection)
Leaf thickness
24 ± 0.3
(measured at the securing point to rear axle)
- 0,05
Bush seat inner diameter 40 - 0,2
-0
D = bush outer diameter 40.2 - 0.15

−0
Rear shock absorbers
Mannesmann ARVIN
Sachs MERITOR
Length between eye centres:
Open mm 460 ± 3 460 ± 3 480 ± 3
Closed mm 315 ± 3 315 ± 3 315 ± 3
Stroke mm 145 145 165
Stabilizer bar
Models: 29 L - 35 S
Stabilizer bar diameter (mm) 20
Levelling and height values
Distance between upper chassis edge and road level

Suspension condition Max. distance (mm)
(mm)
Max. height 620 + 40
Self-levelling 580 -
Min. height 520 - 60

ELECTRIC SYSTEM WABCO (ECAS)

Figure 96
61099
Legend
20000 Battery 52502 Key switch
25926 Relay for enabling suspension lifting and stopping 53051 Suspension lifting control switch
the lowering function 53052 Suspension lowering control switch
25927 Relay for enabling suspension lowering and 58713 Failure warning led
stopping the lifting function 58918 Board with 32 optical indications plus instruments
42354 Pneumatic suspension system failure switch 78233 Vehicle lifting solenoid valve unit
52090 Suspension levelling switch 86023 Vehicle lifting/lowering control unit

PNEUMATIC SYSTEM WABCO (ECAS)

Electronic-control
Figure 97
000216T
Legend
1 - ECU (ECAS). 15 - Right chassis control solenoid valve.
2 - Manual chassis levelling control switch. 16 - Left chassis control solenoid valve.
3 - Chassis lifting control switch. 17 - Choke valve.
4 - Chassis lowering control switch. 18 - Drier filter
5 - Warning light ECAS. 19 - Air spring discharge solenoid valve.
6 - Stop light switch. 20 - One-way valve.
7 - Speedometer - tachograph.
21 - Compressor.
8 - Right air spring.
22 - One-way valve
9 - Right level sensor.
10 - Hydraulic load sensing valve*. 23 - Intake filter.
11 - Load sensing valve control pneumatic cylinder*. 24 - Compressor motor
12 - Left level sensor. 25 - Motor control relay
13 - Left air spring. 26 - Diagnosis socket
14 - Electrocompressor and distribution valve unit. * For vehicles without ABS only.

Print 603.93.281
PNEUMATIC SYSTEM ON VEHICLE

Vehicles without ABS
Figure 98
112174
Legend
1 - Warning light
2 - Right level sensor
3 - Right air spring
4 - Chassis lowering control button
5 - Manual chassis levelling control button
6 - Electronic control unit
7 - Chassis lifting control button
8 - Hydraulic brake corrector
9 - Corrector control pneumatic cylinder
10 - Left air spring
11 - Pneumatic feeding unit
12 - Left level sensor
13 - Central diagnosis connector

Vehicles with ABS

Figure 99
112175
Legend
1 - Warning light
2 - Right level sensor
3 - Right air spring
4 - Chassis lowering control button
5 - Manual chassis levelling control button
6 - Electronic control unit
7 - Chassis lifting control button
8 - Left air spring
9 - Pneumatic feeding unit
10 - Left level sensor
11 - Central diagnosis connector

CHASSIS SELF-LEVELLING, LIFTING AND Figure 101

LOWERING
Figure 100
62356
This unit produces the compressed air required to supply the

pneumatic system and enables to bleed air from the
pneumatic system to lower the load bed.
112176
766175 ELECTRONIC CONTROL UNIT
Operation
Figure 102
The system consists of the following:
- Pneumatic supply unit (electrocompressor, solenoid
valve unit);
- One ECU;
- Two level sensors;
- Two air springs;
- Three levelling push buttons (1, 2, 3);
- One warning light (4).
Level sensors send to ECU the signals corresponding to
chassis-road distance. The ECU processes these signals,
generates accordingly activation signals and sends them to the
electrocompressor.
Turn the ignition key to ”MAR” and depress push buttons (1,
2, 3) for lifting, lowering or activating the self-levelling function
of the chassis.
This system enables vehicle running up to 20 km/h under
whatever height and level condition. When this speed is
exceeded, chassis automatic levelling is activated.
62357
Variation operations are indicated by warning light (4) blinking.
MAIN SYSTEM COMPONENTS The ECU is the mastermind of the system.

It controls every logic function of suspensions under both
790560 PNEUMATIC SUPPLY UNIT static and dynamic stage.
ECU receives signals from the control switches set in the cab
Specifications and data and lifts and lowers the load bed accordingly. It also receives
Type Wabco signals from the level sensors and controls the
Lubrication Dry operation electrocompressor and the air spring to keep the vehicle in the
Max. operating pressure 12.7 bar self-levelling condition.
Operating temperature -30 C° to 65° C
Rated voltage 12V DC ECU indicates any system failure through the dedicated
warning light set on the instrument panel.

Print 603.93.281/A
ECU programming/setting Level sensor replacement

WABCO ECU is not requiring programming since it is Removal
supplied already programmed.
Figure 104
Setting can be performed by MODUS, E.A.SY. and IT2000
diagnostic systems and shall be performed when replacing the
following:
- ECU;
- level sensor;
- level sensor levers.
Connect the diagnostic tool to the 38-pin socket and proceed
as follows to obtain correct setting:
- check and adjust to 110 mm the level sensor lever length,
if required;
- lift the chassis by depressing the proper video push
button (max. lifting);
- Insert the special spacers provided (99346151) between
the chassis and the rear axle measuring 65 mm; 62460
- lower the chassis completely by depressing the proper

video push button (max.lowering); Disconnect the electrical connection (2), loosen the screw
(⇒) and disconnect the levers. Loosen the fastening screws
- set ECU by depressing the proper video push button. and remove the level sensor (1).
Refitting
Reverse removal operations to perform refitting.
768822 LEVEL SENSOR Perform level sensor and ECU setting as shown in the
Figure 103 relevant paragraphs ”ECU programming/setting” and
”Level sensor adjustment”.
Level sensor adjustment

Figure 105
62358
Level sensors inform constantly the ECU on distance changes

between chassis and road level.
62584
Level sensors consists of a coil secured to the chassis and a
small piston.
When chassis height changes, a cam and a lever linked to the
axle make the piston move inside the coil, thus modifying its Operate on adjustment screws and set relay lever X value to
inductance. 110 mm.
These changes will be used by the ECU in the different stages Perform ECU setting as shown in the relevant paragraphs
of the system. ”ECU programming/setting”.

Revi - February 2005
Print 603.93.281
500731 AIR SPRING 784310 LOAD SENSING VALVE

62359
Air spring is an elastic element dedicated to contain pressure

air and to change its extension irrespectively of the applied
load. 62361
Vehicles not fitted with ABS/EBS/ABD systems have been

provided with the following components to obtain brakeforce
Air spring replacement distribution:
Removal
- double circuit load sensing valve;
Figure 107 - load sensing valve pneumatic actuator.
The load sensing valve controls automatically the braking
torque produced by brakes on the rear axle, according to the
load applied on the rear axle, measured and transferred to the
load sensing valve of the pneumatic actuator.
The following diagram shows the brakeforce distribution ratio
corresponding to 0.15 as a function of pneumatic pressure
change inside air springs.
Figure 109
62360
Position the vehicle on level ground.
Lift the rear part of the vehicle and rest the chassis on the
proper stands.
Use the hydraulic jack to support the rear axle.
Bleed the system and disconnect the air spring (3) supply pipe
(2).
Loosen upper (1) and lower fastening nuts.
62362
Lower the rear axle and remove the air spring (3). Legend
A Hydraulic output pressure in bar;

Refitting B Hydraulic control pressure in bar;
C Pneumatic control pressure in bar;
D Characteristic curves, 0.15 ratio (without load);
E 1:1 ratio (with load);
F Pneumatic pressure/load characteristic curves.

Load sensing valve replacement Perform required operations in the following sequence:
Removal - position the vehicle with the rear wheels set on the brake
Figure 110 test bed 99336914;
- connect gauges 99372269 or Modus to pressure control
intakes set upstream and downstream connector;
- should gauges not be fitted with valves for automatic
bleeding, bleed air by loosening the suitable ring nuts
Figure 112
62433
Bleed the system, loosen the screws (3) and disconnect the
pneumatic actuator (2).
Loosen the fastening screws of the load sensing valve (1) and
remove it including the pneumatic actuator (2).
62578
Refitting
- Loosen nut (1);
- apply 5 kg to plate (3) in point (2);
Perform load sensing valve adjustment as shown in the - start engine;
relevant paragraphs ”Load sensing valve adjustment - disconnect the pneumatic actuator (4);
on vehicle”. - with engine running at idle, depress the brake pedal
gradually until obtaining 100 bar pressure read on the
Load sensing valve adjustment on vehicle gauge set upstream connector. This value shall be constant
This device shall be checked and adjusted, if required, at and shall be read on vehicle with load and without load;
regular intervals by checking the values indicated on the plate - simulate the fully laden condition by lifting completely the
(Figure 111) located on the internal part of the engine hood. relay lever (3) and the unloaded condition by lowering the
lever completely;
- read output pressure value under both vehicle conditions
(laden and unloaded); obtained values shall comply with
Should the plate or the relevant technical data be those indicated on the plate, otherwise replace the load
! missing, ask the manufacturer for a duplicate sensing valve;
specifying the following: - operate the relay lever (3) to check whether the load
- Vehicle type and wheelbase sensing valve piston is sliding smoothly into its seat,
- Rear axle weight otherwise replace the load sensing valve;
- Load sensing valve No. - reconnect the pneumatic actuator (4);
- load the vehicle to obtain 1500 kg weight on the rear axle
evenly distributed on the right and left side of the vehicle
Figure 111
with ± 5 kg tolerance;
- with engine running at idle and 100 bar pressure read on
the gauge set upstream the connector, check whether the
output pressure value read on the gauge set downstream
the connector is corresponding to the values indicated on
the plate, otherwise replace the load sensing valve;
- stop the vehicle, tighten nut (1) to the specified torque and
remove applied loads.
Perform this check with gradually increasing pressure.

!
To check the load sensing valve, every braking system
component shall be in perfect operating conditions. When
replacing the leaf spring for special set-up, a new plate is
required with properly corrected values.
62577
- when tests are over, check brake performance.
LOAD SENSING VALVE PLATE

500730 REAR SUSPENSION OVERHAUL

500450 LEAF SPRING
Removal
Figure 113
62365
Position the vehicle on level ground. Lift the rear part of the Refitting
vehicle and rest the chassis on the proper stands. Use the
hydraulic jack to support the rear axle.
Bleed the system, remove the wheel, loosen the air spring
lower fastening screw (1). Loosen shock absorber lower Reverse removal operations to perform refitting.
fastening nut (3) and disconnect it.
Loosen nuts (2) and remove the U bolts (4) and the elements
securing the leaf spring to the rear axle.
Loosen and remove the pin (6) and remove the leaf spring (5). 528960 REAR STABILIZER BAR
Refitting Removal
Figure 115
500940 REAR SHOCK ABSORBERS

Removal
Figure 114
62364
Operate on both vehicle sides.
Loosen the screws (1) and the nut (3). Remove the stabilizer
bar (4) including the joints (2).
Refitting
62363
Lift the rear part of the vehicle and use the jack to support the
rear axle. Loosen the upper (3) and the lower (1) fastening
nuts and remove the shock absorber (2).

PANHARD REACTION BAR

Removal
Figure 116
62368
Loosen the ”Panhard” reaction bar (4) fastening screws (3 and Refitting
5) and remove it.
Loosen the relay rod (2) fastening screws (1 and 6) and Reverse removal operations to perform refitting.
remove it.

DAILY EURO 4 WHEEL AND TYRES 1
SECTION 9
5025 Wheel and tyres
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . 4
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FAULT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 5
STATIC BALANCING OF THE WHEELS . . . . . . 8
TYRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 9
HOW TYRE BEHAVIOUR DEPENDS

ON PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 9

2 WHEEL AND TYRES DAILY EURO 4

DESCRIPTION
The wheel rim represents the rigid structure of the wheel and
Figure 2
is identified by the following dimensions:
- diameter of the rim, measured at the base of the
circumferential groove (i.e., on the surface on which the
air chamber rests);
- width of the circumferential groove in the wheel rim (i.e.,
the distance between the surfaces on which the cover
rests).
The tyre has the following functions:
- to absorb the greater part of the jolts caused by roughness
of the road surface by utilising the elasticity of air;
- to generate on the ground the motive force supplied by
the engine necessary for the vehicle to move;
- to ensure the maximum grip and stability of contact
between the tyre and the road, with satisfactory tyre life;
- to withstand the forces generated by sudden braking,
hard acceleration and by the thrust of centrifugal force on
bends;
- to ensure the stability of the vehicle even at high speeds;
to ensure the steerability of the vehicle.
Figure 1
44929
S = Tyre section rated width (mm)

H = Tyre height
D = Max. utilisation diameter (Rx2)
R = Radius under load (static)
Ø = Fitting diameter
E = Min. distance between centres in case of paired tyres
e = Tyre deflection
CdR = Rolling circumference
44928
1. Tyre section rated width (mm)

2. Tyre height-width ratio percentage e.g., H/S = 0,75
3. Tyre structure (R = Radial)
4. Wheel rim diameter in inches
5. Load and speed index symbols
113: tyre load index on simple axis: 1150 kg
111: tyre load index on paired axis: 1090kg
Speed category (N= 140 km/h)
6. Manufacturer’s trade name:
XC A tubeless (IL): tyres without inner tube.

Tyre pressure
Inflation pressure
Tyre type
3,5 bar 4 bar 4,75 bar
weight on front axle
195/65 R16
simple in kg 1410 1569 1800
TL102/104R weight on front axle
TL102/104Q
twin in kg 2663 2963 3400
195/75 R16
simple in kg 1527 1700 1950
TL105/107Q
twin in kg 2898 3225 3700
205/65 R16 simple in kg 1527 1700 1950
TL105/107T weight on front axle
twin in kg 2898 3225 3700
215/65 R16 simple in kg 1613 1795 2060
twin in kg 3055 3399 3900
225/65 R16 simple in kg 1754 1952 2240
twin in kg 3321 3695 4240
Inflation pressure
Tyre type
4 bar 4,5 bar 5,25 bar
225/75 R16
simple in kg 2124 2334 2640
TL116/118Q weight on front axle
TL116/118R
twin in kg 4022 4420 5000
NOTE The pressures indicated refer to cold tyres and an outside temperature of 20ºC.

TOOLS
99305037 Electronic equipment for front wheel balancing on the vehicle
FAULT DIAGNOSIS
Main tyre malfunctions:
1 - Excessive wear.
2 - Irregular wear.
3 - Wehicle pulls to one side.
1 EXCESSIVE WEAR
Excessive speed on particularly uneven ground Reduce speed

YES
NO
Sudden variations in speed, violent or harsh braking Avoid all unnecessary acceleration or braking
YES
NO
Excessive speed with tyre pressures too low Check tyre pressures cold
YES
NO
Tyres pressures too high Reduce pressures

YES
NO
Truck overloaded Consult data on loads permitted

YES

2 IRREGULAR WEAR
Difference in tyre pressures between one pair of Check pressure

wheels and the other YES
NO
Tyre pressures too low; wear more accentuated on the Increase tyre pressure
outsides of the tread than in the middle YES
NO
Tyre pressure too high, with excessive wear in the Reduce pressure
middle of the tread YES
NO
Insufficient toe-in of front wheels; substantial wear on Check and adjust toe-in
the inside surfaces of the tread YES
NO
Front wheel geometry incorrect Restore normal wheel geometry

YES
NO
Distortion of wheel rims causing imbalance If possible, repair the rims or replace; then balance the
YES wheels
NO
Tyres incorrectly fitted to rims Fit the tyre correctly and balance the wheel
YES

Rear axle out of parallel due to breakage of the leaf

Overhaul the suspension
spring centre pin, or springs of different lengths, or bent YES
springs
NO
Excessive toe-in of front wheels; excessive wear of the Check and adjust toe-in
outside surfaces of the tread YES
3 VEHICLE PULLS TO ONE SIDE
Front wheels out of balance Balance the wheels

YES
NO
Front tyres at different pressures Check pressures ensuring that both are at the correct
YES value
NO
Excessive difference in wear between a pair of tyres Replace excessively worn tyre
YES

502511 STATIC WHEEL BALANCING

Figure 3 Turn up the spin switch (6) to the second speed and place the
balancing machine against the tyre.
While the wheel is being spun, it will be found that the
stroboscopic effect on the wheel will make the reference
mark appear stationary; the pointer of the instrument (1),
moving from the value zero, reaches a maximum value on the
scale and then returns to zero.
When the pointer has begun to fall back, withdraw the
balancing machine, turn off the spin-up switch (6) completely
and brake the motor by means of the brake lever (7).
The wheel continues to revolve due to inertia and the
reference mark made on the tyre moves; the point to which
the reference mark has moved should therefore be noted.
Read off from the instrument (1) the value shown by the
pointer, multiply it by 10, giving the value of the balance weight
The front wheels can be balanced on the vehicle using the to be fitted to the rim.
electronic unit 99305037; this has the advantage of balancing
the wheel together with the other rotating masses.
The operation must be carried out as follows: Figure 5
- Raise the front of the vehicle and make sure that the
wheels are free to rotate
- Position the imbalance detector (1) under the axle close
to the wheel being examined, arranging the height so that
the spin-up wheel of unit 99305037 (2) is in contact with
the tyre; position a support stand under the opposite side
of the axle and lower the hydraulic jack.
16998
Figure 4 Fit the balance weight calculated in this way as shown in the
figure.
If during the test, the pointer of the instrument (1, Fig. 4)
remains in the green area of the box, the wheel is balanced.
NOTE If the weight required to balance the wheel is more

than 60 ÷ 80 grams, divide the weight in half and
position the two parts so formed with one half on
the inside and one half on the outside of the rim,
making sure that they are in the same position.
Figure 6
16997
- Connect the cable (3) of the imbalance detector to unit

99305037
- Make a reference mark on the tyre by drawing a radial
mark with chalk or using a strip of gummed paper
- Turn switch (2) to the static balancing position and
sensitivity switch (4) to notch no. 5 on the graduated scale
- Turn on switch (5) for instrument light (1) and strobe
lamp switch (8).
23885
- Turn the spin-up switch (6) of unit 99305037 to the first
speed position so as to make the wheel rotate. To correct the residual imbalance, repeat the operations
already carried out as above; depending on the new reading
of the instrument (1, Fig. 4), refer to the diagram in the figure
and proceed as follows to adjust:

- If the weight is in the zone marked with the letter A, this Figure 7
means that it is too light, and in that case weight must be
added as indicated by the instrument (1, Fig. 4).
- If the weight is in the bottom zone marked with the letter
C, this means that it is too heavy and in that case the
weight must be reduced as shown by the measuring
instrument.
- If the weight is found to be in the zones marked with the
letters B or D, do not remove or add any weight but
instead move it 5 cm upwards in the direction of the
arrows, see Fig. 6.
- 40%
502510 TYRE PRESSURE
The tyre pressures must be checked with the tyres cold. EFFICIENCY 40%
Take great care that the pressure is correct since, if it is higher
than required, a harsh ride and excessive wear of the centre
of the tread will result, while if it is lower, the load is not Figure 8
distributed over the whole tread but is concentrated at either
side, causing premature wear of these areas and also damaging
the internal structure of the tyre.
Unequal pressures between tyres affects the driving stability
of the vehicle and impairs operating safety.
Tyre abnormal wear can occur in different areas of tread.
+ 20%
EFFICIENCY 90%
HOW TYRE BEHAVIOUR DEPENDS ON Figure 9

PRESSURE
Schematic views to demonstrate how tyre behaviour and
performance depend on pressure.
NOTE The value shown inside each tyre indicates the level
of pressure of the tyre, while the efficiency relates
to the life of the tyre.
CORRECT
EFFICIENCY 100%


DAILY EURO 4 STEERING GEAR 1
SECTION 10
5014 Steering gear
Page
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 3
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER STEERING SPECIFICATIONS AND DATA 4
- Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . 11
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
POWER STEERING TYPE TRW . . . . . . . . . . . . . 12
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER STEERING TYPE ZF . . . . . . . . . . . . . . . 14
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHECKS AND OPERATIONS ON THE VEHICLE 16
- Checking maximum pressure . . . . . . . . . . . . . . 16
- Checking hydraulic steering centre

(for ”ZF” power steering only) . . . . . . . . . . . . 16
- Bleeding the air from the hydraulic system . . . . 16
SWIVEL HEADS . . . . . . . . . . . . . . . . . . . . . . . . . 16
PROTECTION CASINGS . . . . . . . . . . . . . . . . . . 16
STEERING GEAR CONTROL . . . . . . . . . . . . . . 16
- Vehicles equipped with an Air-Bag . . . . . . . . . . 16
SAFETY STANDARDS TO BE OBSERVED DURING

REPAIR OR MAINTENANCE OPE- RATIONS
ON VEHICLES EQUIPPED WITH AIR-BAG SYSTEM
PROVIDED BY SUPPLIER . . . . . . . . . . . . . . . . 17
- Preliminary Standards . . . . . . . . . . . . . . . . . . . . 17
- Repairs and inspections required after an accident 17
- Accidents with or without Air-Bag

module activation . . . . . . . . . . . . . . . . . . . . . . 17

2 STEERING GEAR DAILY EURO 4
Page
- Accidents with Air-Bag module activation . . . . 17
- Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Risks for health . . . . . . . . . . . . . . . . . . . . . . . . 18
- Overexposure effects . . . . . . . . . . . . . . . . . . . 18
- Safety Standards to observe when handling Air-Bag

modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Air-Bag module scrapping . . . . . . . . . . . . . . . . 19
- Safety Standards to observe when handling

pretensioners . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Pretensioners scrapping . . . . . . . . . . . . . . . . . . 20
- Operations on system components . . . . . . . . 20
- Removing and scrapping activated Air-Bag module

and pretensioner from vehicle . . . . . . . . . . . . . 20
- Removing and scrapping non-activated Air-Bag

module from a repairable vehicle . . . . . . . . . . 20
- Air-Bag module deployment

Remote activation . . . . . . . . . . . . . . . . . . . . . . 21
- Activating Air-Bag modules and electronic

pretensioners installed on unrecoverable vehicles 21
- Upper steering gear shaft removal . . . . . . . . . . 23
- For vehicles equipped with Air-Bag . . . . . . . . . 23
- For all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Lower steering gear shaft removal . . . . . . . . . . 24
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HYDRAULIC POWER STEERING . . . . . . . . . . . . . 25
- Hydraulic power steering removal . . . . . . . . . . 25
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Steering linkage replacement . . . . . . . . . . . . . 26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Rubber bushing replacement procedure . . . . . 26
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . . 28
- Power steering pump overhaul procedure . . . 28

STEERING GEAR It has two functions:
General - angle driving between spin axis of the steering control and
the wheels’ steering axis.
Generally, the steering gear members consist of: a full steering
gear control, a steering box, the linkage joining the driving - gear down through the coupling ratio the resistant
wheels and, for the hydraulic-type steering box of: an hydraulic moment opposing the wheels under the steering effect.
pump, an oil tank and oil piping. The value of this ratio and the wheel geometry characteristics
In vehicle system 35C-65C with F1C engine, there is installed (toe-in - camber - caster), determine the stress and the type
a pipe coil (A) to cool oil. of steering, more or less direct; this increases or decreases the
The rotary movement given to the steering wheel by the driver sensitivity of the vehicle attitude on road; besides, it
driver is transmitted to the steering box by three shafts joined determines the steering caster action degree, that is, the
one another by universal joints. spontaneous return to straight normal running when the
The universal joints allow the transmission of the rotary steering wheel is released after steering.
movement on different planes.
The upper shaft, on which the steering wheel is keyed, is The tie rods joining the steering levers mounted on stub axles
housed and supported in the upper support by elastic bushes. using knuckle heads are joined by ball joints at the end of the
In addition, the indicator automatic switch-off and the antitheft rack rod. Operating the tie rod the wheel camber is adjusted.
steering lock are keyed to the support. The hydraulic pump is of the blade type:
The steering box is of the type: pinion - rack rod with hydraulic - on F1A engines, it is flanged to the alternator support;
power. - on F1C engines, it is flanged on the left side of the engine base.
The pump incorporates the overpressure control valve.
Figure 1
88735
STEERING GEAR DIAGRAM

POWER STEERING SPECIFICATIONS AND DATA

Steering gear
Steering gear Hydraulic
Hydraulic power steering Pinion and rack type

Type ZF* TRW
Operating pressure X 100 bar
Maximum delivery volume -
No. of steering wheel turns 3,8
R k travell in
Rack i both
b h steering
i directions:
di i 180  1,5
1 5 mm
Type TEXAND F020 SHELL-ALVANIA LS00
Lube oil pinion side kg - 0,060
pipe end side kg - 0,030
Power steering pump blade type with pressure relief valve incorporated
Motor FIA FIC

Type ZF 7612 955117 ZF 7682 955133
Minimum RGM rpm 500 750
Maximum RGM rpm 8500 3500
Maximum pressure bar 100 + 10 115+10
Minimum delivery dm3/min - -
Adjusted delivery dm3/min 9 ± 0,75 9 ± 0,8
Turning circle (theoretical value) [m]
Wheelbase [mm] MODELS

29 L - 35 S 35 C (1) 35 C (2) - 40 C - 45 C - 50 C 60 C - 65 C
Tyres 205 - 225/70 R 15 195/65 R 16 195/75 R 16 225/75 R 16
3000 10,37 10,34 11,04 -
3300 11,25 11,22 11,98 11,79
3450 11,69 11,66 12,46 12,25
3750 12,57 12,54 13,40 13,17
3950 13,15 13,12 14,03 13,78
4100 - 13,56 14,50 (3) 14,24
4350 - - 15,29 (4) 15,01
4750 - - 16,55 (4) 16,24
(1) Front suspension with trasverse leaf spring.
(2) Front suspension with torsion bar.
(3) Models 35C-40C only
(4) Models 45C-50C only

TIGHTENING TORQUES
52376
TORQUE
DESCRIPTION
Nm kgm
1 Screw, steering box fastening nut 50 ÷ 61 5 ÷ 6,1
2 Nut securing the jointed head to the steering box rod 70 ÷ 100 7 ÷ 10
3 Nut, ball joint to steering arm 68 ÷ 83 6,8 ÷ 8,3
SPECIFIC TOOLS
99347074 Knuckle pivot extractor

DIAGNOSTICS
Main hydraulic power steering operating faults:
1 - Steering stiff when turning right and left; 6 - Excessive play at the steering wheel;
2 - Steering stiff only when turning left or right; 7 - Loss of oil;
3 - Steering stiff when the wheel is turned quickly; 8 - Insufficient pressure in the circuit;
4 - When steering, heavy jolts are felt at the wheel; 9 - The vehicle tends to move sidewards;
5 - Torsional vibration of the steering wheel; 10 - Hydraulic power steering pilot light always lighted.
STEERING STIFF
1 WHEN TURNING
RIGHT AND LEFT
Insufficient oil in system Open tank and check oil level. With engine running, top
YES up oil to upper mark on dipstick and bleed system.
NO
Air in hydraulic circuit Check suction tube and pump shaft seal for leaks. Bleed
YES system and top up the oil
NO
Pump regulating valve jammed or blocked Replace the power steering pump
YES
NO
Insufficient oil pump delivery Overhaul or replace pump.

YES
NO
Universal joint not serviceable Make joint free to slide by moving it to and fro several
YES times so that it tilts under its own weight
NO
Internal power steering failure Replace the power steering unit

YES

STEERING STIFF ONLY WHEN

2 TURNING LEFT OR RIGHT
Incorrect position of hydraulic centre (when wheel is

Replace the power steering unit
released, the steering returns to one end of travel by YES
itself): (ZF steering case only).
STEERING STIFF WHEN THE WHEEL

3
IS TURNED QUICKLY
Regulating valve in pump blocked Replace the power steering pump

YES
NO
Insufficient pump delivery (gears worn) Replace the hydraulic pump

YES
NO
Air in steering system Check suction tube and pump shaft seal for leaks. Bleed
YES system and top up the oil
WHEN STEERING, HEAVY JOLTS

4 ARE FELT AT THE WHEEL
Play in universal joint Fit a new seal

YES
NO
Internal failure of hydraulic power steering Replace the power steering unit
YES
NO
Insufficient oil in system Top up oil and bleed system

YES
(Continue)
Front wheel geometry incorrect Check and adjust according to specifications in the section
YES ”Axles”
NO
Wheels out of balance Balance in accordance with instructions given in the

YES section ”Wheels and tyres”
NO
Steering rod joints loose on the levers Replace any worn parts
YES
NO
Irregular pump operation Replace pump

YES
NO
Leakage of oil from hydraulic power steering circuit Check coupling seals for serviceability, replacing any
couplings YES which are worn
5 TORSIONAL VIBRATION OF THE

STEERING WHEEL
Wheels out of balance Balance in accordance with instructions given in the

YES section ”Wheels and tyres”
NO
Wrong wheel toe-in Adjust in accordance with characteristic data for

YES described in the section ”Axles”
NO
Air in hydraulic system Check suction tube and pump shaft seal for leaks. Bleed
YES system and top up the fluid.

6 EXCESSIVE PLAY AT THE

STEERING WHEEL
Play in ball joints and/or elastic supports loosen Secure the supports
YES Replace the ball joints
NO
Play in universal joint Replace universal joint

YES
NO
Internal failure of hydraulic power steering Replace the power steering unit
YES
7 LOSS OF OIL
Tank cover not secured Secure cover

YES
NO
Seal gaskets worn Replace worn seal gaskets, top up oil and bleed
YES
In any case it is necessary to determine the place and the reason why there is oil leakage, eliminate the cause, top up oil in
the tank with the engine started up to the upper mark of the dipstick.
INSUFFICIENT PRESSURE
8
IN THE CIRCUIT
Hydraulic pump not operating correctly Replace the power steering pump
YES
(Continue)
Oil leaking from couplings in power steering Check coupling seals for serviceability, replacing any
circuit YES which are worn
NO
Insufficient oil level in the tank Top up level and bleed circuit
YES
THE VEHICLE TENDS TO Replace the power steering unit

9 MOVE SIDEWARDS
10 HYDRAULIC POWER STEERING PILOT

LIGHT ALWAYS LIGHTED
Hydraulic power steering oil level low Top up oil

YES
NO
Oil pressure sender malfunction Check the windings and in case replace oil pressure
YES sender.

POWER STEERING
Description
Figure 2
3
1 2
4 E
24103
HYDRAULIC POWER STEERING SYSTEM DIAGRAM
HIGH PRESSURE LOW PRESSURE
The power steering system consists of: Figure 3

- a tank (A);
1
- a blade pump (B) with delivery regulating valves (C);
- a series of connecting pipings (D);
- an hydraulic power steering (E). 2
The oil tank, in the engine compartment, feeds the blade pump.
This pump is able to provide a feeding pressure ranging from
a minimum of approx. 4 bar to a maximum of approx. 80+10. 3
The oil come to the steering box, which is similar to a A
mechanical steering as for general building features, from the 6
pump. 4
In fact, its operation is mechanical for pinion to rack coupling,
The rack rod is joined to the wheels with two side tie rods.
The system is self-bleeding; bleeding is performed by
completely steering to the right or to the left with the engine
started and the vehicle stopped. 5
The oil level check must be performed with the engine started.
24104
The distributor consists of:

NOTE The description below concerns the TRW hydraulic - a drive shaft (1) (joined to the steering column);
power steering and due to their similarity, it also
- a distributing valve (4);
applies to the ZF hydraulic power steering.
- a wrench bar (3);
The hydraulic part of the steering box consist of: - a pinion (6).
- a distributor (3); The drive shaft is elastically joined by the wrench bar to the
- an hydraulic cylinder (1); pinion by means of the pin (2). The distributing valve, trigged
on the drive shaft is integral with the pinion by means of a pin
- a double-acting piston (4) integral with the rack rod. (5); it has holes and splines in order to receive and distribute
the oil flow to the hydraulic cylinder. Besides, a stiff joint (A)
The hydraulic connection between distributor and hydraulic
ensures the mechanical working of the hydraulic power
cylinder is achieved using two stiff pipes (2). The distributor (3)
steering in case of failure of the hydraulic system, through a
is integral with the hydraulic power steering pinion.
bayonet joint.

POWER STEERING TYPE TRW

Operation
Figure 4
24105
The hydraulic cylinder (1) is integral part of the hydraulic power steering, The double-acting piston (2) (integral with the rack rod)
slides in the hydraulic cylinder and divides it into two separate chambers A and B.
The power steering is obtained by sending oil under pressure into one of the hydraulic cylinder chambers and discharging it into the
other one. The power generated by the oil pressure on the side surface of the piston causes the movement of the piston and, as
a result, of the rack. The feeding of one of the two hydraulic cylinder chambers occurs when the torque applied to the steering wheel
causes the wrench of the bar; in this condition, the port of the drive shaft and the relevant ports of the distributing valve are joined
depending on the rotary direction of the steering wheel. If the amount of torque applied to the steering wheel does not cause the
wrench of the bar (low wheel resistance), the power steering does not intervene and the steering operates as a mechanical one.
Figure 5
24106
HYDRAULIC POWER STEERING OPERATION DIAGRAM: NEUTRAL POSITION

The oil coming from the pump through the joint (3) goes into the distributing valve, circulates in it and returns in the tank through
the joint (4), simultaneously passing through the chambers (2) and (1).
The drive shaft (A), since it is not subject to wrench, is centred with respect to the distributing valve (B) and drives the oil coming
from the pump directly into the tank through the ports (C). The chokes caused by the shaft (A) position with respect to the
distributing valve (B) cause a pressure of ~ 3.5 bar in the right and left chamber through the ports (D) and (E).

Figure 6
24108
HYDRAULIC POWER STEERING OPERATION DIAGRAM: RIGHT STEERING

The oil coming from the pump through the joint (3) goes into the distributing valve and it is sent to the hydraulic cylinder chamber
(1) causing the movement of the piston.
This movement pushes the oil contained into the chamber (2), through the joint (4), into the tank, passing again in the distributing
valve. The movement of the piston in the direction of the arrow shows a right steering.
The drive shaft (A), rotating clockwise with respect to the distributing valve (B), drives the oil under pressure coming from the pump
through the ports (C), to the left chamber along the ports (E) and joins the discharge and the right chamber circuit by means of the
ports (D).

Figure 7
24107
HYDRAULIC POWER STEERING OPERATION DIAGRAM: LEFT STEERING

The oil coming from the pump through the joint (3) goes into the distributing valve and it is sent to the hydraulic cylinder chamber
(2) causing the movement of the piston. This movement pushes the oil contained into the chamber (1), through the joint (4), into
the tank passing again in the distributing valve.
The movement of the piston in the direction of the arrow shows a left steering.
The drive shaft (A), rotating clockwise with respect to the distributing valve (B), drives the oil under pressure coming from the pump
through the ports (C), to the left chamber along the ports (D) and joins the discharge and the right chamber circuit by means of
the ports (E).
POWER STEERING TYPE ZF

Operation
Figure 8
HYDRAULIC POWER STEERING OPERATION DIAGRAM: NEUTRAL POSITION

19594
With the steering wheel positioned to straight running, the bush (2) is arranged so that the passage of both feeding and discharge
oil of the operating cylinder is closed.
The oil pressures in the right and left chamber of the operating cylinder are balanced.
The oil under pressure coming from the power steering pump (4) through the piping (5) feeds the distributor (1) central grove, flows
in the bush (2) splines, goes out from it and, through the piping (6) returns in the tank (3).
The neutral position of the hydraulic power steering is obtained and, therefore, the vehicle straight ride.

Figure 9
19595
HYDRAULIC POWER STEERING OPERATION DIAGRAM: RIGHT STEERING
The oil under pressure coming from the power steering (4) pump, through the piping (5), feeds the distributor (1) passing in the
central groove.
The rotation of the steering wheel causes a semi-rotation of the bush (2), this one is positioned so that the oil flows in its three splines
and is sent to: the distributor upper groove, in case of right steering (figure 10), or in the distributor lower groove, in case of left steering
(figure 11). The latter sends it to the relevant feeding piping (depending on the steering direction) of the operating cylinder chambers.
Meanwhile, the oil contained in the chamber opposite to the fed one returns in the distributor. From the latter one, it flows in the
discharge grooves of the bush (2) then, through the piping (6), returns in the tank (3).
In this way the hydraulic interlocking is obtained.
Figure 10
19596
HYDRAULIC POWER STEERING OPERATION DIAGRAM: LEFT STEERING

NOTE The only possible interventions on the power 520636 SWIVEL HEADS
steering and mechanical steering systems are: 501438 PROTECTION CASINGS
replacement of ball joints, replacement of protective
rubber boots, linkages and rubber bushings. Follow Figure 12
the instructions provided in the specific paragraphs.
Replace the power steering system if problems
referred to this system only are found.
CHECKS AND OPERATIONS ON THE

VEHICLE
Checking maximum pressure 32875
Figure 11 Check that the protection casings of the knuckle heads are in
perfect condition and that their pivots do not present play,
otherwise replace them as described below.
Loosen the nut (3) securing the knuckle head (2) to the tie rod
(4).
Remove the nut fixing the knuckle head to the steering gear
lever and using the extractor (1) 99347074 remove the
knuckle head.
Unscrew knuckle head from the tie rod of the steering box
noting down the number of turns needed to disassemble.
Remove the fixing brackets (5) and extract the protection
casing (6).
In order to re-fit the assembly, perform the above operation
in reversed order, sticking to the following instructions:
- carefully clean the steering gear tie rod knuckle;
- lubricate the protective boot seats on the power steering
19598 box to facilitate assembly;
Join a pressure gauge (2) on the oil delivery piping on the - screw up the knuckle head with the same number of turns
power steering pump (1). Rotate the steering wheel up to the used to disassemble it;
limit stop, speed up the engine and read on the pressure gauge - fit a new o-ring on the power steering box;
the maximum pressure value, which mast be of 80 bar.
- tighten the nuts of the prescribed torque;
- Adjust toe-in as shown in the respective section.
Checking hydraulic steering centre (for ”ZF”
power steering only)
Lift the front of the vehicle and put the wheels in the straight
ride position.
Start the engine and fully speed up; if the steering gear put itself 501410 STEERING GEAR CONTROL
in steering position, the hydraulic steering centre is wrong and
the hydraulic power steering must be changed. Vehicles equipped with an Air-Bag
501430 Bleeding the air from the hydraulic Before doing any work on steering gear control
! components:
system
Check the oil level in the tank, if necessary top up.
Lift the front part of the vehicle, start the engine and make it - steering wheel;
idle for a certain period. - steering control lever system;
Check that there is no oil leakage from the hydraulic circuit and
check the tank level. - steering gear shaft
Slowly rotate the steering wheel in the two steering directions Strictly observe the safety standards described in the following
so that the air contained in the hydraulic system goes out. paragraphs for Air-Bag system components.
Check again the oil level in the tank and, in case top up.

SAFETY STANDARDS TO BE OBSERVED

DURING REPAIR OR MAINTENANCE OPE- Component removal and refitting shall be performed
RATIONS ON VEHICLES EQUIPPED WITH ! EXCLUSIVELY by skilled and authorised personnel.
AIR-BAG SYSTEM PROVIDED BY SUPPLIER Failure to comply with the following procedure can
result in unintentional activation of the system, severe
injury or repairs not required. IT IS ABSOLUTELY
FORBIDDEN TO DISASSEMBLE Air-Bag MODULE
COMPONENTS.
The following Standards shall be strictly observed
! when performing any type of repair or maintenance
operations on vehicles equipped with Air-Bag safety
system.
System components are designed to operate just on vehicles
of the specified make and type. Air-Bags must therefore not be
Preliminary Standards adapted, reused or installed on other vehicles.
Mount and use them only on the vehicles for which they have
been designed and produced.
Air-Bag modules shall be handled with the utmost care.
! Use, transport and storage of these components are
governed by the handling procedures described in the
following paragraphs. Any reuse, adaptation or installation on a different
! type of vehicle can result in sever injury or death for
passengers in case of collision.
Before starting any bodywork repair operation, welding or Repairs and inspections required after an
whatever work requiring to remove the Air-Bags or the control accident
unit, proceed as follows:
- set ignition key to ”STOP” and take it out; Any safety system component damaged after an
! accident must be replaced.
- always disconnect the battery, i.e.: disconnect the two Do not attempt to repair the control unit, the coil
terminals from the relevant pole and insulate them cable or the Air-Bag modules.
properly by tape;
- wait for at least 10 minutes before proceeding;
- disconnect control unit connector.
Store modules with the cover set upwards, inside a metallic
key-locked cabinet that must be used just with this purpose and Accidents with or without Air-Bag module
that must not contain other type of materials, especially if activation
flammables.
Certain system components must be inspected after any crash,
Adopted connectors wired to Air-Bag modules are provided whether the Air-Bag deployed or not. These components are
with short-circuit clip. It is impossible to activate units the following:
accidentally until Air-Bag modules are connected to a power
source with suitable properties. - steering column;
A system component not activated in case of collision is to be - steering column support;

considered still ”live” (active). - electronic control unit anchoring area and modules;
Live components that shall be removed from vehicles (due to - coil cable;
defects, warranty expiry or other reasons) shall be returned to
the suitable Centre using the following procedure. - dashboard (in the area of the passenger Air-Bag).
If any faulty condition is found, replace the faulty component.
Accidents with Air-Bag module activation

In case of front impact with total system activation, the
following components must be replaced:
- Air-Bag modules;
- pretensioners;
- electronic control unit;
- coil cable.

Inspect cables and connectors to find any burning, external Safety Standards to observe when handling
insulation melting or damages due to excessive heat. Air-Bag modules
If any faulty condition is found on coil cable, electronic control Driver and passenger Air-Bags usually activate in case of
unit anchoring area and modules, replace the faulty collision through the action of the electronic activation
component. control. Gas (mainly nitrogen) produced under these
conditions are not toxic.
Personnel operating on safety system shall strictly observe the
Painting following safety standards.
Since modules and pretensioners are designed to withstand Personnel operating on these devices shall be suitably trained
the temperatures developed during standard baking operation and must observe the following precautions:
on bodywork, no special safety requirement shall be observed - when removing or replacing activated Air-Bags, wear
during painting or baking.
protective polyethylene gloves and goggles and handle
Do not use open flames when working near the modules. just one module at a time;
Electronic control units (including the Air-Bag one) shall always
be removed when temperature in certain rooms is equal to or - always place the Air-Bag module with the cover and
exceeds 85°C. exhaust hole upwards. Never put something on Air-Bag
cover;
Risks for health - once servicing is over rinse hands with water and neutral
soap, in case of eyes contact with residual powders rinse
Precautions to be observed when handling live Air-Bag are the immediately with fresh water;
following:
- before starting servicing, disconnect both battery cables
- wear protective polyethylene gloves and goggles; (first the negative one), insulate terminals by tape and wait
- wash hands and any exposed body part with water and at least 10 minutes before proceeding;
soap after handling live modules. - metal components of the Air-Bag are hot after explosion,
avoid to touch these components for at least 20 minutes
Overexposure effects from module activation;
Since system is completely sealed there is no potential danger - do not repair Air-Bags but send faulty modules to
of exposure to propelling gas. supplier. Do not heat the Air-Bag module by welding,
Propelling gas mixture is at solid state, it is therefore impossible percussion, drilling, mechanical machining, etc.;
to inhale gas even in case of gas generator cartridge breakage. - never install on vehicle a damaged or fall Air-Bag module;
There is no risk for health in case of gas leakage.
Avoid in any case contact with the skin and do not swallow the - it is prohibited to store Air-Bag modules together with
propelling gas. flammable material or fuels;
In case of: - gas generators must not come into contact with acids,
- contact with the skin: rinse immediately with water and greases or heavy metals since contact can result in
soap; formation of poisonous, noxious gas or explosive
compounds;
- contact with eyes: rinse immediately with fresh water for
15 minutes at least; - never use open flames when working near Air-Bag
modules or system components.
- inhalation: bring immediately the injured person to open
air;
- swallow: make the injured person vomit if conscious.
Always call the doctor in any of the above cases.

Spare parts shall be stored in their original package and Safety Standards to observe when handling
temporary storing shall follow the same procedure as for live pretensioners
modules disconnected from vehicle, i.e. storage into dedicated
In case of front impact, driver and passenger pretensioners
metallic key-locked cabinet (resistant to shocks and provided
usually activate just a minute before Air-Bag modules
with grids to enable natural ventilation). Cabinet shall be
Personnel operating on these devices shall be suitably trained
provided with proper warning plates (RISK OF EXPLOSION
and must observe the following precautions:
- NO OPEN FLAMES - NO OPENING BY
UNAUTHORISED PEOPLE). - when handling activated pretensioners, i.e. with activated
propelling gas, wear protective gloves and goggles;
- once servicing is over rinse hands with water and neutral
Air-Bag module scrapping soap, in case of eyes contact with residual powders rinse
Air-Bag modules must not be scrapped together with the immediately with fresh water;
vehicle, but must be previously removed and activated as
described in the following pages. - disconnect both battery cables (first the negative one),
Air-Bag units must always be activated before scrapping. insulate terminals by tape and wait at least 10 minutes
An Air-Bag module not exploded during an accident is to be before proceeding;
considered still ”live”. - pretensioner produce heat during activation, it is
Live materials MUST NOT BE ACTIVATED but must be sent therefore necessary to wait at least 10 minutes before
to a specialised centre (in Italy to GECMA in Chivasso) operating;
specifying on the freight note:
- protect pretensioners against fall or shock during handling
- Air-Bag DEVICE CONTAINING PYROTECHNIC or transport; damaged or fallen pretensioners must not
CHARGE TO BE DEACTIVATED. be used and must be returned to supplier communicating
Devices must be sent using their original packages only. Should the reason for;
the original package be not available, a new one shall be - never carry pretensioners by the seat belt;
requested to SPARE PARTS.
In case of Air-Bag device replacement, the original package - pretensioners must be protected against sparks and open
shall obviously be kept in good conditions to send the flames and must not stay in contact with surfaces with
non-activated device. temperatures exceeding 100°C for more than 6 hours;
FOREIGN MARKETS shall observe local current laws and - propelling gas not burnt is flammable, therefore
regulations. generator components must never be disassembled,
damaged or tampered;
- it is prohibited to store pretensioners together with
flammable material or fuels;
- gas generators must not come into contact with acids,
greases or heavy metals since contact can result in
formation of poisonous, noxious gas or explosive
compounds;
- seat belts with pretensioners shall be stored in proper
key-locked compartments or cabinets, suitably aerated
and away from open flames and heat sources.
Failure to observe these procedures can result in
! unintentional Air-Bag module activation and severe
injury. Live Air-Bag units must NOT be disposed of
using the common disposal procedure. Live Air-Bag
units contain substances dangerous for health that can
cause severe injury if the sealed container is damaged
during disposal.

Propelling gas residues shall be considered with attention.

After any impact involving pretensioner activation, These residues that are mostly concentrated on the generator
! the seat belt is unserviceable and must be replaced. body or in small amount in the bag can contain copper or
chlorides (e.g. potassium chloride). Combustion residues are
very alkaline and corrosive.
Always wear skin protections and goggles. Activated Air-Bags
must always be stored in dry and well ventilated places.
Pretensioners scrapping
Non-activated pretensioners (not installed on vehicle) must
always be activated before scrapping. Non-activated
pretensioners installed on vehicle must not be scrapped
together with the vehicle, but must be previously removed. Removing and scrapping non-activated
Pretensioner not activated during an accident is to be Air-Bag module from a repairable vehicle
considered still ”live” and therefore it is necessary to follow the
procedure described in this manual.
Never cut the cables or tamper the connector
Operations on system components ! between vehicle wiring and Air-Bag module.
Connector contains a safety clip.
Once servicing operations are completed, the system shall be
tested by Modus, I.W.T. or equivalent diagnostic equipment.
Air-Bag components are provided at installation with a label
with a removable part showing system and components date If connector is cut or removed from Air-Bag unit, the safety clip
of installation. is disabled and this can result in unintentional activation and
The removable part is detached and data are stored together severe injury.
with the test report provided by Modus, by the workshop that Air-Bag systems have a backup power supply located in the
has installed the components. control unit. This power supply shall be deactivated by
After 10 years from installation, unless prior replacement, a new disconnecting the two battery terminals and waiting for at least
Air-Bag system (cable and components) shall be installed. As 10 minutes before starting any operation on whatever Air-Bag
said above components technical data and the date of component.
installation will be filed. Keep the bag and the external bag cover in opposite direction
to body when handling a live Air-Bag module. When placing
a live Air-Bag on the bench or some surface like that, set the
Removing and scrapping activated Air-Bag bag and the cover facing upwards and far from people. Never
module and pretensioner from vehicle place objects near a live Air-Bag, since in case of module
Always wear gloves and goggles when handling activated deployment objects will be thrown away like shells.
Air-Bag or pretensioner. Wash hands and exposed skin with
water and neutral soap after handling activated Air-Bag or
pretensioner. In case of exposure to secondary products, rinse
eyes immediately with fresh water. Failure to observe these
indications can result in severe injury.
To remove and scrap activated Air-Bag module and Always store live Air-Bag modules an pretensioners
pretensioner proceed as follows: ! in fresh, dry, close and safe place. Do not expose to
- follow instructions contained in this manual to remove open flames or temperatures exceeding 150°C.
activated Air-Bag module and pretensioner; Never cut, drill, solder or weld an Air-Bag module or
its components. Failure to observe these indications
- disconnect Air-Bag module and pretensioner mechanical can result in unit damages, fire, unintentional
fixings; deployment and severe injury.
- disconnect component connector form Air-Bag wiring;
- put Air-Bag module and pretensioner in the proper sealed
nylon bag;
- send to authorised collection/disposal centre;
- dispose of, recycle or scrap deployed Air-Bag module and
pretensioner using the suitable procedure.

Damaged live Air-Bag modules and pretensioners (e.g. electric Air-Bag module deployment
connection breakage), shall be store far from corrosive or Remote activation
oxidising substances. Failure to observe these indications can General instructions:
result in fire and/or severe injury. - activation procedure can be performed in open area,
suitably defined and fenced, far from flammable materials,
liquids or other substances and far from people. Set the
Air-Bag module on a firm surface and lock it;
Air-Bag modules and pretensioners are provided
! with backup power supply giving the electrical pulse - clean this area from any material (glass, instruments, parts,
required to bag deployment when the accident etc.) which could become like shells during deployment;
damages the battery or the cables before the sensor - check whether connector C2 is disconnected from
activates the gas generator. remote activation device (10 m).
- connect electric connector C1, specified by vehicle
manufacturer, to remote activation Air-Bag module;
Figure 13
- connect connector C2 to remote activation device;
A - connect remote activation device to 12V circuit or
equivalent device;
- stand protected;
- wear goggles and protective clothes;
- depress double activation push-button;
- wait for approx. 20 minutes before touching the activated
C1 Air-Bag module since it is hot;
- dispose of, recycle or scrap, as required, activated Air-Bag
Lb modules as described in the relevant chapters.
Activating Air-Bag modules and electronic

C2 pretensioners installed on unrecoverable
vehicles
This procedure is to be used when scrapping a vehicle with one
or more live Air-Bag modules. This procedure is valid whether
L Air-Bag system and/or electronic pretensioners are sound or
not.
It is recommended to activate pyrotechnic charges on vehicles
by directly connecting the electric connector of each module
C2 to remote activation device.
Deployment procedure shall be performed outdoor,

+12V ! away from people and in a well defined area. Check
8663
for absence of objects and flammable fluids near
modules and pretensioners. Do not remain on the
AIR-BAG MODULE REMOTE ACTIVATION DIAGRAM vehicle during activation and remember to close the
doors. Stand protected (e.g. behind a wall, a vehicle,
etc.) against thrown-away objects, if any. Let
generators and modules cool down after deployment
(20 min. at least before proceeding). Failure to
C1 = Air-Bag module connector observe these indications can result in severe injury.
C2 = remote activation device connector (Air-Bag
connector with safety clip, counterparts with male
pins on Air-Bag side)
Lb = braid length = approx. 1 m
L = main cable, safety distance 10 m
A fenced area
B Remote activation device

General instructions: Figure 14
- follow all WARNINGS, PRECAUTIONS and safety

instructions reported in this manual; ABP ABG
- bring the vehicle outside in the provided area; C1 C1
- remove from the area around the Air-Bag covering all
materials and slugs (glasses, tools, components etc.) and Lb Lb
make sure that no inflammable liquids are nearby;
- disconnect the two battery cables (first the negative C2 C2
cable) and wait for at least 10 minutes before proceeding;
- use a connecting braid (L= about 1 m) with specific
Lb
C1 C2
terminal connector for the electric connection with the
module to activate;
- reach the electric module connection (Air-Bag or PTG
electronic pretensioner), following the instructions of this
manual;
- disconnect connector C1 of the pretensioner or Air-Bag
module;
- check whether connector C2 is disconnected from
remote activation device;
- connect the electric connector C1 of the pretensioner or
Air-Bag module to the connecting braid of the remote
activation device; L
- connect connector C2 to remote activation device;
C2
- place people in a safe place;
- connect the remote control device to a 12 Volts circuit A
or equivalent device;
- press the double activation push-button to activate all
pretensioners and Air-Bag modules at the same time; +12V
8664
- after activating the Air-Bag modules and pretensioners, VEHICLE PYROTECHNIC CHARGES ACTIVATION DIAGRAM,
leave them cooling before touching them (about 20 SINGLE ACTIVATION
minutes);
- after activating the Air-Bag modules and pretensioners,
the vehicle can be scrapped - by squashing or crushing - ABG= driver Air-Bag
and/or recycled, depending on the cases. ABP = passenger Air-Bag
C2 = remote activation device connector
C1 = specific pyrotechnic charge connector
L = main cable, safety distance 10 m
Lb = braid length
PTG = driver pretensioner
A. Remote activation device

541415 Upper steering gear shaft removal

Figure 17
Figure 15
62108
62107
- Lift the Air-Bag module (1) in order to disconnect
connector (2);
Disconnect the battery (2) cables (1-3) first the negative cable - Remove the Air-Bag module (1) from the steering wheel
(1) then the positive one (3) and insulate them taping the (3).
terminals.
After removal, non-activated Air-Bag modules must
! be stored with plate laying on the surface in a suitable
key-locked cabinet.
For vehicles equipped with Air-Bag For all vehicles

Follow the safety standards given in the relevant chapter and Remove fixing nut (4).
wait for 10 minutes before proceeding.
Figure 16 Figure 18
62109
62108
Set front wheels in straight running and mark (→) steering

For vehicles without Air-Bag, remove the pressure-fit cover wheel assembly position (1) on upper steering gear shaft (2)
(2) on the steering wheel. Remove the steering wheel (1) from the shaft (2).
For vehicles with Air-Bag, turn the steering wheel and position For vehicles with Air-Bag, make sure not to extract or damage
it as shown in the figure, in order to easily reach the screws (1 coil device cable (3).
and 3) and remove them.

To remove steering angle sensor (15), you just need to take

Make sure that steering wheel removal has lifted the off cover (16) and unscrew the three screws (17) that secure
! top cap of the coil device. If the top cap turns, it will it to the steering column stalk.Mark universal joint (6) assembly
be necessary to block it by bringing it to the outside. position on lower shaft (8) and loosen the fixing screw (7).
If you hear a ”click”, it means that the cap is blocked. Remove the screws (4-5) and disconnect the upper steering
For any removals of the winding device, meticulously gear shaft (1) from the lower steering gear shaft (8).
observe what specified in “Electric System” section. To replace or disassemble switch (12) it is necessary to
unscrew screws (11) using a proper punch or drill them in
order to eliminate the most of material to remove them. Make
sure not to damage switch thread in case of reuse.
At refitting, the new screws (11) must be tightened till the
Figure 19 hexagonal head is sheared from its rod.
Refitting
For refitting reverse removal operations and observe the
following recommendations:
- reconnect shafts and refit steering wheel matching the
marks made during removal operations;
- at refitting, the self-braking nuts and the steering wheel
fixing nut must always be replaced;
- tighten nuts and screws to the prescribed torque;
- after tightening steering wheel fixing nut to upper shaft, it
is necessary to crimp the nut;
- when refitting is completed, carry out operation test on
indicator switch and horn.
62110
Remove the two screws (2) and remove the upper protection (1).
Remove the three screws (4) and remove the lower NOTE On vehicles equipped with ESP, the steering angle
protection (3). sensor is fitted inside the steering column stalk. In
this case, you will have to carry out the functional
checks as well as the calibration procedure
Figure 20 described in the relevant chapter of the “Brakes”
section (page 63).
541413 Lower steering gear shaft removal
Figure 21
102313
Cut electric cable fixing clamps and disconnect connectors

(9-10-13). 62112
On vehicles equipped with ESP, take off connector (14) of Remove the upper steering gear shaft as described in the relevant
steering angle sensor (15) incorporated into the steering chapter (operation 541415). Lift cover (1) from floor. Unscrew
column stalk. Loosen screw (3) locking indicator switch the three fixing screws (2) of lower shaft (3) support (4).
retaining clamp to gear shaft (1).
Remove the indicator switch (2) from the gear shaft (1).

Figure 22
62113
Mark universal joint (6) assembly position on hydraulic power

steering (3) shaft. Refitting
Loosen screw (7) and remove hydraulic power steering lower
shaft.
For refitting reverse removal operations and observe the
following recommendations:
Refitting - after refitting the hydraulic power steering to the front
cross member or to the driving axle, turn the pinion up
to bring the rack to the end of the stroke. Turn again the
For refitting reverse removal operations, complying with
pinion to the opposite direction for a number of turns
upper steering gear shaft refitting operations.
equal to half of the turns required to the rack to complete
the whole stroke (approx. 2 turns);
- in this position, set steering wheel in straight running
5014 HYDRAULIC POWER STEERING condition and connect the elastic joint to hydraulic power
541413 Hydraulic power steering removal steering pinion fork or the universal joint to the hydraulic
power steering.
Proceed as follows to remove the hydraulic power steering: - At refitting, the self-braking nuts must not be reused but
Loosen front wheel fixing screws or nuts. replaced with new ones.
Lift the front part of the vehicle, support it by proper stands
- tighten screws and nuts to the prescribed torque;
and brake rear wheels.
Position tool 99321024 near the wheels, remove wheel fixing - fill hydraulic power steering system tank in and carry out
screws or nuts. Remove the wheels. the drainage as described in the relevant section;
Remove cap (1) from hydraulic power steering oil tank. - check and adjust toe-in as described in the relevant
Disconnect pipes (4-5) from hydraulic power steering (3) and section.
drain system oil into a suitable container.
Steer wheel hubs in both directions to drain out oil from the
The only repair operations to carry out on hydraulic
system.
! power steering and mechanical steering are the
Remove nuts (8) fixing kingpins (10) to steering levers (9) and
following: joint head replacement and rubber boots
remove the latter using extractor 99347074.
replacement. In these cases, follow the operations
Loosen the screw (7) fixing the universal joint (6) to the
described in the relevant section.
hydraulic power steering shaft (3).
If defects depending only on the hydraulic power
Remove the fixing screws (2) and remove the hydraulic power
steering are found, replace it.
steering (3).

Steering linkage replacement Refitting

Removal Figure 25
Figure 23
86012
86010
POWER STEERING SYSTEM SPARE PARTS
Use suitable pincers to loosen the retainer clamps (2 and 4), 1. O-ring - 2. Clamp - 3. Protective boot - 4. Clamp -
remove the protective boot (3) from the power steering box 5. Steering linkage - 6. Nut - 7. Head - 8. Tube - 9. Tube -
(1) and move it aside to access the steering linkage connection 10. Power steering unit - 11. Rubber bushing.
(5) to the rack rod.
Figure 24
Reassemble by reversing the disassembly sequence; observe
the following precautions:
- replace o-rings (1) and clamps (2 and 4) with new parts;
- lubricate (→) protective boot (3) seats on power steering
unit (10) to facilitate assembly of the boots;
- tighten steering linkage joints (5) at 100 ± 10 Nm (10 ±
1 kgm).
Rubber bushing replacement procedure

86011
Use a suitable ram to remove/refit rubber bushings (11).
Tighten the rack rod (2) in a vice with lead covered jaws,
loosen the joint (3) and remove the steering linkage (4).
Remove the o-ring (1). Repeat the operations to remove the
opposite steering linkage. Follow the removal/refitting
operations described in the respective sections to reuse ball
joints.
Do not take the rack rod (2) to end of stroke after

removing the linkage (4) to avoid damaging the
power steering o-rings.

501450 POWER STEERING PUMP Power steering pump overhaul procedure

Replace the power steering pump if poor operation is found.
F1A engine power steering pump

Figure 26
86013
F1C engine power steering pump

Figure 27
89008
Operation of the power steering pumps for FIA/F1C engines

is similar to that of 8140 engines.


DAILY EURO 4 HYDRO-PNEUMATIC SYSTEM - BRAKES 1
SECTION 11
78 Hydro-pneumatic system
52 Brakes
Page
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM

CIRCUIT DIAGRAMS
(MISCELLANEOUS AND GENERATORS) . . 5

CIRCUIT DIAGRAMS (VALVES) . . . . . . . . . . 6

CIRCUIT DIAGRAMS
(TANKS AND ACCUMULATORS) . . . . . . . . 12

CIRCUIT DIAGRAMS
(CONVERTERS, CYLINDERS AND CALIPERS) 13

CIRCUIT DIAGRAMS
(CALIPERS AND CYLINDERS) . . . . . . . . . . . 14

CIRCUIT DIAGRAMS
(SEMI-COUPLINGS AND COUPLING HEADS) . . . . 15

CIRCUIT DIAGRAMS
(INDICATORS AND SWITCHES) . . . . . . . . . 17

CIRCUIT DIAGRAMS (BRAKES) . . . . . . . . . . 19
PIPES AND COUPLINGS . . . . . . . . . . . . . . . . . . 19
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Re-flanging rigid pipes . . . . . . . . . . . . . . . . . . . 19
- Bending rigid pipes . . . . . . . . . . . . . . . . . . . . . . 20
- Cutting rigid pipes . . . . . . . . . . . . . . . . . . . . . . 20
- Replacing flexible hoses with threaded couplings 21
- Replacing flexible hoses with quick release couplings 22
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 24
- Outline diagram for vehicles 29L - 35S without ABS 24
- Outline diagram for vehicles 29L - 35S with ABS 8 . 25
- Outline diagram for vehicles 29L - 35S with ESP 8 . 26
- Outline diagram for vehicles 35C - without ABS 27
- Outline diagram for vehicles 35C with ABS 8 . 28

2 HYDRO-PNEUMATIC SYSTEM - BRAKES DAILY EURO 4
Page Page
- Outline diagram for vehicles 35C with ESP 8 . . 29 - Air bleeding from the ABS/ESP system hydraulic
circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
- Outline diagram for vehicles 40C - 45C - 50C - 60C -
65C with ABS 8 . . . . . . . . . . . . . . . . . . . . . . . . 30
- ABS 8/ESP 8 system bleeding procedure sequence 58
- Outline diagram for vehicles 35C with ESP 8 . . 31
- Mechanically controlled load sensing valve (vehicles
- Braking system main components layout . . . . . 32 35C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
- Location of the main brake system components on - Regulation of load proportioning valve on vehicle . 59
vehicles with ABS . . . . . . . . . . . . . . . . . . . . . . . 34
- Location of the main brake system components on - Dual mechanically controlled load sensing valve
vehicles with ESP . . . . . . . . . . . . . . . . . . . . . . . 36 (vehicles 29L - 35S) . . . . . . . . . . . . . . . . . . . . . 60
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Adjusting the load sensing valve . . . . . . . . . . . . 60
- Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STABILITY CONTROL AND ANTI-SKID DEVICES . . . 61
- Emergency brake . . . . . . . . . . . . . . . . . . . . . . . 37
ABS SYSTEM FUNCTIONS . . . . . . . . . . . . . . . . . 61
- Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . 37
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - Antilock braking system (ABS) . . . . . . . . . . . . . 61
- Front and Rear disc brakes . . . . . . . . . . . . . . . . 37

- Electronic braking distribution device (EBD) . . . 61
FAULT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 38
- Electronic Stability Program (ESP) - Option . . . 61
- Diagnosis Instruments . . . . . . . . . . . . . . . . . . . . 38
FUNCTIONS INCLUDED IN THE ESP SYSTEM ONLY 61
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 46
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - Acceleration drive control device (ASR) . . . . . 61
SPECIFICATIONS AND DATA - HYDRAULIC

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - Engine braking torque control (MSR) . . . . . . . . 61
SPECIFICATIONS AND DATA - BRAKES . . . . . . 52 - Hill holder control (HHC) . . . . . . . . . . . . . . . . 61
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
- Hydraulic Brake Assistant (HBA) . . . . . . . . . . . 61
- Functional check of vacuum brake system . . . . 54
- Electro-hydraulic modulator/control unit for 29L -
BRAKING SYSTEM MAIN COMPONENTS . . . . 55 35S vehicles ) . . . . . . . . . . . . . . . . . . . . . . . . . . 62
- Vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . 55
- Electro-hydraulic modulator/control unit for 29L -
35S vehicles ) . . . . . . . . . . . . . . . . . . . . . . . . . . 63
- Vacuum servo brake . . . . . . . . . . . . . . . . . . . . . 55
- Bleeding air from the hydraulic circuit (vehicles not - Rev sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
equipped with ABS) . . . . . . . . . . . . . . . . . . . . . 56
- Phonic wheels . . . . . . . . . . . . . . . . . . . . . . . . . 64
- Bleeding air from the hydraulic circuit with deaerator
device (vehicles not equipped with ABS) . . . . . 56
ESP SYSTEM SENSORS . . . . . . . . . . . . . . . . . . . . 64

Page Page
- Yaw sensor with built-in side acceleration sensor . . 64 - Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
- Longitudinal acceleration sensor . . . . . . . . . . . . 64 REPLACING THE ESP COMPONENTS . . . . . . . 76
- Steering angle sensor . . . . . . . . . . . . . . . . . . . . 64 - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

BRAKE REPAIR OPERATIONS . . . . . . . . . . . . . . 65
LONGITUDINAL ACCELERATION SENSOR . . 77
- Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
- Replacing brake linings . . . . . . . . . . . . . . . . . . . 65
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
- Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
- Removal/Re-fitting of brake calipers . . . . . . . . . 67
YAW SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 78
REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
- Removal/Refitting of brake calipers . . . . . . . . . . 68
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
- Removal/Refitting brake calipers . . . . . . . . . . . . 70 - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
OVERHAUL OF BRAKE CALIPERS . . . . . . . . . . . 70 ELECTROHYDRAULIC MODULATOR/CONTROL

UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- 2x44 - 2x48 - 2x60 Brembo brake calipers . . . 70
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
- 1x52 - 1x60 Brembo brake calipers . . . . . . . . . 71
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
OVERHAUL OF BRAKE DISCS . . . . . . . . . . . . . . 72
MACHINING AND GRINDING OF DISC BRAKES . . . 72 - Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 79
OVERHAULING PARKING BRAKE . . . . . . . . . . . 73 - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
WHEEL NUT TIGHTENING SEQUENCE . . . . . 73 - Bench overhauling . . . . . . . . . . . . . . . . . . . . . . 80
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
- Adjusting parking brake . . . . . . . . . . . . . . . . . . 75 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

STEERING ANGLE SENSOR . . . . . . . . . . . . . . . . 76


Print 603.43.671
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS

(MISCELLANEOUS AND GENERATORS)
DESCRIPTION SYMBOL
HYDRAULIC FLOW
AIR FLOW
ELECTRICAL LINE
ABLE TO ROTATE
CROSSOVER OF CONNECTED LINES
PRESSURE TEST POINT
QUICK-RELEASE COUPLING
COCK
1 2
COCK WITH OUTLET
SILENCER
COMPRESSOR 0 2
0 2
ENERGY SAVING COMPRESSOR
4
VACUUM PUMP 3 2
HYDRAULIC PUMP 0 2
HYDRAULIC HAND PUMP
32780

GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTION SYMBOL
CONDENSATE SEPARATOR
FILTER 1 2
DEHUMIDIFIER 1 2
4
DEHUMIDIFIER 21 1
22
DEHUMIDIFIER WITH BUILT-IN 21 1

REGULATOR 22
23
AUTOMATIC CONDENSATION
DRAIN VALVE
CONTROLLED CONDENSATION
DRAIN VALVE
HAND CONDENSATE DRAIN VALVE
7
CONTROLLED ANTI-ICING UNIT 1 2
AUTOMATIC ANTI-ICING UNIT

1 2
21 23
PRESSURE REGULATOR WITH 1
INDEPENDENT CIRCUIT
22 24
PRESSURE CONTROLLER 1 21
PRESSURE CONTROLLER 1 21
23
PRESSURE CONTROLLER
(GOVERNOR) 1 2
PRESSURE LIMITING VALVE 1 2
32782 32783

DESCRIPTION SYMBOL
PROPORTIONAL REDUCING VALVE 1 2
MATCHING VALVE 1 2
21 23
FOUR CIRCUIT PROTECTION VALVE 1
22 24
21
THREE CIRCUIT PROTECTION VALVE 1 23
22
21
TWO CIRCUIT PROTECTION VALVE 1
22
NON-RETURN AIR INLET VALVE 1 2
NON-RETURN AIR INLET VALVE 1 2
SAFETY VALVE
CHECK VALVE 1 2
2
CHECK VALVE 2
1
2
DOUBLE SHUT-OFF VALVE
11 12
U
DIFFERENTIAL DOUBLE SHUT-OFF
VALVE M S
THROTTLE VALVE WITH QUICK

RETURN 1 2
THROTTLE VALVE
CONTROL VALVE 1 2
32783 32784 32785

DESCRIPTION SYMBOL
DUMP VALVE 1 2
BRAKE CONTROL VALVE

11 A 21
12 P 22
BRAKE CONTROL VALVE

11 21
BRAKE CONTROL VALVE 11 21
4
12 22
PARKING BRAKE CONTROL VALVE 21

11 22
PARKING BRAKE CONTROL VALVE

1 2
BRAKE VALVE
1 2
CONTROL VALVE
1 2
CONTROL VALVE 21
1 22
RETARDER CONTROL VALVE

13 R 23
4
SERVO CONTROL VALVE
1 2
32786

DESCRIPTION SYMBOL
41 42
SERVO CONTROL VALVE
1 2
SERVO CONTROL VALVE FOR

SINGLE LINE
1 2
41 42 43
TRAILER BREAKING TRIPLE CONTROL
VALVE
1 2
42
41 43
TRAILER BREAKING TRIPLE CONTROL
VALVE WITH BUILT-IN SERVO
SWITCHING 11 22
12
1 2
LOAD PROPORTIONING VALVE
11 21
DUAL LOAD PROPORTIONING
VALVE 12 22
12
LOAD PROPORTIONING VALVE 21
WITH BY-PASS 11
LOAD PROPORTIONING VALVE 1 2

WITH BUILT-IN RELAY
4
4
LOAD PROPORTIONING VALVE

WITH BUILT-IN RELAY WITH AIR 1 2
CONTROL
41 42
32786 32787

DESCRIPTION SYMBOL
LOAD PROPORTIONING VALVE 1 2

WITH AIR CONTROL
41 42
LOAD PROPORTIONING 1 2
VALVE WITH AIR CONTROL
4
PROPORTIONAL REDUCING VALVE 1 2
4
SLAVED PROPORTIONAL
REDUCING VALVE
1 2
2
SLAVED LIMITING VALVE 1
LEVELLING VALVE
21 22
1 2
LEVELLING VALVE
12 23
HAND OPERATED SUSPENSION
RAISING CONTROL VALVE 11 21
LEVELLING VALVE WITH 23 24

BUILT-IN TRAVEL LIMITER
21 22
32787 32788

DESCRIPTION SYMBOL
2
42
PROPORTIONAL CONTROL VALVE
41
1
13
HAND OPERATED SUSPENSION 11 21
CONTROL VALVE WITH ELECTRICAL
MONITORING
12 22
1 3
ELECTROPNEUMATIC VALVE
1 2
ELECTROPNEUMATIC VALVE 1 2
ELECTROPNEUMATIC VALVE 21
1 22
VR ABS HZ2
HYDRAULIC MODULATOR FOR ABS VL HZ1
HL HR
4
AUGMENTER VALVE
1 2
32788


(TANKS AND ACCUMULATORS)
DESCRIPTION SYMBOL
COMPRESSED AIR TANK
BRAKE FLUID RESERVOIR
AIR SPRING
32789


(CONVERTERS, CYLINDERS AND CALIPERS)
DESCRIPTION SYMBOL
VACUUM SERVO BRAKE
VACUUM SERVO BRAKE
DUAL CIRCUIT MASTER CYLINDER
SINGLE CIRCUIT MASTER CYLINDER
AIR/HYDRAULIC CONVERTER
AIR/HYDRAULIC CONVERTER
HYDRAULIC BRAKE CYLINDER
SLAVE CYLINDER
BRAKE CYLINDER
SPRING CYLINDER
COMBINED BRAKE CYLINDER
FIXED DISK BRAKE CALIPER
32790 32791


(CALIPERS AND CYLINDERS)
DESCRIPTION SYMBOL
FLOATING DISK BRAKE CALIPER
FLOATING DISK BRAKE CALIPER

WITH PARKING
MECHANICAL FLOATING DISK BRAKE

CALIPER
SERVO CLUTCH
SERVO CLUTCH
32791


(SEMI-COUPLINGS AND COUPLING HEADS)
DESCRIPTION SYMBOL
A
”ISO” SEMICOUPLING
M
ISO VERSION
A
”ISO” SEMICOUPLING
M
VERSION WITH ISO COUPLINGS
A
”CUNA” SEMICOUPLING
B
ITALIAN VERSION
M
”CUNA” SEMICOUPLING
A
”NATO” SEMICOUPLING
M
NATO VERSION
32792 32793

GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS

AND COUPLING HEADS)
DESCRIPTION SYMBOL
4
1 5
2 3
SEMI-COUPLING
V
Z
A
SINGLE LINE VERSION
A
M
SEMI-COUPLING
V
Z
A
SINGLE LINE VERSION
12
22
SEMI-COUPLING 4
SINGLE LINE VERSION
12
A
22
M
SEMI-COUPLING 4
1 2
SINGLE LINE VERSION
32793


(INDICATORS AND SWITCHES)
DESCRIPTION SYMBOL
PRESSURE GAUGE
PRESSURE GAUGE
PRESSURE TRANSMITTER
LAMP
MECHANICAL OPERATED SWITCH
PRESSURE SWITCH
LOW PRESSURE SWITCH
AUDIBLE WARNING
SENSOR
32794

GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)
DESCRIPTION SYMBOL
SINGLE CYLINDER HYDRAULIC BRAKE
TWIN CYLINDER HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE

WITH PARKING BRAKE
SINGLE CAM OPERATED BRAKE
TWIN DUAL CAM OPERATED BRAKE
32795

799512 PIPES AND COUPLINGS

General Figure 3
The pipes in the braking systems of commercial vehicles are
currently of two types:
- Flexible nylon hose with single or two-ply structure and in
the following diameters (∅ 6-8-10-12-16 mm) supplied as
spares in metre lengths.
- Rigid metal pipes of the following diameters (∅
4.75-6.35-8-10-12 mm). Pipes from ∅ 4.75 to ∅ 10 mm
are supplied as spares in straight lengths of 4, 5 and 6 m,
while those which are over 10 mm diam. are supplied as
spares ready cut, bent and flared.
31973
Re-flanging rigid pipes
Deburr pipe (1), insert union fitting (2) on this and position it
Figure 1 between blocks (3) bearing against pin (5). Lock pipe (1) with
screw (4).
Figure 4
C 31971
TYPES OF RE-FLANGING OF RIGID PIPES 31974
A Type re-flanging Move pin (4) to neutral position. Tighten screw (1) until matrix
die (2) comes up against blocks (3), thus forming the end of
Figure 2 the pipe (5).
B Type re-flanging
Figure 5
31972
Position of press 99386523 (3) the blocks (1) so that the

stamped numbers indicating the diameter of the pipes to be
worked are facing towards the due (2). The choice of the
31975
matrix die (2) depends on the diameter of the pipe to be
re-flanged. Additionally, the diameter of the pipe that can be Fix matrix die (2) to press 99386523 (1).
re-flanged is stamped on the matrix die. For re-flanging follow the instructions given above for A Type
re-flanging.

C Type re-flanging
Figure 6 Figure 9
31976 31979
Fit nut (2) and ring (3) over the pipe (1). Position pipe (1) in tool (3) and bend the pipe by acting on lever
(2).
Figure 7 Figure 10
31980
31977
To remove the pipe (2) from the tool (3) use lever (1).
Fit union fitting (2) and tighten so that ring (3, Figure 6) is locked
over the pipe (1).
Bending rigid pipes Cutting rigid pipes

Figure 8 Figure 11
31978 31981
Position pipe (2) in tool (3) 99386523 and tighten screw (1).
Fit tool (1) 99386523 and select components (2) and (3) By holding the pipe (2) still, rotate the tool (3) until the pipe
according to the diameter of the pipe to be bent. has been completely cut.

After having cut the pipe, deburr and shape the ends as - Re-flange the support ring when fitted on the vehicle or
described previously. at the test bench on a union fitting.
- The pressure and the final distance of the pressure ring
NOTE By turning tool (3) around the pipe (2), screw (1) front edge from the reinforcement bush should be in
becomes loose. To completely cut the pipe, you accordance with those shown in the table below.
must tighten the screw (1) as soon as it becomes
loose.
NOTE When the hose is incorrectly fitted, do not reuse the
Replacing flexible hoses with threaded hose once the bush and support ring have been
couplings removed.
Carefully follow the instructions below:
Hose Distance between Fitting pressure
Figure 12 bush edge and ring (N/mm2)
mm edge mm (*)
6x1 da 1 a 1,5 0,040

Twin-layer
8x1 da 2 a 2,5 0,050
10 x 1,5 da 2 a 2,5 0,050
Single layer 12 x 1,6 da 2 a 2,5 0,060
16 x 2,34 da 3 a 3,5 0,060

10397
- Only use type approved hoses;

(*) See reference h, Fig. 14
- Check the condition of the new hose, that must be free
from cracks, cuts or scores;
- Cut the hose at 90°, with respect the to axis, to the Figure 14
required length by means of pipe-cutter pliers 99387050;
Fit the following in the specified order over the hose:
- Nut (3), pressure ring (2) (the thickest part should be facing
the nut (3) and the reinforcement bush (1);
- The bush must be in perfect condition (it must be free from
deformation or hammer dents);
Figure 13
10399
1. Reinforcement bush - 2. Pressure ring - 3. Nut -

4. Union fitting - 5. Hose - h. Distance between bush edge
10398 and ring edge (see table)
ASSEMBLY OF REINFORCEMENT BUSH
Introduce the end of the prepared hose into the union fitting
A = CORRECT ASSEMBLY
until the reinforcement bush flange rests in the appropriate
B = INCORRECT ASSEMBLY
seat:
- Fit the reinforcement bush with tool 99372219 ensuring - To lock the nut on the union fitting, tighten this up by hand
contact between its flange and end of the hose; and then by means of a box wrench and dynamometric
- Make sure that the end of the hose penetrates into the wrench; this must tightened up to the required driving
rake throat of the flange; torque.

When fitting the hose to the vehicle, some important points Replacing flexible hoses with quick release
should be borne in mind: couplings
- Bends must comply with minimum radii, so as to avoid
constrictions
Swivel couplings:
Diameter of pipe Minimum radius of curvature
mm mm Figure 16
6x1 ~ 40
8x1 ~ 50
10 x 1,5 ~ 60
12 x 1,6 ~ 75
16 x 2,34 ~ 100
Make sure that the hoses are not in contact with sharp
! edges or with sharp metal parts or sources of heat, 39306
but are at a minimum safe distance of 15mm from
these. Screw the coupling into the threaded seating provided on the
air valve, and tighten it to the driving torque indicated in the
- When hoses run through chassis members or metal parts, table.
make sure that the holes through which they pass are
fitted with rubber grommets, and that these are in good Banjo couplings:
condition;
- Avoid sliding the hose along sharp edges which might Figure 17
cause cuts;
- When the hose has to be attached to existing pipe work,
take into account of the additional heat to which it may
be subjected (power steering pipe work). In this case the
hose must be protected with shields;
- When the hose has been connected, check that it is not
under tension between the attachment points, instead
leaving it slightly slack to take up the more substantial
variations in temperature, especially for short lengths;
- Before fitting, thoroughly clean the hoses by blowing
compressed air through them to safeguard operation of 1
the system.
39307
Figure 15
- Check that the seal ring (1) is in its seal;
- Tighten the coupling until the seal gasket is in contact with
the valve;
- Direct the valve correctly and, by keeping the moveable
part still, lock the hexagonal nut to the driving torque
indicated in the table.
Swivel and banjo couplings
13132
COUPLING DRIVING TORQUE (Nm + 10%)
- Protect the hoses if grinding or welding operations are
THREAD
carried out on the vehicle. A notice is fitted in the cabin
indicating the precautions to be observed to avoid M 10 x 1,0 mm 22
damage.
M 12 x 1,5 mm 24
For greater safety and convenience in working, it is
M 14 x 1,5 mm 28
! advisable to remove the hoses during these
operations.
M 16 x 1,5 mm 35
When fitting is finished, check that all seals (unions, couplings,
M 22 x 1,5 mm 40
etc.) are completely free from leaks.

Figure 18 Figure 20
39308
- Insert the hose (2) by hand into the coupling (1), with a
force between 30 and 120 N according to the diameter
of the hose, so that reference mark L1 is inside the hose
while mark L2 remains visible.
33977
- Only use type approved hoses;

Figure 21
- Check the condition of the new hose, that must be free
from cracks, cuts or scores;
- Cut the hose at 90°, maximum error 15°, with reference
to the axis. Use pipe-cutter pliers 99387050 to cut to the
required length.
Figure 19
33978
When removing couplings (1) on pneumatic components, check

the condition of the seal ring (2) and, if necessary, replace.
A
COUPLING SEAL RING DIMENSIONS
33976
THREAD
A = Mark to identify end of tube travel M 10 x 1,0 10,1 x 1,6
- Use indelible ink to clearly mark two reference notches on M 12 x 1,5 11,0 x 2,0
both diametrically opposite faces of the pipe at an angle
of ≥ 75°, set to distances L1 and L2, to ensure correct M 14 x 1,5 -
fitting in place.
M 16 x 1,5 15,0 x 2,0
M 22 x 1,5 -
NOTE L1 and L2 vary according to the diameter of the hose
and are to be measured at the longer part of the hose
(see Figure 18).
Whenever a hose is removed from a quick release

D L
0 -0,5
L1 +1
-0,5
L2 +1 ! coupling, the coupling itself must be replaced. Spare
+0,5
quick release couplings are supplied complete.
(mm) (mm) (mm) (mm)
6 19,8 17 22
8 20,5 18 23 Quick release and threaded couplings are not

! interchangeable. This also applies to flexible hoses
12 25 22 28 used with quick release couplings and flexible hoses
used with threaded couplings.
16 27,1 24 30

BRAKING SYSTEM
Outline diagram for vehicles 29L - 35S without ABS
Figure 22
52378
1. Pressure reducer - 2. Vacuum tank (2 litres) - 3. Servo brake - 4. Hydraulic pressure test point - 5. Dual mechanical operated
load proportioning valve (for vehicles with mechanical suspensions) - 6. Parking brake lever - 7. Rear brake caliper -
8. Rear brake disc - 9. Dual pneumatic operated load proportioning valve (for vehicles with pneumatic suspensions) -
10. Front brake disc - 11. Front brake caliper - A. From pneumatic suspension circuit.

Outline diagram for vehicles 29L - 35S with ABS 8

Figure 23
74938
1. Electro-hydraulic modulator - 2. Vacuum pump - 3. Vacuum tank - 4. Servo brake - 5. Hydraulic pressure test point -
6. Parking brake lever - 7. Rear brake caliper - 8. Rear brake disc - 9. Electronic control unit -
10. Wheel revolutions sensor - 11. Phonic wheel - 12. Front brake disc - 13. Front brake caliper.

Outline diagram for vehicles 29L - 35S with ESP 8

Figure 24
109109
1. Electro-hydraulic modulator - 2. Vacuum pump - 3. Vacuum tank - 4. Servo brake - 5. Hydraulic pressure test point -
6. Parking brake lever - 7. Rear brake caliper - 8. Rear brake disc - 9. Yaw sensor - 10. Longitudinal acceleration sensor -
11. Electronic control unit -12. Wheel revolutions sensor - 13. Phonic wheel - 14. Front brake disc -
15. Front brake caliper - 16. Steering angle sensor

Outline diagram for vehicles 35C - without ABS

Figure 25
109110
1. Pressure reducer - 2. Vacuum tank (2 litres for 35C, 40C vehicles, 5 litres for 45C / 50C / 60C / 65C vehicles) -
3. Servo brake - 4. Hydraulic pressure test point - 5. Dual mechanical operated load proportioning valve (for vehicles with
mechanical suspensions) - 6. Parking brake lever - 7. Rear brake caliper - 8. Rear brake disc - 9. Dual pneumatic operated load
proportioning valve (for vehicles with pneumatic suspensions) - 10. Front disc brake - 11. Front brake caliper - A. From the
pneumatic suspension circuit.

Outline diagram for vehicles 35C with ABS 8

Figure 26
109111
1 Electro-hydraulic modulator - 2. Vacuum pump - 3. Vacuum tank - 4. Servo brake - 5. Hydraulic pressure test point -
6. Parking brake lever - 7. Rear brake disc - 8. Rear brake caliper - 9. Electronic control unit -

Outline diagram for vehicles 35C with ESP 8

Figure 27
109112
6. Parking brake lever - 7. Rear brake disc - 8. Rear brake caliper - 9. Electronic control unit - 10. Wheel revolutions sensor -
11. Phonic wheel - 12. Front brake disc - 13. Front brake caliper. - 14. Yaw sensor - 15. Longitudinal acceleration sensor -
16. Steering angle sensor

Outline diagram for vehicles 40C - 45C - 50C - 60C - 65C with ABS 8
Figure 28
109113
6. Parking brake lever - 7. Parking drum brake - 8. Rear brake disc - 9. Rear brake caliper - 10. Electronic control unit -

Outline diagram for vehicles 40C-45-50C-60C-65 with ESP 8

Figure 29
109114
6. Parking brake lever - 7. Parking drum brake - 8. Yaw sensor - 9. Longitudinal acceleration sensor - 10. Rear brake disc -
11. Rear brake caliper - 12. Electronic control unit - 13. Wheel revolutions sensor - 14. Phonic wheel -
15. Front brake disc - 16. Front brake caliper. - 17. Steering angle sensor

32
Base - March 2006

Figure 30
Vehicles 29L-35S
HYDRO-PNEUMATIC SYSTEM - BRAKES
Braking system main components layout
109116
1. Servo brake - 2. Front brake caliper - 3. Front brake disc - 4. Vacuum pump - 5. Vacuum tank - 6. Pressure test points -
7. Brake-force corrector - 8. Rear brake disc - 9. Rear brake caliper.
DAILY EURO 4
Print 603.93.651
Print 603.93.651
DAILY EURO 4
Figure 31
Vehicles 35C - 40C - 45C - 50C - 60C - 65C
109117
1.Servo brake - 2. Front brake caliper - 3. Front brake disc - 4. Vacuum pump - 5. Vacuum tank - 6. Pressure test point - 7. Proportional load valve - 8. Rear brake disc -
9. Rear brake caliper
33
Base - March 2006

34
Base - March 2006

Figure 32
Vehicles 29L-35S
FRONT LH BRAKE PIPING REAR RH
FRONT RH BRAKE PIPING REAR LH
ELECTRICAL SYSTEM WIRING

Location of the main brake system components on vehicles with ABS
109118
1. Vacuum brake - 2. Electrohydraulic modulator - 3. Front brake disk - 4. Phonic wheel - 5. Wheel revs sensor - 6. Vacuum device - 7. Vacuum chamber -
8. Electronic control unit - 9. Front brake caliper - 10. Hydraulic pressure check sockets - 11. Rear brake disk - 12. Rear brake caliper - 13. Brake lights indicator switch (on
vehicles with EDC there are two switches), inform the ABS - EDC control unit that the vehicle is braking - 14. Hydraulic accumulator -
15. Electrohydraulic modulator - 16. Electronic control unit. - A. Fitting the electro-hydraulic modulator/control unit for ABS 8 systems.
DAILY EURO 4
Print 603.93.651
Print 603.93.651
DAILY EURO 4
Figure 33
REAR BRAKES PIPING
FRONT BRAKES PIPING

ELECTRICAL SYSTEM WIRING
Vehicles 35C - 40C - 45C - 50C - 60C - 65C
109119
1. Vacuum brake - 2. Electrohydraulic modulator - 3. Front brake disk - 4. Phonic wheel - 5. Wheel revs sensor - 6. Vacuum device - 7. Vacuum chamber -
8. Electronic control unit - 9. Front brake caliper - 10. Hydraulic pressure check sockets - 11. Rear brake disk - 12. Rear brake caliper - 13. Brake lights indicator switch (on vehicles
with EDC there are two switches), inform the ABS - EDC control unit that the vehicle is braking - 14. Hydraulic accumulator -
15. Electrohydraulic modulator - 16. Electronic control unit. - A. Fitting the electro-hydraulic modulator/control unit for ABS 8 systems.
35
Base - March 2006

Location of the main brake system components on vehicles with ESP

Vehicles < 3,5 ton.
Figure 34
107690
1. Acceleration sensor - 2. Yaw sensor - 3. Steering angle sensor - 4. Electro-hydraulic modulator/control unit

DESCRIPTION BRAKES
Service brake Front and Rear disc brakes
The service brake is of the pedal type with two independent
hydraulic circuits. Both circuits are served from the The ABS phonic wheels are fitted on the wheel hubs.
vacuum-type servo brake. - Front BREMBO 2x48 (model 29L - 35S);
The load proportioning valve is inserted in the hydraulic circuit - Front BREMBO 2x48 (model 35C - 40C - 45C - 50C);
of the rear brakes so as to compensate the braking action of
the rear wheels as a function of the load being carried. - Front BREMBO 2x60 (model 60C - 65C);
By means of a servo brake the pedal acts on the twin section - Rear BREMBO 1x52C (model 29L - 35S);
master cylinder that puts the brake liquid under pressure. - Rear BREMBO 1x60C (model 35C);
Movement of the pistons in the caliper casing, as a - Rear BREMBO 2x44 (model 40C - 45C - 50C).
consequence of the hydraulic pressure, causes the brake
linings to be compressed on both surfaces of the brake disc - Rear BREMBO 2x46 (model 60C - 65C).
and therefore brings the vehicle to a standstill. An electric wire is embedded in the brake linings which is
connected to a tell-tale light on the driving panel to indicate
the lining wear.
Emergency brake
Incorporated in the service brake, the twin circuit system

allows a single axle to brake even when the other brake is
faulty, by acting on the service brake pedal.
Parking brake
Mechanical design consisting of a hand lever and associated

linkages and wires that act on the rear wheel bakes.

FAULT DIAGNOSIS
SECTION I
Faults affecting the ABS/ESP systems can be found by means of the Modus, E.A.SY. and IT 2000 diagnosis instruments.
These instruments are necessary to perform exhaustive diagnosis and take appropriate measures as regards every single fault.
Each single instrument displays the diagnosis and repair help.
Diagnosis Instruments
MODUS (Maintenance and Diagnostic System)
A computerized fault-diagnosis station dedicated to diagnosing the brake systems, air suspensions, engines and systems controlled
electronically.
The station is equipped with auxiliary functions, such as: programming electronic control units, consulting the spare parts catalogue
and service time schedules.
The vehicle has a 30-pin diagnosis socket to interface with the instrument.
E.A.SY. (Electronic Advance System)

The E.A.SY. system allows you to easily diagnose and program the various electronic control units fitted to the vehicle. It is made
up of an ECI module for communication with the electronic control units and a Panasonic PC.
The ECI module allows you, by taking advantage of the Panasonic PC, to easily carry out work on the road; in particular, diagnostic
work can be assisted by a specialized remote centre, thanks to the wireless technology incorporated into the Panasonic PC (e.g.
GPRS).
IT 2000 (IVECO Electronic Tester)

This makes it possible to take immediate action on the vehicle, identifying it with the chassis number.
It saves the results of diagnostics actions performed.
It can be used as a portable Personal Computer, too, being fitted for remote diagnosis.
By using MODUS as the mother station it is possible to update and configure the IT 2000.
IT 2000 interfaces with the vehicle via a 30-pin diagnosis socket.

SECTION 2
4 - Delayed action of parking brake
Main operating faults in the brake system: 5 - Vehicle skids when braking
1 - Rear axle service brake is inefficient or irregular
6 - Rapid brake lining wear
2 - Front axle service brake is inefficient or irregular
7 - Too long or abnormal travel of brake pedal
3 - Inefficient or no parking brake
8 - Noisy brakes
REAR AXLE SERVICE BRAKE IS

1 INEFFICIENT OR IRREGULAR
Leaks or breakage in pneumatic system pipes. Tighten or replace damaged fittings. Replace broken or
YES damaged pipes.
NO
Worn or vitrified brake linings. Overhaul or replace the brake linings.

YES
NO
Automatic clearance device is faulty (caliper 1x52). Replace the brake caliper.
YES
NO
Rear brakes are faulty. Overhaul the rear brakes, replacing worn parts.
YES
NO
Servo brake is faulty. Overhaul or replace servo brake

YES
NO
Load proportioning valve is faulty (vehicles without Adjust and, if necessary, replace the load
ABS). YES
proportioning valve.
(Continue)

Brake liquid has not been periodically changed. Replace brake liquid.
YES
NO
Presence of air in hydraulic system Bleed-off any air from hydraulic system.
YES
NO
ABS system is faulty. Make diagnosis with Modus.

YES
FRONT AXLE SERVICE BRAKE IS

2 INEFFICIENT OR IRREGULAR
Leaks or breakage in pneumatic system pipes. Tighten or replace loose or damaged fittings. Replace
YES broken or damaged pipes.
NO

YES
NO
Overhaul or replace servo brake

Servo brake is faulty.
YES
NO
Brake caliper is faulty. Overhaul and, if necessary, replace brake caliper.

YES
(Continue)

Front brakes are faulty. Overhaul and, if necessary, replace any worn parts.
YES
NO
Brake liquid has not been periodically changed. Replace brake liquid.
YES
NO
Presence of air in hydraulic system. Bleed-off any air from hydraulic plant.
YES
NO
ABS system is faulty. YES Make diagnosis with Modus.
3 INEFFICIENT OR
NO PARKING BRAKE
Tie-rods are faulty. Adjust or overhaul tie-rods and replace any worn
YES parts.
NO

YES
NO
Rear brakes are faulty. Overhaul the brakes and replace any worn parts.
YES

DELAYED ACTION OF PARKING

4 BRAKE
Tie-rods are faulty. Overhaul tie-rods and replace any worn parts.
YES
NO
Shoe return spring is faulty. Replace shoe return spring.

YES
NO
Rear calipers are faulty (calipers 1x52). Overhaul calipers and replace any worn parts.
YES
NO
Parking drum brake is faulty (2x44 calipers). Adjust or overhaul the parking drum brake and replace
YES any worn parts.
5 VEHICLE SKIDS WHEN BRAKING
Leaks or breakage in hydraulic system pipes. Tighten or replace loose or damaged fittings. Replace
YES broken or damaged pipes.
NO
Load proportioning valve is faulty (vehicles without Adjust and, if necessary, replace load proportioning
YES
ABS). valve.
(Continue)

Front brakes are faulty. Overhaul front brakes.

YES
NO
Rear brakes are faulty. Overhaul rear brakes.

YES
NO
ABS system is faulty. Make diagnosis with Modus.

YES
RAPID BRAKE
6 LINING WEAR
Load proportioning valve is faulty (vehicles without Adjust and, if necessary, replace load proportioning
ABS). YES valve.
NO
Brakes are faulty. Overhaul brakes.

YES

TOO LONG OR ABNORMAL TRAVEL

7 OF BRAKE PEDAL
Servo brake is faulty. Replace servo brake.

YES
NO
Automatic clearance device is faulty (calipers 1x52). Replace automatic clearance device.
YES
NO
Brake liquid with low boiling point due to: Replace brake liquid (use type Tutela DOT SPECIAL).
- Failure to perform yearly change YES
- Presence of water in system

- Use of wrong liquids.
NO
Presence of air in hydraulic system. Bleed-off any air from hydraulic system.
YES

8 NOISY BRAKES
Worn brake linings. Replace brake linings.

YES
NO
Foreign bodies between discs and brake linings. Remove all foreign bodies from between brake linings
YES and discs.
NO
Disk brakes off-centred. Adjust or replace disc brakes.

YES

TIGHTENING TORQUES
TORQUE
COMPONENT
Nm kgm
Screw securing flange and brake disk to wheel hub (Front axle 5818 - 5819) 98.1 ÷ 107.9 9.8 ÷ 1..7
Screw securing flange and brake disk to wheel hub (Front axle 5823)
- torque clamping 43 ÷ 53 4.3 ÷ 5.3
- angle clamping 28.4º ÷ 30.4º
Screw securing brake disc to wheel hub (Front axle 5817) 19.5 ÷ 24 2 ÷ 2.5
Screws to fasten wheel 180 ÷ 200 18 ÷ 20
Screws to fasten brake caliper support to stub axle (Axle 5817 - 5818 - 5819) 176 ÷ 217 18 ÷ 22
Screws to fasten cover to stub axle 7 ÷ 10 0,7 ÷ 1
Wheel hub nut (Front axle 5817 - 5818 - 5819) 320 ÷ 420 32 ÷ 43
Nut securing wheel hub (Front axle 5823)

- torque clamping 50 ÷ 60 5÷6
Screw securing caliper to caliper mounting (Front axle 5818 - 5819 - 5823)
Nut securing wheel (Rear axle 450311/1 - 450511) 290 ÷ 349 29 ÷ 34.9
Screw securing brake disk to half shaft (Rear axle NDA R.S.) 13 ÷ 21 1.3 ÷ 2.1
Screw securing drive shaft to wheel hub (Rear axle NDA R.G - 450511) 63 ÷ 76 6.3 ÷ 7.6
Ring nut retaining wheel hub bearing (Rear axle NDA R.S./R.G - 450511) 618 ÷ 667 61.8 ÷ 66.7
Screws securing brake disc to wheel hub (Rear axle NDA R.S./R.G - 450511) 69 ÷ 76 6.9 ÷ 7.6
Screws securing caliper moutning to shoe mounting (Rear axle NDA R.S./R.G - 450511) 177 ÷ 217 18 ÷ 22.1
Nut securing wheel (Rear axle 450517/2) 284.5 ÷ 343.3 28.5 ÷ 34.3
Screw to fasten cover and sheet metal guard to rear axle box (Rear axle NDA R.S.) 81 ÷ 100 8.1 ÷ 10
Screw to fasten cover and sheet metal guard (Rear axle NDA R.S.) 10 ÷ 16 1 ÷ 1.6
Ring nut securing bearing to half shaft (Rear axle NDA R.S.) 559 ÷ 677 57 ÷ 69
Screw securing shoe mounting to rear axle box (Rear axle NDA R.G. - 450511) 85 ÷ 97 8.5 ÷ 9.7
Screws securing sheet metal guard (Rear axle NDA R.G. - 450511) 8 0.8
Screw securing caliper to caliper mounting (Front axle 5817)
Sensor support retaining screw (Rear axle NDA R.G. - 450511 - 450517/2) 5÷7 0.5 ÷ 0.7

TIGHTENING TORQUES
TORQUE
COMPONENT
Nm kgm
Screw securing flange and brake disk to wheel hub (Front axle 5823)
Screws to fasten brake caliper support to stub axle (Axle 5823) 110 ÷ 140 11.2 ÷ 14
Nut securing wheel hub (Front axle 5823)

Screw securing drive shaft to wheel hub (Rear axle 450517/2) 56 ÷ 69 5.6 ÷ 6.9
Screw securing brake caliper (Rear axle 450517/2) 150 ÷ 177 15 ÷ 17.7
Ring nut retaining wheel hub bearing (Rear axle 450517/2) 441 ÷ 540 44.1 ÷ 54
Screws securing brake disc to wheel hub (Rear axle 450517/2) 54 ÷ 59 5.4 ÷ 5.9
Screw securing shoe mounting to rear axle box (Rear axle 450517/2) 70 7
Brake shoe/axle casing retaining screw (Rear axle 450517/2) 52 ÷ 57 5.2 ÷ 5.7
Calliper guide bushing socket head screw 28 ÷ 32 2.8 ÷ 3.2

TOOLS
99301005 Brake disc assembly
99306010 Appliance to bleed air from brake and clutch systems
99355087 Wrench (65 mm) for wheel hub nut (NDA R.G - 450511)
99355184 Wrench for ring nut retaining drive shaft bearing (rear axle NDA RS)
99357080 Spanner (91.5 mm) for adjusting wheel hub bearings nut
(Rear axle 450517/2)

99370241 Tool for mounting drive shaft bearing (rear axle NDA RS)
Tool for driving bearing and phonic wheel onto wheel hub (rear axles
99370498 NDA R.G. - 450511)
99372236 Tool to retract brake caliper piston (rear axle NDA R.S. - NDA R.G.)
99372249 Parking brake shoes adjusting tool
Pair of gauges to check pressure and to adjust hydraulic

99372269 brakeforce distributor
Tool for fitting wheel hub internal seal (use with 99370006)
99374132 (Axle 450517/2)

99386523 Flanging tool for brake system pipes
99389819 Torque wrench (0 ÷ 10 Nm) with square 1/4” connection.

SPECIFICATIONS AND DATA - HYDRAULIC SYSTEM

DESIGNATION
Vacuum pump
- BOSCH ES F009 D00 165 (F1A engines) - BOSCH ES F009 D00 886 (F1C engines)
Emptying time (4.5 litre tank) at a pressure of: 0.5 bar 4.5 S
0.8 bar 12.5 S
Vacuum servo brake
- Vehicles 29L - 35S - 35C Type 11”: BOSCH 0204051186 (tip: 157 mm) (combi vehicles)
Pneumatic cylinder diameter 288.9 mm
Hydraulic (or master) cylinder diameter 25.4 mm
Stroke 21 + 21 mm
- Vehicles 40C - 45 - 50 Type 10” T: BOSCH 0204021694 (dual) (tip: 157 mm)
Stroke 17.5 + 23.5 mm
- Vehicles 60C - 65C Type 10” T: BOSCH 31.75 (dual) (tip: 157 mm)
Stroke mm
Pneumatic operated load proportioning valve
- BOSCH 796801
Ratio 0.25
- BOSCH 796803
Ratio 0,15
ABS8 system electro-hydraulic modulator/control unit (*)
- BOSCH 0 265 231 692 (vehicles 29L - 35S) - (PN IVECO spare parts 504182308 - EZ)
- BOSCH 0 265 331 896 (vehicles 5C - 45C - 50C) - (PN IVECO spare parts 504182310 - EZ)
- BOSCH 0 265 231 894 (vehicles 60C - 65C) - (PN IVECO spare parts 504182323 - EZ)
ABS8/ASR8 system electro-hydraulic modulator/control unit (*)
ESP8 system electro-hydraulic modulator/control unit (*)
- BOSCH 0 265 334 528 (vehicles 35C) - (PN IVECO spare parts 504182319 - EZ)
* The component shall be supplied filled with brake fluid for storing.

SPECIFICATIONS AND DATA - BRAKES
FRONT AXLE DISC BRAKES 5817 5818 5819 5823
Brake caliper cylinders:

∅ - quantity 2 2 2
- diameter ∅ mm 45 48 52
Brake lining thickness:
S - normal S mm 12 15
- min. allowed S mm 2.9 ÷ 3.4 (*)
3010,2
∅ Disc brake diameter ∅ mm 300 2900,2
2900,2
Disc brake thickness:

- normal S mm 28 280,2 300,2
- min. allowed S1 mm 8.7 8.7 9.7
S2 mm 7.7 7.7 10.5
(*) Remaining thickness of friction material to have the light on (cutting cable)
AXLE WHEEL HUBS
Type of front axle 5817 5818 5819 5823
-
Wheel hub bearings end play mm
-
Not adjustable
Wheel hub bearing axial clearance adjustment Retaining nut torque

450511
NDA NDA
REAR AXLE DISC BRAKES 450311/1 450517/2
R.S. R.G.
450310
Brake caliper cylinders:
∅ - quantity 1 1 2 2
- diameter 52C 60C 44 48
Brake lining thickness: 15
S - min. allowed S mm 2.9 ÷ 3.4 (*)
+0,2
∅ Disc brake diameter mm 296 0,2 294 0,2 289 −0 306 0,2
Disc brake thickness:

- normal S mm 16 0,1 24 0,1 22 0,1 28 0,1
- min. allowed S mm 13 19
S1 mm - 7.7 - 9.2
S2 mm - 6.7 - 7.8
Parking drum brake
Drum diameter:
+0,15 +0,15
- Nominal ∅ mm - - 172 −0 190 −0
Max 173 mm Max 191
S Brake lining thickness:
- Nominal S mm - - 4.25 mm 6.2
- Min. allowed S1 mm - - Min. 1.5 mm Min. 3.5
Brake lining diameter:

∅ ∅ mm - -
- Nominal 171.2 ÷171.5 189.2 ÷189.5
- -
Brake lining width L mm ~42
42
L
G
Clearance between brake linings G mm 0 2÷0 5
0.2÷0.5 0 3÷0 4
0.3÷0.4
and drum
(*) Remaining thickness of friction material to have the light on (cutting cable)
NDA NDA
AXLE WHEEL HUBS 450511 450517/2
R.S. R.G.
Wheel hub bearings UNIT-BEARING SET-RIGHT
Wheel hub bearings end play - 0.16
Nm - 0÷4
kgm - 0 ÷ 0.4
By means of nut
Adjustment of wheel hub bearings end play
TUTELA W90/M-DA TUTELA W140/M-DA (SAE

Rear axle oil
(SAE 80 W 90) 85 W 140)
Quantity 1.35 1.90 3

CHECKS
Device Designation Checks

Pressure Reducer Connect a vacuum meter to the intake line.
At full operation the pressure reduction must reach the value
of 0.80 ÷ 0.85 bar. If this value is not obtained, check if there
are any leaks in the pressure piping and servo brake
components.
Check that the distance between the top of the rotor and
cover (with unit fitted) is comprised in the range 0.07 ÷
0.14mm.
Vacuum servo brake Check the functionality and that there are no leaks. With the
vacuum meter fitted on the piping between the pressure
reducer and servo brake with engine at full speed, check that
the pressure reduction values are in the range 0.80 ÷ 0.85 bar
with the pedal both released and pressed fully down for a
period of 1 minute of rotation of the engine.
Brake liquid compensation tank Check the level of the brake liquid and eventually top up with
Tutela DOT SPECIAL to the specified level. Change the brake
liquid once per year.
Load proportioning valve Check that the values measured with special manometers, via
the test points, correspond to those indicated on the
self-adhesive plate applied to the inside of the vehicle.
Disk brake caliper Check the condition of the brake linings; check for scratches
on the discs and the efficiency of the pistons.
Pipes and fittings Ensure that metal pipes are in perfect condition, with no dents
or cracks. Also make sure that they are not near sharp edges
of the body work or chassis that could damage them.
Check that the rubber and cloth flexible hoses are not in
contact with oil or mineral grease, or rubber solvents. Press
hard on the brake pedal and check that the pipes are not
blown, and check that there are no leaks.
Check that all brackets fastening the pipes are securely fixed
- loose fastenings cause vibrations that could give rise to
breakage.
Check that there are no leaks from fittings, otherwise tighten
them fully, taking care when tightening not to cause irregular
pipe torsion.
In all the above cases the parts are to be replaced if there is a
minimum of doubt as to their efficiency.
Apart from their condition, it is recommended to replace hoses
after considerable mileage, or after a period of long vehicle use.
This will avoid sudden breakage due to age and fatigue.
Functional check of vacuum brake system

With the engine stopped, press the brake pedal a few times in order to annul the vacuum in the servo brake. Press the pedal once
again and keep it pressed, in the brake position, by putting a certain pressure on it. Start the engine and check the pedal stroke:
- if the stroke of the pedal increases, this implies that the servo brake and pipes are satisfactory;
- if the pedal remains still, this implies that the outside has penetrated into the vacuum plant that is not perfectly sealed, or the
servo brake is faulty.

BRAKING SYSTEM MAIN COMPONENTS

790530 Vacuum pump
Figure 35
The figure shows the version for vehicles with engine F1C.
As regards the vehicles with engine F1A/F1C, the vacuum de-
vice is incorporated into the vacuum oil pump unit.
109121
This is the component which generates a reduction in

pressure for operation of the servo brake.
Diagnostics
TROUBLE POSSIBLE CAUSES CURE

Oil leakage from cover Incorrect driving torque Lock screws to correct driving torque indicated in appropriate
between power reducer and table.
engine.
Cover seal surface not Check the seal surfaces, replace any defective parts or place
completely flat. them on a flat surface.
Broken seal between pump Replace seal.
and engine.
Poor efficiency Excessive backlash between Replace blades, or the entire pressure reducer.
the blades and sliding surfaces.
Bad sealing of connecting pipes Check the seal and eventually replace the connecting pipes or
or uni-directional valve. replace the uni-directional valve.
Insufficient lubrication. Carefully clean the oil pipes.
794101 Vacuum servo brake
Figure 36
This is a device which increases the force applied by the pedal

and consists of two main components:
- a power reducer pneumatic section;
- an hydraulic section (master cylinder and brake liquid
tank).
The servo brake is manufactured in such a way that in case
the pneumatic section fails, the brakes can still work. In this
case the braking action is obtained by one master cylinder.
32279

784010 Bleeding air from the hydraulic cir- Having terminated this operation connect the load
cuit (vehicles not equipped with ABS) proportioning valve control rod.
Front brake circuit
Figure 37 Finish bleeding-off air from the brake circuit, top up
! to the maximum level with Tutela DOT SPECIAL
brake liquid.
784010 Bleeding air from the hydraulic cir-

45021 cuit with deaerator device (vehicles
not equipped with ABS)
One end of a transparent plastic pipe (2) should be fitted to
the bleeder screw (1) with the end placed into a container Front brake circuit
(3) that has been partially filled with brake liquid. Figure 39
Repeatedly press the brake pedal
By maintaining the brake pedal in the down position unscrew
the bleeder screw (1) one full turn.
Tighten the bleeder screw, repeatedly press the brake pedal.
Repeat the above operation until the brake liquid comes out
in a uniform manner.
Bleed off the air from the opposite brake assembly. Check
that the level of brake liquid in the relevant tank is always
sufficient.
This operation will allow the air in the hydraulic circuit liquid
piping to be expelled.
52399
Rear brake circuit
Figure 38
As an alternative you can bleed-off air from the brake circuit
with the deaerator device 99306010 by following the
procedures below:
1. load the air tank (4);
2. fill the tank with brake liquid (5);
3. one end of a transparent plastic pipe (6) should be fitted
to the bleeder screw with the end placed into a container
that has been partially filled with brake liquid;
4. replace the brake liquid tank cover with one (7) taken
from the box supplied with the deaerator;
45022
5. insert the deaerator 99306010 pipe (1) on the cover of
the brake liquid tank;
6. unscrew the bleeder screw one full turn, open the cock
Disconnect the load proportioning valve control rod and valve (3) until there is a reading of 1 ÷ 1.2 bar on the
lock it at the top so as to set the proportioning valve in the manometer (2).
fully open position.
When the brake liquid comes out in a uniform manner from
Bleed off the air from the hydraulic circuit as described for the the circuit, close the bleeder screw and discharge air from the
front brake circuit. aerator tank (4). Repeat this operation for all wheels.

Air bleeding from the ABS/ESP system hydraulic circuit

The procedure must be performed with the engine stopped and the key turned to running (Key ON).
Get connected to the diagnosis take-off located in the cabin, on the passenger’s side, by means of a suitable instrument. Follow
the “BLEEDING” procedure described by the instrument.
NOTE Press the brake pedal over and over again during the process.
The correct blow-off sequence for the four wheels is as follows:
- rear left wheel (RL)
- front left wheel (FL)
- front right wheel (FR)
- rear right wheel (RR)
As regards the systems of the ABS 8/ESP 8 type, no other sequence is permitted. As far as ABS 5.3 systems are
concerned, on the contrary, you may act on the single wheels without having to perform the entire procedure.
After every single wheel has been bled, visually inspect the brake fluid level and top up, if necessary. Do not fill with
fluid that has already been used.
In the event that either one single phase or the entire blow-off process is repeated, you will have to wait at least 5
minutes in order to let the system solenoid valve cool. Otherwise, the valves themselves may be damaged due to
overheating.
Prior to tightening the drain screws, make sure that the corresponding routine has been completed, and the brake
fluid flows out smoothly (no air bubbles should appear).
In order to ensure correct bleeding, the vehicle is to be set in a proper way. You will have to clean the drain screws and procure
a transparent tube and a container partially filled with brake fluid, to be connected to the screw of the wheel being bled.

ABS 8/ESP 8 system bleeding procedure sequence
Call the “BLEEDING” Open the drain screw of the

routine. corresponding wheel.
After rear left wheel bleeding

has been completed (as
Open the front left wheel indicated by the diagnosis
instrument), tighten the drain
drain screw. screw and then proceed with
the front left wheel.
After front left wheel bleeding

has been completed (as
signalled by the diagnosis Open the front right wheel
instrument), close the drain
screw and proceed with the drain screw.
front right wheel.
After front right wheel

bleeding has been completed
Open the rear right wheel (as signalled by the diagnosis
drain screw. instrument), close the drain
screw and proceed with the
rear right wheel
After rear right wheel bleeding In case of failure of one single

has been completed (as step or the entire bleeding
signalled by the diagnosis process, the whole procedure
instrument), close the drain will have to be repeated.
screw. The procedure will
now be completed.
NOTE After air bleeding from the braking circuit has been completed, fill with brake fluid up to the top level (do not fill with
oil that has already been used).

784310 Mechanically controlled load sensing Figure 42

valve (vehicles 35C)
Figure 40
52385
52387
The load proportioning valve automatically adjusts, as a function LOAD PROPORTIONING VALVE PLATE
of the load acting on the rear axle, the braking torque produced
by the brakes of the axle itself. This valve has the important job, The operations are to be carried out in the following order:
especially when the vehicle is light without any load, to limit the - set the vehicle with its rear wheel on a weighing machine
braking torque that would otherwise block the rear wheels with 99336914 or on the brake test bench;
a consequent skidding and jerking of the vehicle. - connect the pressure gauges 99372269 or Modus to the
Figure 41 pressure test points upstream from the load
proportioning valve;
- if the pressure gauges are not equipped with a valve for
automatic bleeding, bleed off the air through the
pressure gauges by unscrewing the appropriate ring nuts;
- load the vehicle so as to have a load (B) on the rear axle
divided equally between the right- and left-hand sides of
the vehicle with a tolerance of ±5 kg;
Figure 43
52386
PERFORMANCE CURVE
A. Inlet pressure (Bar) - B. Outlet pressure (bar)
Ratio = 0.25
Regulation of load proportioning valve on
vehicle
To stop the vehicle from skidding or the wheels from being
locked when braking, you must check the device at regular
intervals and eventually adjust if necessary. This consists in
verifying the values indicated on the plate
(SENZA CODICE) applied on the inside of the bonnet.
If there is no plate or if the data is missing, ask the

52388
manufacturer for a duplicate by indicating:
! - loosen the nut (1);
- Vehicle type
- connect a weight (A, page 50) to the plate (5) at point
- Number of leaf springs (2);
- Vehicle pitch - tighten the nut (1) at the specified torque and remove
- Weight of rear axle the loads (A and B).
- Number of load proportioning valve - start up the engine;

- Load the vehicle to obtain the loading sequence shown 784310 Dual mechanically controlled load
in the table in fig. 37, equally shared on the rear axle on sensing valve (vehicles 29L - 35S)
the left and right sides of the vehicle with a tolerance of
± 5 kg.
Figure 44 Figure 45
52390
The load sensing valve automatically regulates the braking
52389 torque generated by the brakes of the rear axle according to
the load weighing on the rear axle.
- with the engine idling and a pressure of 100 bar, shown It has the important function, especially when the vehicle has no
on the pressure gauge (3) upstream from the sensing load, of limiting the braking torque that would lock the rear
valve, check that the outlet pressure shown on the wheels causing the vehicle to skid.
pressure gauge (2) downstream from the sensing valve
corresponds to the values given on the rating plate,
otherwise replace the sensing valve; Figure 46
- Proceed as follows if the pressure read downstream of
the corrector do not correspond to the values shown in
SENZA CODICE.
- Disconnect the bar (4, SENZA CODICE) from the axle.
- in addition, use the transmission lever (3,
SENZA CODICE) to check that the load sensing valve
stem runs smoothly in its seat, otherwise replace the
sensing valve;
- reconnect the adjustment rod (4, SENZA CODICE) to
the rear axle;
Perform the check by gradually increasing the

! pressure.
52391
To check the load sensing valve, all the components of the
braking system must be in full working order. In addition, in the
case of replacing the leaf springs for special versions it is A. Inlet pressure (in bar) - B. Outlet pressure (in bar)
necessary to install a new rating plate whose values are correct. Ratio = 0.15
Adjusting the load sensing valve

- Once the checks have been completed, verify the
operation of the brakes by testing them. This adjustment is similar to that described above,
using the following loads.
TABLE OF LOADS FOR ADJUSTING THE LOAD
SENSING VALVE
Model Load (A) Load (B)

kg kg TABLE OF LOADS FOR ADJUSTING THE LOAD
35C 3.5 1500 SENSING VALVE
40C 3 1500
45C 4 1800
50C semi-elliptic and Model Load (A) Load (B)
double flex. parabolic leaf springs 9 1800 kg kg
50C single flex. parabolic 29L 9 1500
leaf springs. 4.5 1800 35S 6,5 1500

STABILITY CONTROL AND ANTI-SKID DEVICES

The devices described below are integrated into three FUNCTIONS INCLUDED IN THE ESP
different types of systems: SYSTEM ONLY
ABS SYSTEM FUNCTIONS Acceleration drive control device (ASR)

This system prevents driving wheel skid through quick action
Antilock braking system (ABS) on the engine and brakes. It allows the vehicle to set off safely
and fast even on slippery roads or when one driving wheel
This system comprises an electro-hydraulic modulator and is skidding. It also reduces the risk of understeering when you
an electronic control unit mounted on the modulator, accelerate too much when cornering.
located in the engine bay, four sensors and four phonic
wheels that measure the number of turns of the wheels.
The tendency for one or more wheels, whether front or rear, Engine braking torque control (MSR)
to lock, which is detected by the sensors through the pulses This system avoids driving wheel drag due to the exhaust
of the phonic wheels, is communicated to the electronic brake. It ensures vehicle stability when releasing on slippery
control unit that, by means of the electro-hydraulic roads (e.g. snow, ice), and assists in keeping the path when
modulator, independently or simultaneously regulates the cornering and shifting down, especially on slippery roads. It
pressure in the hydraulic circuit of the front and rear axles. requires a slight increase of revs number, through the CAN
line.
Electronic braking distribution device (EBD)
This system acts at a level prior to ABS operation. It ensures Hill holder control (HHC)
a sensitive control over the tendency of the rear wheels to This function allows the vehicle to be kept automatically
lock with respect to the front ones, when braking, by locked (braked) until the clutch is closet and the driver
optimizing the braking force in the different conditions of subsequently presses the accelerator pedal, thus preventing
load, travel and state of use of the vehicle. undesired vehicle motion.
This device substitutes the function of the mechanically The function is actuated automatically: the braking situation
operated load sensing valve. If this device fails, braking takes is detected by the sensor inside the modulator. When the
place with the same pressure on front and rear brakes. brake pedal is released, the vehicle will be kept braked for 2.5
seconds, thus allowing the driver/system to put the gear (and
the vehicle to be started). This ensures safe, easy start with
Electronic Stability Program (ESP) - Option any incline, regardless of the weight carried.
It monitors the vehicle’s behaviour steadily (both on straight
stretches and bends, when braking or accelerating). Hydraulic Brake Assistant (HBA)
It also monitors the driver’s actions: steering the wheel, The main feature of the HBA function is to recognize an
pressing the brake pedal, accelerator position, speed. emergency braking situation followed by “automatic”
It is always active in the background, i.e. the ESP system increase of vehicle deceleration.
compares the actual vehicle ride with the driver’s desired ride Vehicle deceleration is only restricted to actuation of ABS
50 times a second. It recognizes dangerous situations before control, thus taking the greatest advantage of the grip
the driver does. between the tyre and the roadbed currently available.
The system considers the different possibilities of coming into Therefore, ordinary drivers can now achieve braking
operation. It brakes on every single wheel separately. distances which only experienced drivers could achieve in
It operates on the engine control system. the past.
If the driver reduces the braking intensity, vehicle
deceleration is reduced depending on the reduction of the
force applied onto the pedal.
Therefore, the driver can control deceleration accurately
after overcoming the emergency situation.
The extent of the braking request from the driver
corresponds to the force applied onto the pedal. The force
applied onto the pedal is derived from measuring the
pressure in the brake pump.

526716 Electro-hydraulic
modulator/control unit for 29L - 35S
vehicles )
ABS8/ESP8 systems
Figure 47
102113
1. Hydraulic accumulator - 2. Electro-hydraulic modulator - 3. Electronic control unit - A. ABS8 connector -

B. ESP8 connector - F/MC1. Front axle power supply - R/MC2. Rear axle power supply - LF (or FL for ABS8/ESP8 systems).
Left front axle output - RR. Right rear axle output - RF (or FR for ABS8/ESP8 systems). Right front axle output - LR (or RL
for ABS8/ESP8 systems) . Left rear axle output
The electronic control unit has the task of controlling the

electro-hydraulic modulator solenoid valves according to the NOTE The devices comprising the control unit and
signals from the wheel speed sensors. electro-hydraulic modulator of the various models
The electro-hydraulic modulator modulates the pressure of are not interchangeable.
the brake fluid in both front and rear circuits according to the
control signals from the control unit.
The parts inside the hydraulic unit are not

compatible with mineral oil and unsuitable fluids.
In case of contamination by such fluids, the unit
shall be replaced and properly disposed of.

526716 Electro-hydraulic
modulator/control unit for 29L - 35S
vehicles )
ABS8 systems (vehicles 35C - 65C) / ESP8 (vehicles 35C only)

Figure 48
102114
1. Hydraulic accumulator - 2. Electro-hydraulic modulator - 3. Electronic control unit - A. ABS8 connector -

B. ESP8 connector - F/MC1. Front axle power supply - R/MC2. Rear axle power supply - LF (or FL for ABS8/ESP8 systems).
Left front axle output - RR. Right rear axle output - RF (or FR for ABS8/ESP8 systems). Right front axle output - LR (or RL
for ABS8/ESP8 systems) . Left rear axle output
The electronic control unit has the task of controlling the

electro-hydraulic modulator solenoid valves according to the NOTE The devices comprising the control unit and
signals from the wheel speed sensors. electro-hydraulic modulator of the various models
The electro-hydraulic modulator modulates the pressure of are not interchangeable.
the brake fluid in both front and rear circuits according to the
control signals from the control unit.
The parts inside the hydraulic unit are not

compatible with mineral oil and unsuitable fluids.
In case of contamination by such fluids, the unit
shall be replaced and properly disposed of.

526713 Rev sensor Longitudinal acceleration sensor

526712 Phonic wheels Figure 51
Figure 49
102116
It measures the vehicle’s acceleration and deceleration

35383
changes.
These signals continuously inform the control unit about the
The system for measuring the speed of rotation of the wheels vehicle’s behaviour.
is composed of the wheel speed sensor and the phonic wheel.
The phonic wheel is housed or incorporated in the brake disc The comparison between these signals and those from the
of the wheel and turns at the same speed as the wheel. By driver (steering-wheel position, wheel spin number/speed
induction in the sensors it generates alternating voltages whose and pressure on the brake pedal/accelerator position) allows
frequency is in proportion to the speed of rotation of the the ESP control unit to define the actions to be taken. The
respective wheel. These voltage signals are transmitted to the hydraulic unit controls brake pressure as quickly as possible,
control unit for processing. separately for every single wheel.
Moreover, the ESP system may decrease the engine revs
number by means of the engine control feature.
ESP SYSTEM SENSORS
Yaw sensor with built-in side acceleration
sensor
Steering angle sensor
Figure 50
Figure 52
102115
It measures the motion of the vehicle around its own vertical

axis (yaw) as well as the vehicle’s side acceleration.
These signals continuously inform the control unit about the
vehicle’s behaviour. 102117
The comparison between these signals and those from the

It measures the steering angle required by the driver.
driver (steering-wheel position, wheel spin number/speed
and pressure on the brake pedal/accelerator position) allows The comparison between this signal and those from all the
the ESP control unit to define the actions to be taken. The other sensors allows the ESP control unit to define the
hydraulic unit controls brake pressure as quickly as possible, actions to be taken. The hydraulic unit controls brake
separately for every single wheel. pressure as quickly as possible, separately for every single
wheel.
Moreover, the ESP system may decrease the engine revs
number by means of the engine control feature. Moreover, the ESP system may decrease the engine revs
number by means of the engine control feature.

5274 BRAKE REPAIR OPERATIONS

Front brakes Figure 55
The following operations have been carried out on vehicles
with 2x48 Brembo front calipers.
527417 Replacing brake linings
The braking system effects safety. All repairs and

! servicing operations must be exclusively carried out
by skilled, qualified personnel.
109131
The oil inlet hose to the calliper must not be Remove screw (3) securing brake caliper (2) to support (4).
disconnected during the operations that follow. Move bush (1) inside brake caliper (2), tilt the brake caliper.
!
Figure 56
Figure 53
109132
455026
Disconnect cable (4) from braking gasket (3) and unthread
Set the vehicle on level ground and lock the rear wheels. Loosen the cable from brake caliper (5).
the nuts (1) securing the front wheels. Lift the front of the Dismount braking gaskets (2 and 3) from caliper support (1).
vehicle with a hydraulic lift and rest it on two stands (3).
Figure 57
For 2x48 brake calipers

Figure 54
109133
Withdraw pistons (1) by a retractor or other suitable tool (2),

paying attention not to damage piston surfaces and
protection cowlings.
109122 Retracting the pistons will increase the level of brake

fluid in the reservoir. For this reason, check the fluid
Disconnect electrical connection (3) of wear sensor from does not spill out of the reservoir and damage
chassis cable and release the cable of the electrical vehicle paintwork during the operation.
connection from securing blade (2).
Remove rubber protection plug (1).

For 2x60 brake calipers Checks

Figure 58 Figure 60
109135
Check the conditions of check springs (1) or (4, Figure 58)

of braking gaskets and sliding bushes (2); should they be
worn, replace them.
109056
Visually check the conditions of dust cowlings (3 and 4).
Remove safety springs (2) from pins (3). Should they be deformed or cracked, they must be replaced.
Unthread pins (3) from brake caliper (6) and recover springs Remove dirt from brake caliper using a metal brush and
(4) checking braking gaskets (1). avoiding to damage the dust cowlings.
Disconnect electrical connection (5) for gasket wear Clean pads rest area using suitable materials and products
signalling unit. (e.g. a wet cloth); on the contrary, do not use a
Unthread braking gaskets (1) from brake caliper (6). nitro-perchlorate based diluent, petrol, etc., which might
damage the protection cowlings.
Check brake disk surfaces and make sure that the disk is not
corroded, scored or grooved.
Slight superficial cracks are acceptable; however, brake disk
must be ground as described in relating chapter; on the
contrary, if the disk is worn out, it must be replaced.
Figure 59
We suggest that both brake discs be renewed also
! in case one of them only needs to be replaced.
As regards brake lining pairs, always replace a
complete series for each axle.
Always overhaul both brake calipers also in case one
of them only seems to be damaged.
For 2x48 calipers

Figure 61
109134
Withdraw pistons (1) by a retractor or other suitable tool (2),

paying attention not to damage piston surfaces and
protection cowlings.
Retracting the pistons will increase the level of brake

fluid in the reservoir. For this reason, check the fluid 109132
does not spill out of the reservoir and damage Insert new brake liners (1) in the brake calliper mount and
vehicle paintwork during the operation. check that they slide in their seats.
Fit cable (4) into brake caliper (1), and connect the cable to
braking gasket (3).

Figure 62 527413 Removal/Re-fitting of brake calipers

Removal 2x48 calipers

Figure 65
109131
Move bush (1) inside brake caliper (2) and position the
caliper on caliper support (4).
Screw screw (3) and tighten it to prescribed torque. 109137
Disconnect electrical connection (1) of wear sensor from

Figure 63 chassis cable and release the cable of the electrical
connection from support blade (2).
By suitable wrench, disconnect hose (3) of brake liquid from
pipe and drain brake liquid into special container.
If necessary, plug the pipe preventing piping complete
draining.
NOTE The hose has to be removed at the bench.
109122
Brake liquid is venomous and corrosive: in case of
! accidental contact, immediately wash with water and
Mount protection plug (1). neutral soap.
Connect cable (3) of wear sensor to support blade (2) and
cable connection to chassis cable connection.
Figure 66
For 2x60 calipers
Figure 64
109056
109138
Mount braking gaskets (1). Remove rubber protection plug (1).

Position springs (4) and fit pins (3) into brake caliper (6). Unscrew screws (2), take off brake caliper (4) and disconnect
Mount safety springs (2) into pins (3). electrical cable (3) of braking gasket wear sensor.
Connect electrical connection (5) of braking gasket wear Check braking gaskets conditions. If braking gaskets are found
signalling unit. to be worn out, replace them and follow checks as described
in relating chapter.

Removal 2x60 brake caliper 527447 Removal/Refitting of brake calipers

Figure 67
Figure 68
45045
109139
Set the vehicle on level ground, loosen the nuts (1) securing
Dismount braking gaskets as described in relating chapter. the wheels.
By suitable wrench, disconnect hose (3) of brake liquid from Lift the front of the vehicle with a hydraulic lift and rest it on
pipe and drain brake liquid into special container. two stands (2).
If necessary, plug the pipe preventing piping complete Unscrew the nuts (1) and remove the wheels.
draining. Figure 69

neutral soap.
109140
Remove screws (4) and take brake caliper (2) off caliper
support (1). Disconnect electrical connection (3) of wear sensor from
Refitting chassis cable and release the cable of the electrical
connection from support blade.
Remove rubber protection plug (1) and unscrew screw (2).
Check the pistons are fully retracted inside the
caliper body. Figure 70
Refit by carrying out the operations described for
removal in reverse order, observing the required
tightening torques.
Drive slowly without prolonged, sudden brake

! application during the first period of use of new
brake pads because braking efficiency is reduced.
Press the brake pedal repeatedly to restore pressure in the 109141

system and correct brake pedal stroke.
Move (→-) bush (3) inside brake caliper (2) and tilt the brake
caliper.
527440 REAR BRAKES Disconnect cable (1) from braking gasket (4) and unthread
The following operations have been carried out on vehicles the cable from brake caliper (2).
with 2x48 Brembo rear calipers. Dismount braking gaskets (4 and 5) from caliper support (6).
They should be considered similar also for 2x44 - 1x52C - For 2x44 and 2x48 calipers, withdraw pistons (7) following
1x60C Brembo rear calipers unless stated otherwise. indications in Figure 57.

For x52 - 1x60 calipers

We suggest that both brake discs be renewed also
Figure 71
! in case one of them only needs to be replaced.
As regards brake lining pairs, always replace a
complete series for each axle.
Always overhaul both brake calipers also in case one
of them only seems to be damaged.
Figure 73
51223
Using tool 99372236 (1) retract the piston (3) by pushing

constantly in line with the piston axis with a force of approx.
300 ÷ 400 N while turning the tool clockwise until the piston
(3) is fully retracted.
During this operation, take care not to twist the

! protective cap (2) or let it swell out.
109143
Let the air out of the cap by moving it away from the
brake caliper. Fit new gaskets (4 and 5) into caliper support and check for
their freely sliding in their seats.
Fit cable (1) into brake caliper (2) and connected the cable
Checks to braking gasket (4).
Move (→) bush (3) inside brake caliper (2) and position it on
Figure 72 caliper support (6).
Figure 74
109142
Check the conditions of springs (4) and sliding bushes (2); 109140
should they be worn out, replace them.
Visually check the conditions of dust cowlings (1) and (1, Screw screw (2) and tighten it to prescribed torque.
Figure 78). Should they be deformed or cracked, they must Mount rubber protection plug (1).
be replaced. Remove dirt from brake caliper using a metal Connect the cable of wear sensor (3) to support blade and
brush and avoiding to damage the dust cowlings. cable connection to chassis cable.
Clean pads rest area using suitable materials and products
(e.g. a wet cloth); on the contrary, do not use a For all brake callipers
nitro-perchlorate based diluent, petrol, etc., which might
damage the protection cowlings. Drive slowly without prolonged, sudden brake
Check brake disk surfaces and make sure that the disk is not ! application during the first period of use of new
corroded, scored or grooved. brake pads because braking efficiency is reduced.
Slight superficial cracks are acceptable; however, brake disk
must be ground as described in relating chapter; on the
contrary, if the disk is worn out, it must be replaced.
Press the brake pedal repeatedly to restore pressure in the
system and correct brake pedal stroke.

527443 Removal/Refitting brake calipers Removal

Removal
Figure 75 Refit by carrying out the operations described for
removal in reverse order, observing the required
tightening torques.
Replace the hose if anomalies are found.
Bleed air from hydraulic system as described in

! relating chapter.
527413 OVERHAUL OF BRAKE CALIPERS

2x44 - 2x48 - 2x60 Brembo brake calipers
109144
Disassembly
For Brembo 2x44 - 2x48 brake caliper
Disconnect electrical connection (4) of wear sensor from
chassis cable and release the cable of the electrical
connection from support blade. Figure 77
By suitable wrench, disconnect hose (3) of brake liquid from
pipe and drain brake liquid into special container.
If necessary, plug the pipe preventing piping complete
draining.

109145
neutral soap.
Slide the slippage sleeves (1) and take out the protection
casings (2).
Remove plug (1), unscrew screws (2) and take brake caliper
(5) off support (6).
For 1x52 - 1x60 brake calipers
Figure 76
Figure 78
50735
109146
Remove the retaining clip (1) and unhook the parking brake Remove the dust covers (1 and 2) and keep the sliding bushes
rope. (3).

Figure 79 Check wear of brake liners and safety springs. Replace the
parts which are either deformed or worn.
It is recommended to replace the piston dust covers and seal
rings even if they do not show any signs of deformations or
defects.
Assembly
Lubricate the pistons and seal rings with brake liquid
Tutela DOT SPECIAL.
109147
Figure 81
Place the caliper on a work bench. Insert a block of wood (2)
so that the pistons can be removed without damaging them,
and to make the operations safe for the technician.
By means of a gun (3), introduce air into the brake caliper the
pistons (1) are extracted.
Remove the dust boots (3) from the respective seats.
Figure 80
45035
Insert the seal rings (1) into the relevant seats of the caliper
casing.
Figure 82
45035
Remove the seal rings (1) from the brake caliper cylinder
seats.
Cleaning and checking of main components
For all types of brake calipers
When washing the metal components use hot water
with Fiat LCD type detergent.
By means of a metal brush, remove any dirt from the 45036
brake caliper, then eliminate any residual dirt with
the use of a brush. Carefully clean the seats of the Insert the dust boots (4 and 5) in their seat on the brake
guide pins, sliding bushes, pistons and the pistons calliper (1). Fit the cylinders (2) and the sliding bushings (3)
themselves. or (1, fFigura 77) and make sure they slide freely.
By means of a suitably sized synthetic brush, remove Correct sliding if required by lubricating the bushings with
all traces of grease from the seats of the sliding Klueber glk1pf grease.
bushes. Open the bleeder valves, then carefully blow
compressed air into the brake caliper casing. Insert the dust covers into the relevant sears on the pistons
(2) and on the sliding bushes (3).
By means of a piece of canvas soaked in methylated
spirits or similar, carefully clean the sliding surfaces. 1x52 - 1x60 Brembo brake calipers
Check the wear on the sliding bushes, pistons and
The 1x52 callipers (rear, 29 L - 35 S vehicles) are
relevant seats on the brake caliper casing. Make sure
! equipped with an automatic brake liner wear
that the sliding surfaces are neither damaged or
tensioner device and the components cannot be
worn.
removed.
Insert the bushes and pistons into the seats and Consequently, replacement/overhauling operations
check that they are free to slide, otherwise restore on the piston, dust boot and internal components
or replace as necessary. must only be carried out by specialised personnel.
Only the sliding bushings can be overhauled. The
removal/refitting procedure is the same as that
A regular braking effect depends a great deal on the
described for the other callipers.
! condition of the sliding surfaces.

527411 OVERHAUL OF BRAKE DISCS Figure 85
Figure 83
45040
45038
By means of the lathe 99301001 (1), machine both working
To take down and fit back the brake disk (1) follow the surfaces of the drum brake.
procedures described in the “axles” section.
Check the wear on the surfaces of the drum brakes.
NOTE During this grinding operation, gradually move the
When values different from those indicated in the sequential wheel towards the working surface in
specifications and data table are found, machine and grind the order to completely remove the swarf left over
disk brakes and, if necessary, replace them. from turning.
527411 MACHINING AND GRINDING OF

DISC BRAKES
Figure 84
45039
- Fit the disk brake (1) complete with the wheel-hub to

the late arbor 99301005 (2);
- fit a set of spacers on the shaft to remove unit end play,
tighten the lock nut and apply the lathe support;
- place the tool-holder (3) along the axis of the drum
brake (1) then adjust the work depth of the tools;
- turn down the drum brake (1) by passing over the
surface a few times depending on the condition of the
surface itself.

WHEEL NUT TIGHTENING SEQUENCE OVERHAULING PARKING BRAKE
Dismantling parking drum brake

Figure 86
Figure 87
45048
52747
Release shoe (1) return springs (2 and 5). Save the adjusting
device (3).
AXLE TIGHTENING ORDER
Remove retaining brackets (4 and 6) and detach shoes (1).
Tighten the screws at the specified torque in the order

shown.
Figure 88
45049
Remove shoe retaining pins (3) and parking brake wire

hitching device (4).
NOTE Disjoin support (1) and withdraw sensor (2) to

remove ABS sensor (2).
To reassemble the sensor (2), push it as far as it will
go inside support (1) and fasten the latter to the rear
axle.

For models 35C - 40C (not including vehicles with NDA R.G. rear axle) - 45C - 50C
Figure 89
45047
VIEW OF THE PARKING DRUM BRAKE

For models 60C - 65C
Figure 90
62674
VIEW OF THE PARKING DRUM BRAKE

Check inner disc diameter to establish whether it can Check brake jaw conditions and replace if anomalies are
be reused. found.
Measure the inner disc diameter with a sliding gauge If the brake lining surface is oily, trace the cause and repair
without moving the arms to an angle. the fault.
Measure the drum diameter in several spots to The minimum brake seal thickness is 3.5 mm for models 60C
determine ovality and wear. Also examine depth of - 65C, and 1.5 mm for models 35C - 40C - 45C - 50C.
scoring on the braking surface. If this is not so, even if only slightly above or below the
Max permitted ovality and/or eccentricity tolerance specified value, replace them.
is 0.1 mm. Check serviceability of shoe return springs.
Replace the disc if wear or evident signs of overheating are

found (see specifications and data table).

Assembly - lift the rear of the vehicle, resting the chassis frame
on the stands;
Figure 91 - loosen the lock nut (3);
- take the parking brake lever, in the cab, onto its third
catch;
- screw down the tightener screw (2) until the rear
wheels are hard to turn by hand;
- operate 3-4 times the lever in the cab to set parts,
then check whether the stroke is of approx. 6 steps;
- lock the lock nut (3);
- lower the vehicle.
B. For further adjustments, it is necessary to proceed as fol-
lows:
74991 Case 1 — With disk removal
- lift the rear of the vehicle, resting the chassis frame
on the stands;
- loosen the screw (2) completely;
Loosen the tensioner under the chassis in the middle of the - remove the disc as described in the ”REAR AXLES”
vehicle. section;
Reverse disassembly operations to reassemble.
Using a sliding gauge, measure the diameter of the brake seal - run the checks described on page 61;
(2), check that the values correspond with those indicated on - use the adjustment device (1, SENZA CODICE) to
the specifications and data tables, if not, adjust the device (1) obtain the distances given in the ”Specifications and
until the correct values and data are obtained. Data” table;
- mount the disc and wheels. Firmly apply the parking
brake a few times to settle the sheaths of the ropes;
- take the parking brake lever, in the cab, onto its third
catch;
- screw down the tightener until the rear wheels are
hard to turn by hand;
- lock the tightener lock nut;
5027 Adjusting parking brake
(vehicles with parking drum brake) - lower the vehicle.
Case 2 — Without removing disks
Figure 92 - lift the rear part of the vehicle resting the chassis on
the supporting stands provided for the purpose and
remove wheels;
- loosen the lock nut (3);
Figure 93
52277
A. Play recovery is not automatic. Minor lever stroke exten-

sion (corresponding to approximately 2 notches in addi-
tion to the normal lever stroke which is 7 notches) by
means of the tensioner (1) as shown below:
86295

- remove the brake upper slot rubber plug (3); Vehicles with parking brake on brake disc
- use tool 99372249 (1) to operate the manual ad- Clearance recovery is automatic, but if the ropes are
juster internal ring nut (2) and widen the shoes until removed or replaced it is necessary to adjust their length in
the disk can no longer be turned using just the hands; accordance with points A and B.
- always with tool 99372249 (1), loosen the above
mentioned adjusting ring nut (2) by 3 notches and
check whether the disk is free to turn;
- refit the rubber plug into the slot;
- refit rear wheels; REPLACING THE ESP COMPONENTS
- set the lever in the cab to the third position; Some modifications or repairs affecting the ESP system
- screw the tightener screw (2, Figure 81) until wheels components require a specific calibration procedure.
can no longer be turned using just the hands;
The repairs that require such procedure are detailed as
- operate 3-4 times the lever in the cab to set parts,
then check whether the stroke is of approx. 6 steps; follows:
- lock tightener lock nut;
- lower the vehicle. - replacing the electronic control unit (integrated into the
electrohydraulic modulator) of the system’s braking
apparatus;
- replacing the steering angle sensor fitted inside the
steering wheel;
NOTE Should new brakes/disks be replaced at the same - replacing the longitudinal acceleration sensor.
time, drum brakes are not to be adjusted. Only
adjust the main cable tightener since brakes are
adjusted yet to the rated installation value. NOTE Replacing the yaw sensor requires no calibration.
STEERING ANGLE SENSOR

Replacing
Figure 94
109148
Below is the description of sensor calibration only. As far as steering angle sensor replacement is concerned, refer to the
description on page 24 of the “Steering” section.
Calibration
With both the steering-wheel and the wheels in straight position (after checking toe-in), you will obtain the sensor “zero”
condition through the diagnosis instrument, i.e. you will assign its absolute zero position.
Use a diagnosis instrument to clear the errors.
Carry out a road test, to make the control unit verify whether errors are still found. Drive along a straight road at a constant
speed. Steer to the right and then to the left several times, after making sure you do not endanger other drivers.
NOTE Drive back to the service centre, then use a diagnosis instrument to verify that the anomaly is no longer found.
Drive back to the service centre, then use a diagnosis instrument to verify that the anomaly is no longer found.

526741104 LONGITUDINAL ACCELERATION SENSOR
Figure 94
109149
Removal Refitting
Disconnect the battery cables in the engine compartment. Re-attachment is carried out by reversing the order of
Take off the instrument board covering. detachment operations. Also follow the advice below:
- never change the sensor position and fastening points.

Figure 95 The sensor features an offset position compared with
the vehicle centre line, which must not be modified.
- After re-attachment has been completed, follow the
calibration procedure described below.
Calibration
Calibration must be carried out with the vehicle on a flat
ground.
Assign the sensor “zero” position by means of the diagnosis
instrument.
Always clear the errors (if any) found in the control unit
memory by means of the diagnosis instrument.
Carry out a functional road test to verify whether errors are
still found.
This consists of driving the vehicle to a slight slope and
102316 subsequently verifying whether the vehicle is kept braked
over 2.5 seconds.
Disconnect electric connection (3). Drive back to the service centre, then use a diagnosis
Unscrew the two sensor (2) fastening screws (1). instrument to verify that no anomaly is found any longer.
Remove sensor (2).

526742104 YAW SENSOR
Figure 96
109150
Removal Figure 98
Disconnect the battery cables in the engine compartment.
Take off the instrument board covering.
Figure 97
102319
Unscrew the two sensor (2) fastening screws (1) by using a

suitable wrench to remove the side right screw, considering that
the latter cannot be accessed easily. Then, remove sensor (2).
Refitting
of detachment operations. Also follow the advice
102318 below:
Disconnect electric connection (2). - never change the sensor position and fastening
points. The sensor features an offset position
compared with the vehicle centre line, which
must not be modified.
Take off glove compartment (1) on the passenger’s
! side. If the vehicle is equipped with passenger’s Calibration
airbag, follow the safety rules indicated in the
relevant chapter of the “Steering” section. NOTE Replacing the yaw sensor requires no calibration
procedure.

526741104 ELECTROHYDRAULIC MODULATOR/CONTROL UNIT
Figure 99
109151
Removal Refitting
Disconnect the battery cables in the engine compartment. Re-attachment is carried out by reversing the order of
Take off the hydraulic braking system fluid cap, then remove detachment operations. Also follow the advice below:
the filter. - connect the connector with great attention, taking care
Suck the braking system fluid by means of a syringe. to insert it perpendicularly to the seat to avoid damaging
the pins;
- after re-attachment has been completed, perform the
programming and calibration procedures described
below.
Figure 100
Programming
Programming requires entering the following variant codes
(by means of the diagnosis instrument): type of drive, engine,
MTT, wheelbase, type of front and rear suspensions, height.
Easy compares the type of vehicle (PIC reading) with the
control unit code to avoid installation errors (single wheels
instead of dual wheels), and downloads the variant codes into
the control unit.
102320
Disconnect the six oil ducts from modulator (1). Calibration

Clear the modulator parts of the oil escaped when
disconnecting the ducts. Replacing the modulator/control unit requires calibration of
Disconnect the electric connection. the longitudinal acceleration sensor (described on page 64).
Loosen the screws securing the modulator to the support In this case, the steering angle sensor shall not be calibrated
bracket. since it features its own internal memory.
Remove the modulator/control unit (1).

Bench overhauling
Disassembly
Figure 101
102321
Loosen the four screws (1) securing control unit (2) to

electrohydraulic modulator (3).
Take control unit (2) out of the modulator.
Assembly

detachment operations.

DAILY EURO 4 CAB AIR-CONDITIONING 1
SECTION 12
5501 Bodywork
5001 Chassis Frame
5532 Cab air-conditioning
NOTE As far as the chassis is concerned, refer to printed

document no. 603.93.461
Page
SAFETY STANDARDS TO OBSERVE WHEN
WORKING ON VEHICLES EQUIPPED
WITH THE AIR-BAG SYSTEM . . . . . . . . . . . . 3
CAB AIR-CONDITIONING . . . . . . . . . . . . . . . . . . 3
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR-CONDITIONING SYSTEM MAIN
COMPONENTS AND FUNCTIONAL
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIR-CONDITIONING AND HEATING . . . . . . . . 4
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Air-conditioning . . . . . . . . . . . . . . . . . . . . . . . 4
- Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . 5
- Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Drier filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Expansion valve . . . . . . . . . . . . . . . . . . . . . . . . 6
- Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONTROL AND SAFETY DEVICES . . . . . . . . . . . 7
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Three-level pressure switch . . . . . . . . . . . . . . 7
- Outside air temperature sensor . . . . . . . . . . . 7
AIR-CONDITIONING UNIT (“M. MARELLI”
OR “DENSO” TYPE) . . . . . . . . . . . . . . . . . . . 8
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Electronic control unit . . . . . . . . . . . . . . . . . . 8

2 CAB AIR-CONDITIONING DAILY EURO 4
Page
”M. MARELLI” TYPE HEATER/AIR-CONDITIONER

UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Components . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Components . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PROCEDURE FOR EMPTYING AND REFILLING THE
AIR-CONDITIONING SYSTEMS WITH
R134A REFRIGERANT . . . . . . . . . . . . . . . . . . 11
- R134A refrigerant recovery and refilling
station (99305146) . . . . . . . . . . . . . . . . . . . . . 11
CONTROL FASCIA . . . . . . . . . . . . . . . . . . . . . . . . 12
SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION FLOW CHART . . . . . . . . . . . . . . . . 15
RECOVERING REFRIGERANT
FROM THE VEHICLE SYSTEM . . . . . . . . . . . 16
CREATING A VACUUM IN THE SYSTEM . . . . . . 18
RESTORING OIL IN THE SYSTEM . . . . . . . . . . . . 20
FILLING THE SYSTEM WITH REFRIGERANT . . . . 21
CHECKING THE PRESSURES IN THE SYSTEM . . 23
OPERATIONS PRIOR TO DISCONNECTING
THE STATION FROM THE SYSTEM . . . . . . 23
LEAK FINDER FOR AIR-CONDITIONING
SYSTEMS WITH HFC R134A (9905147) . . . . 23

SAFETY STANDARDS TO OBSERVE WHEN WORKING ON VEHICLES EQUIPPED WITH

THE AIR-BAG SYSTEM
! Before doing any work, you MUST observe the SAFETY rules given in section 10 “Steering system”
CAB AIR-CONDITIONING
General
The purpose of the air-conditioning system is to make the cab comfortable as regards the following parameters:
- temperature and relative humidity of outside air;
- temperature and relative humidity in the cab.
The system subjects the air to thermodynamic transformations that affect its temperature, relative humidity and purity. This is
accomplished by:
- Ventilation, or introducing air taken from the outside (therefore with the temperature and humidity of the surrounding
environment) into the cab.
- Air-conditioning, or cooling and de-humidifying the air, with the possibility of heating it afterwards as preferred so as to
change the temperature and humidity in the cab.
VENTILATION
Description
Ventilation is the function of drawing in fresh air from the outside, cleaned of pollen and dust by a special filter, or recycling the
air in the cab.
This system is composed of a shell, designed to house the electric fan unit, air ducts, fresh air intake and recycled air intake. The
electric fan has several speeds to draw in and circulate large masses of air.

AIR-CONDITIONING SYSTEM MAIN COMPONENTS AND FUNCTIONAL DIAGRAM
Figure 1
52279
A. Refrigerant liquid inlet - B. Refrigerant liquid outlet - H. High-pressure circuit - L. Low-pressure circuit.
1. Condenser - 2. Three-level pressure switch - 3. Drier filter - 4. Compressors - 5. Heater/fan unit - 6. Evaporator -
7. Expansion valve - 8. Pollen filter.
AIR-CONDITIONING AND HEATING Heating

Heating is accomplished by a radiator, in the heater unit, in
Description which the engine coolant circulates.
This is accomplished by integrating an air-conditioning and a
heating system. Special doors allow air to pass through the radiator only
when the heating function is activated.
This integration makes it possible to change the temperature
and humidity in the cab. The main components of the air-conditioning and heating
system comprise:
Air-conditioning - compressor (4);
Air-conditioning is accomplished by taking advantage of the - condenser (1);
high capacity of some gases to lower temperature
- drier filter (2);
considerably in their phase of expansion, thereby making it
possible to absorb heat from the cab. - three-level pressure switch (3);
- expansion valve (7);
This condition is obtained by two different levels of pressure
(high, when the refrigerant fluid is in its liquid state, and low, - evaporator (6);
when the fluid is in its gaseous state) that are established and - heater/fan unit (5);
maintained during operation of the system. - pollen filter (8).

MAIN COMPONENTS
553239 Compressor Figure 3
Figure 2
52282
52281
The compressor is located between the evaporator and the The electromagnetic friction device is composed of an
condenser. Its function is to: electromagnetic coil (2), a pulley (1) and a front disc (3).
- draw refrigerant fluid in the form of vapour at low When the system is not running, the pulley (1) turns idle on
pressure and low temperature from the evaporator the bearing (4) since it is driven by the engine via the V-belt.
through the inlet (2);
On switching on the air-conditioning system, the
- compress the refrigerant fluid drawn up and introduce
electromagnetic coil (2) attracts the front disc (3) on the
it at high temperature and high pressure into the
pulley (1) that comes to be virtually keyed onto the
condenser through the outlet (1).
compressor shaft and makes it rotate.
The compressor is driven by the electromagnetic friction
device mounted on the compressor shaft.
Specifications and data 553232 Condenser

Figure 4
COMPRESSOR
Type SCO 8 C
Displacement cm3 80 cm3
Stroke mm 33
Rev. No.:
Max RPM 7800
Refrigerant
Oil type ND - OIL 8
Refrigerant amount kg 0.72
Oil amount 80 ± 20 cm3
Airtightness test 3.14 MPa
Pressure test High 530 MPa
Low 250 MPa
ELECTROMAGNETIC FRICTION
Torque min 26 Nm
52283
Voltage rating V 12
Absorbed pressure W max 35 The condenser is a heat exchanger located between the
Weight kg 1.5 compressor and the drier filter. Its function is to transform the
refrigerant fluid from its gaseous to its liquid state.
Belt 4k-type
Pulley actual diameter mm 105 This transformation is made by the refrigerant fluid releasing
heat to the outside air. This is why the condenser is installed
on the vehicle so as, in the best conditions, to take advantage
of the air stream produced by the forward motion of the
vehicle.

When the vehicle is stationary or in a traffic jam, the flow of This valve has two passages for the refrigerating fluid:
air needed to transform the refrigerant fluid is produced,
- the bottom one enabling the refrigerant to pass (5) from
under the control of the three-level pressure switch, by the
the drier filter to the evaporator (2). Along this route
fan for cooling the engine coolant.
there is a spring (4) that, appropriately set, makes it
possible to obtain such a leap in temperature
NOTE The condenser located in vehicles with F1C engine, (overheating) as to make sure that the refrigerant, at the
has the drier filter incorporated. evaporator inlet, is entirely in its gaseous state. In
addition, there is also a modulating element, in this case
a ball (3) housed in the gauged pipe that controls the
flow rate of refrigerant to the evaporator;
553234 Drier filter - the top one enabling the refrigerant to pass (1) from the
Figure 5 evaporator to the compressor (6). Along this route
there is a temperature sensor (7) that, depending on the
temperature at the evaporator outlet, makes it possible
to control the flow rate of refrigerant, by means of the
modulating element (3), and control the overheating, by
means of the spring (4).
553231 Evaporator
Figure 7
52284
The drying filter is located between the condenser and the

expansion valve. On the vehicles equipped with the F1C
engine, it is incorporated into the condenser and performs
the following function:
- reserve tank for excess refrigerant fluid during variable filling
phases;
- filtering element for the solid particles generated by
compressor wear;
- eliminating the moisture formed in the system.
553233 Expansion valve
Figure 6
52286
The evaporator is a heat exchanger located between the

expansion valve and the compressor.
Its function is to:
- change the state of the refrigerant from a liquid, at the
inlet, to a gas, at the outlet;
- absorb the heat in the cab and thereby produce the
required refrigerating effect.
To be able to perform these functions, an electric fan draws
warm, moist air from the cab and conveys it onto the
evaporator.
52285 Since this air is at a higher temperature than the refrigerant,
it gives some of its heat to the refrigerant and cools down,
The expansion (block) valve is located between the drier while the moisture it contains condenses on the evaporator
filter and the evaporator. fins in the form of droplets.
Its function is to control and proportion the flow of This produces cold, dehumidified air.
refrigerant fluid to get the highest refrigerating capacity out This change takes place with considerable heat absorption.
of the system and to lower the pressure of the refrigerant (at A special channel collects the condensation formed and
the filter outlet) to a pre-set value so that the fluid, circulating discharges it outside.
in the evaporator, can be drawn up by the compressor in a The considerable cooling of the radiating pack is due to the
completely gaseous form. change in state, from liquid to gas, of the refrigerant.

CONTROL AND SAFETY DEVICES 553242 Outside air temperature sensor
Description It is fitted into the left side rear-view mirror.
The system is equipped with specific devices that, by checking

the pressure and temperature, make it possible to protect the
system from possible trouble and provide optimal operation.
553235 Three-level pressure switch
Figure 8
52287
The three-level pressure switch is mounted on the pipe

connecting the drier filter to the expansion valves. It has the task
of operating the electric fan for the condenser and radiator
when the vehicle is stationary or running at low speed, so there
is no air stream caused by the forward motion of the vehicle,
and it is therefore necessary to activate refrigerant condensation
by forced ventilation.
In addition, it has the task of disconnecting the electromagnetic
coupling of the compressor pulley when the pressure of the
fluid (high pressure side), in spite of the action of the condenser
and radiator fan, reaches dangerous limits or when the heating
load conditions are not sufficient to make the refrigerant
evaporate.

553230 AIR-CONDITIONING UNIT (“M. MARELLI” OR “DENSO” TYPE)

Figure 9
52289
General 553248 Electronic control unit

A special casing, configured so as to permit insulation, houses
the radiator-heater, evaporator, fan unit, internal air
(recirculation air) and external air (fresh air) intakes, direction Figure 10
flaps, ducts and vents for the flow of treated air.
This unit has to control the following parameters and
functions automatically under the control of the control unit:
air temperature at vents, fan speed, air distribution,
recirculation, and compressor activation.
The system needs to make provision for the possibility of
adjusting the following parameters and functions manually:
fan speed on 5 positions, air distributor on 4 positions (5 in
automatic mode), recirculation, and compressor activation.
The manual controls have priority over automatic mode and
are kept in memory until the user deliberately cancels the
command, returning control of the relative function to 52290
automatic mode. The automatic air-conditioning/heating system is controlled

If one of the parameters is changed manually, the others by an electronic control unit that governs both systems
remain under automatic control. (air-conditioning and heating) and determines the mixture
and quantity of air to be introduced into the cab to provide
The air temperature at the vents is always controlled the required conditions.
automatically to produce the temperature shown on the
display in the cab (unless the system is not in operation). To obtain the required temperature in the cab, the control
unit also takes into account the data from the sensor that
measures the outside air temperature.
The control unit therefore governs the following functions:
- switching the air-conditioning system on and off;
- using external or recycled air; the hot/cold air mixture;
- the amount of air to introduce into the cab (with the
different fan speeds).
Every time the battery is disconnected, when it is
reconnected the control unit automatically zeroes the
positions.

Revi - April 2002
553230 ”M. MARELLI” TYPE HEATER/

AIR-CONDITIONER UNIT Figure 11
Components
1. Strip on A.I. flange
2. Treated air sensor
3. Front door hatch
4. Distribution bushing
5. Recirculation door
6. LH air intake box
7. Cond. drain pipe retaining bracket
8. Mixing actuator
9. Rear box
11. Complete distribution door
12. Strip
13. Strip
14. Radiating mass
15. Wiring harness
16. Tie rod
17. Distribution lever
18. MAX DEF cam
19. Fan potentiometer
20. Mixing potentiometer
21. Control mounting
22. Knob adapter ring
23. Prism
24. Complete microswitch
25. Control pin
26. Knob
27. Cap spring
28. Cap
29. Condensation drain pipe
30. Strip
31. Condensation drain tub
32. Control unit
33. Condensation drain tub strip
34. Front box
35. Self-tapping insert
36. Mixing/foot door lever
37. Bushing
38. Transmission
39. Vent./demist. door lever
40. Water pipe fixing U-bolt
41. Distribution cam
42. Control mounting bracket
43. Anti-frost sensor
44. Wiring retainer clamp
45. Fan strip
46. Electric fan
47. Connection cover
48. Motor mounting
49. Spacer
50. Connector bracket
51. Electronic control
52. Evaporator
55. Evaporator strip
56. Pipe
57. OUT O-ring
58. Expansion valve
59. OUT O-ring
60. Fixing screw
61. IN O-ring
62. IN O-ring
63. Pipe passage strip
64. Pipe strips
65. A.I. actuator
66. A.I. door lever
67. RH air intake box 52294
68. Tie rod

Figure 12 553210 HEATER UNIT

Components

2. Rear box
3. Pipe strip
4. RH air intake box
5. Tie rod
7. Strip on A.I. flange
8. Doors
9. LH air intake box
10. Recycle air intake control transmission
11. Bowden clip
12. A.I. door lever
13. Wiring
14. Mixing flexible transmission
15. Mixing control lever
16. Recycle air intake lever
17. Control pin
18. Spring
19. Cap
20. Cap, cap spring
21. Complete distribution - temperature knob
22. Knob prism
23. Recycle air intake cursor
24. Clamp
25. Control mounting
26. Light guide cable
27. Connecting rod
28. I.A.- REC flexible transmission
29. Distribution control lever
30. Switch
31. Distribution flexible transmission
32. Connection cover
33. Motor mounting
34. Connector bracket
35. Frame bracket
36. Electric fan
37. Self-tapping insert
39. Transmission
40. Distribution cam
41. Mixing bowden clamp
42. Control fixing bracket
44. Vent/def door lever
45. Wiring retainer clamp
46. Fan strip
47. Water pipe fixing U-bolt
48. 4-speed resistor
49. Bushing
50. Front box
53. Radiating mass
54. Side gasket
55. Gasket on tub
56. Water pipe assembly
A. Flexible transmission
60920

PROCEDURE FOR EMPTYING AND

REFILLING THE AIR-CONDITIONING NOTE This procedure does not describe the phases of
SYSTEMS WITH R134A REFRIGERANT loading and unloading refrigerant to and from
external and internal containers or maintenance.
R134A refrigerant recovery and refilling Therefore, please refer to the operating and
station (99305146) maintenance manual of the appliance.
This station has been made to be used on all air-conditioning/
heating systems for motor vehicles using R134A gas. The station is composed of:
By connecting the station to a refrigerating system the gas it 1 control panel;
contains can be recovered, cleaned and made ready to be
reloaded into the system or be transferred to an external 2 container to restore any oil recovered when unloading;
container. In addition, it is possible to see the amount of oil 3 flexible hoses;
taken from the system, restore it and ”empty” the system.
4 container to collect any oil recovered from the system;
To be operative, the station needs to absorb approximately
5 filler cylinder with graduated scale revolving.
3 kg of refrigerant.
For prompt use it is advised to have at least 2 kg of refrigerant
in the filler cylinders and to keep the station as level as possible.
Figure 13
50631

CONTROL FASCIA
Figure 14
Figure 15 50634
FILLER CYLINDER OIL TANK
50632

Control fascia diagram legend

M1 Low pressure gauge
M2 High pressure gauge
M3 Filler cylinder pressure gauge
LOW Low-pressure valve
HIGH High-pressure valve
REF Refrigerant filler and drain valve
V1 Valve on low-pressure pipe
V2 Valve on high-pressure pipe
V3 Oil injection valve for A/C system
V5 Oil drainage valve
V9 A/C system washing refrigerant service valve
10 Moisture indicator
VS Safety and drainage valve
L3 Alarm warning light
L4 Maximum level warning light
L5 Minimum level warning light
A Unit process / bottle heater switch
LA1 Unit process indicator light
LA2 Bottle heater indicator light
B Refrigerant process / vacuum process switch
LB1 Refrigerant process indicator light
LB2 Vacuum process indicator light
C Recovery recycle cycle / Filling switch
LC1 Recovery recycle cycle indicator light
LC2 Filling indicator light
D Vacuum / vacuum test switch
LD1 Vacuum indicator light
LD2 Vacuum test indicator light
Filler cylinder legend

1 Pressure values in bar (vertical lines, revolving top cylinder).
2 Weight of load in grams (oblique lines, revolving top
cylinder) 50 g division between lines.
3 Tank level viewer (internal cylinder).

SAFETY STANDARDS - never expose the unit or operate it in acidic or wet

environments or close to open containers of inflammable
substances;
This station is exclusively for professionally trained
operators who must be familiar with refrigerating - the unit must operate in places with good ventilation;
systems, refrigerant gases and the damage - never alter the settings of the safety valves and control
pressurized equipment can cause, therefore: systems;
- never use bottles or other storage containers that are not
approved and are not fitted with safety valves;
- always wear gloves and goggles when working with - never load any container over 80% of its maximum
refrigerant gases. Contact of refrigerant liquid with the capacity;
eyes can cause blindness; - never leave the unit powered if it is not to be used
- avoid all contact with skin (low boiling point -30°C can immediately. Cut off the mains power supply when it is
cause frostbite); not planned to use the equipment.
- never inhale the vapours of refrigerant gases;

- before connecting the station with a system or external
container, check that all the valves are closed;
The station is equipped with special fittings to avoid
- before disconnecting the station, check that the cycle is contamination with systems using R12. Do not attempt to
over and all the valves are closed. This will prevent adapt this unit for use with R12.
dispersing refrigerant gas into the atmosphere;

OPERATION FLOW CHART
Preparing the station
First recovery
Wait 3-5 minutes
Second recovery
Drain off oil

from the system
Operate on the system
Vacuum for 5-10 minutes

with first vacuum test
Is there any NO Vacuum for 30 minutes

YES leakage? with second vacuum test
NO Is there any
leakage? YES
Load oil
into the system
Search for leakage with Load up to 200 g

electronic leak finder refrigerant
NO Search system for leakage

Is there any Fully load
YES leakage? the system with electronic leak finder
Pressure check NO Is there any YES

leakage?
Are the values

acceptable? NO
YES
Disconnect the station

from the system

RECOVERING REFRIGERANT pipe with a smaller diameter (H) connecting the drier
FROM THE VEHICLE SYSTEM filter with the evaporator).
Before starting to disconnect the pipes from the - Connect the pipe marked LOW under the pressure
air-conditioner, check whether it is possible to do the repairs gauge to the evaporator outlet (the outlet is the one on
without discharging the gas. the pipe with a larger diameter (L) connecting the
evaporator with the drier).
If this is not possible, the following operations must be carried
- Open the valves V1 and V2.
out:
- Open the LOW and HIGH cocks.
- Connect the pipe marked HIGH under the pressure
gauge to the evaporator inlet (the inlet is the one on the
Figure 16
DEMONSTRATIVE FIGURE 52295

- connect the station to the electricity mains (220 V - 50 - put the switches A, B and C back onto position 0;
Hz); - close the V1, V2, LOW and HIGH valves.
- press the switch A (Process Unit) onto position 1
The respective indicator light LA1 will come on;
- press the switch B (Refrigerant Process) onto position 1;
- the respective indicator light LB1 will come on; NOTE If the refrigerant reaches the maximum level
(maximum level indicator light L4 on), the recovery
- press the switch C (Recovery Recycle) onto position 1. cycle must be stopped immediately by pressing
The recovery and recycling operation will start switch C onto position 0 and transferring the
automatically. The respective indicator light LC1 will
come on to signal the operation in progress. refrigerant from the filler cylinder to a suitable
On completing this operation the unit will automatically external bottle.
stop and the indicator light LC1 go out. Wait for a few
minutes so that any pockets of refrigerant at low pressure
remaining in the system can increase their pressure, by
absorbing heat, and be able to be recovered. The station
will automatically repeat the recovery cycle if the above - Continue the operations following the instructions given
conditions occur; on the following pages.
Figure 17
50636

CREATING A VACUUM IN THE SYSTEM After a few minutes of operation (10 at most) if the system
has no leaks the indicator light LD2 VACUUM TEST will
This operation should be carried out if all the repairs have
also come on. From this time on, evacuation should be
been performed and the system components have been
continued for at least two hours to obtain a good
properly refitted. This operation is the phase prior to refilling,
evacuation.
therefore proceed as follows:
NOTE Do not run the vacuum cycle when there is even The indicator light LD2 vacuum test fails to come on
minimal pressure in the station or system. if there is a leak. Stop evacuation, eliminate the leak
and repeat the evacuation procedure.
- Connect the pipes to the specific system connections and

open the V1-V2/LOW and HIGH valves. - At the end of the time programmed for evacuation, press
- Press the switch A (Process Unit) onto position 1. the switch D (vacuum test) onto position 2 and leave the
The respective indicator light LA1 will come on. system in this state for 3-5 minutes.
The indicator light LD2 VACUUM TEST is on if the
- Press the switch B (Vacuum Process) onto position 2. system has a good seal. The indicator light LD2 VACUUM
The respective indicator light LB2 will come on. TEST goes out if there is a leak. Eliminate the leak and
- Press the switch D (Vacuum) onto position 1. The system repeat the evacuation cycle.
will automatically start being evacuated and the respective - Put the switches D and B back onto position 0 and
indicator light LD1 will come on to signal the operation proceed with the following phase.
in progress.
Figure 18
50637

It is possible that at the end of each recovery cycle the station 3 Quantify and record the amount of oil discharged.
may have recovered lubrication oil from the compressor, 4 Eliminate the recovered oil correctly.
which should be drained off into a specific graduated container This oil cannot be reused.
(1). The same amount of new oil as has been removed must
1 Slowly open the valve V5 (Oil Discharge). be added to the system.
2 When all the oil has been discharged into the container (1)
close the valve V5.
Figure 19
50638

RESTORING OIL IN THE SYSTEM - disconnect the metering device (1) from the injection
valve V3 and fit the protective cap back on.
If during the recovery and recycle phase, oil from the system
has been removed, it must now be replenished: NOTE Keep the oil containers well sealed in order to avoid
- take the metering device supplied with the right amount contamination. In particular, remember that oil is
of lubricant for the system concerned, or previously extremely hygroscopic:.
measured;
- connect the metering device (1) to the lubricant injection
valve V3; - never open the oil injection valve V3 if the system has
positive pressure;
- open the valve V3 and then carry out the system vacuum
phase for a few moments; - oil should only be injected with a vacuum in the system;
- open the valve mounted on the metering device - the oil level must never fall under the suction pipe (air
container (1). The oil will be drawn into the system; would get into the system).
- close the valve V3 and the valve on the metering device
container when the required quantity of lubricant has
been drawn in;
Figure 20
50639

FILLING THE SYSTEM WITH

REFRIGERANT NOTE To transfer refrigerant from an external bottle to
the filler cylinder and vice versa, refer to the
Before refilling, it is wise to be aware of some important rules: equipment manual.
- know the quantity of refrigerant to use (it is normally Considering that the amount of refrigerant depends
written on an adhesive plate affixed on the vehicle); on its pressure, to know the actual weight it is
necessary to turn the outside of the filler cylinder so
- the filler cylinder is equipped with a minimum level check the line of the diagram matches the level viewer. In
that prevents introducing incondensable gas into the this way we can know the exact quantity of
system. refrigerant in the cylinder (starting weight).
This is why the last approx. 600 g of refrigerant it contains When calculating the weight of the refrigerant, in
cannot be used; addition to the 600 g that cannot be used,
- therefore, before filling, check that the cylinder contains remember to increase the load by approximately
100 g (this is the weight of refrigerant contained in
a sufficient quantity for filling (maximum quantity that can the station-system connecting pipes). The right
be used 3800 g); quantity of refrigerant to introduce into the system
- if the pressure inside the filler cylinder indicated on the will therefore be given by: 600 g + 100 g + (quantity
pressure gauge (2) is greater than as required, which can referred to the system capacity).
be seen on the filler cylinder window approx. 10 bar max, Always check before filling that the indicator on the
discharge the excess pressure through the valve (1) on ”console” shows the refrigerant contains no
the pressure gauge assembly to bring it down to the right moisture, in which case the indicator will be bright
green. If this is not so, replace the filters in the station
level, reading the value on the pressure gauge. as instructed in the equipment manual.
Figure 21
50640
COULANT
QUANTITY CONTAINED OIL QUANTITY TO BE
R134 COULANT COULANT TOTAL
IN THE PIPINGS ADDED INTO SYSTEM
VEHICLE COMPRESSOR QUANTITY PROVIDED QUANTITY TO BE SET
(150 cm length) AT EACH ND 8 TYPE
FOR IN SYSTEM ON CHARGING TOOL
THAT ARE USED FOR CHARGING
RECHARGING
DAILY (8140 engine): 100 [g] for low pressure
WITH CAB, VAN, SPECIAL SC 08 720 g pipe, 100 [g] for high 1020 g 30 g
OPT 6650
ITEMS, 6+1 pressure pipe
DAILY (8140 engine): 100 [g] for low pressure
WITH CAB, VAN, SPECIAL DENSO 10 PA 17 720 g pipe, 100 [g] for high 1020 g 40 g
OPT 6652
DAILY (F1A engine): 100 [g] for low pressure
OPT 6652
100 [g] for low pressure
DAILY (F1A engine): DENSO 10 PA 17 1200 g pipe, 100 [g] for high 1500 g 40 g
COMBI OPT 6652
pressure pipe
DAILY (F1C engine): 100 [g] for low pressure
OPT 6652

When the cylinder contains the necessary quantity for filling - having loaded 200 ÷ 500 g of refrigerant, depending on
(both pipes must already be connected to the system the size of the system, stop filling by moving the switch C
connectors since the vacuum operation has already been (Charge) onto position 0;
performed), proceed as follows: - check the system is properly sealed with the electronic
- close the LOW valve, keep the HIGH and V1 - V2 valves leak finder;
open; - complete filling the system until the pre-calculated
- press the switch B (Refrigerant process) onto position 1, residual weight in the cylinder is reached;
the indicator light LB1 will come on; (Residual weight = Total weight - System capacity weight)
- press the switch C (Charge) onto position 2, the - complete filling, move the switches C - B and A onto
respective indicator light LC2 will come on and refrigerant position 0 (A had been moved for the vacuum).
will flow from the station into the system; Check again there is no leakage;
- close the HIGH valve.
NOTE When filling, if the level of refrigerant in the cylinder
falls under the required quantity the system will stop
and the Minimum Level indicator light (L5) will
come on.
Figure 22
50641

CHECKING THE PRESSURES IN THE SYSTEM LEAK FINDER FOR AIR-CONDITIONING

SYSTEMS WITH HFC R134A (9905147)
After filling, leave the pipes connected and carry out the
following check: Tool L-780A makes it possible to identify leakage of HFC
134A gas from the system extremely accurately in the order
- close the HIGH and LOW valves, V1 and V2 open; of 3.3 g a year with the switch on maximum sensitivity.
- turn on the engine, switch on the air-conditioner and This instrument requires no settings, the operator only needs
check on the pressure gauges M1 and M2 that the to select the desired sensitivity.
pressures correspond, normally: low pressure no less than
1 bar, high pressure 15 ÷ 18 bar, depending on the system The instrument warns the operator of any gas leakage with a
specifications. buzzer and a LED that flashes in proportion to the
concentration of gas.
OPERATIONS PRIOR TO DISCONNECTING In addition, the LED indicates the battery is flat if it goes out.
THE STATION FROM THE SYSTEM Operating temperature is between 0 C and 50°C.
Always observing the above safety rules, carry out the The instrument is equipped with a flexible probe to reach
following operations: particularly difficult fittings or parts.
- check that all the valves are closed: LOW - HIGH, V1 - The two levels of sensitivity are:
V2; - low sensitivity = 16.5 g/year;
- disconnect the pipes of valves V1 - V2 and put the caps - high sensitivity = 3.3 g/year.
back onto the system valves;
- Check the system again with the leak finder.
NOTE Normally, with the air-conditioner switched on, air NOTE Before checking vehicles, wait for the engine to cool,
should come out of the vents at a temperature the hot parts can falsify the test.
lower than 5°C and after a period of operation to
stabilize the temperature of the ducts.
Figure 23 Figure 24
50642 50643


DAILY EURO 4 SCHEDULED MAINTENANCE 1
SECTION 13
Scheduled maintenance
Page
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Table of maintenance services . . . . . . . . . . . . . 3
F1A ENGINE VEHICLES . . . . . . . . . . . . . . . . . . . 4
- Inspection and/or maintenance interventions . 4
- Extra plan operations . . . . . . . . . . . . . . . . . . . 5
F1C ENGINE VEHICLES . . . . . . . . . . . . . . . . . . . 6
- Inspection and/or maintenance interventions . 6
- Extra plan operations . . . . . . . . . . . . . . . . . . . 7
DIAGRAM OF CHECK
AND/OR MAINTENANCE POINTS . . . . . . . 8
MAINTENANCE OPERATIONS . . . . . . . . . . . . 9

2 SCHEDULED MAINTENANCE DAILY EURO 4
Print 603.43.351

Print 603.43.671
MAINTENANCE
Table of maintenance services

The Extra Plan operations (designated with the letters EP) are complementary to standard services (designated with letter M for
Maintenance).
They are maintenance operations to be carried out at regular time or mileage intervals and concern optional components that
are not present on all models.
Important! The correlation between kilometres and months only applies in cases where the distance travelled by the vehicle
corresponds roughly to the specified average annual mileage. This is indicated only in order to suggest a hypothetical maintenance
programme,. Note that the time intervals specified for Extra Plan operations (designated by letter T for Time) are to be adhered
to regardless of the actual mileage covered.
The kilometre frequency for engine lubrication is in relation to a percentage of sulphur in diesel of under 0.5%.
NOTE: If using diesel with a percentage of sulphur above 0.5%, the oil-change frequency has to be halved.
Use engine oil: ACEA B5 (Urania Daily)
To schedule the work, keep to the following chart:

Print 603.43.671/A
F1A ENGINE VEHICLES

Standard Services Extra plan Time Operations
Engine oil
Engine-oil Engine
M1 M2 EP1 EP2 T1 T2 T3 T4
Every Every Every Every
Every year Every year
ACEA B5 40,000 km 120,000 km 240,000 km 240,000 km Every Every
Urania Daily (1) Engine F1A at the start at the start
or or or or 2 years 3 years
of spring of winter
800 hours 2,400 hours 4,800 hours 4,800 hours
(1) IVECO recommend Urania Daily ACEA B5 SAE 5W30 for benefits in terms of “fuel economy”. IVECO have already introduced this lubricant with
new vehicles
D Average speed calculated at 50 km/h
D In the case of very low mileage or anyhow under 40,000 km/year, the engine oil and filter must be changed every
12 months.
D In case of urban use of the vehicle requiring repeated regeneration of the particulate filter (on the vehicles equipped
with such component), the replacement of the engine oil filter and engine oil might be required in advance of the
scheduled time. In this case, the need to carry out this out-of-schedule operation will be signalled by the vehicle
computer.
D In case of annual covered distances of less then 40,000 km, the rear axle oil shall be changed at least every two years.
D In case of annual covered distances of less then 40,000 km, the gearbox oil shall be changed at least every three years.
Inspection and/or maintenance interventions (F1A engine vehicles)

M1 M2
Typ off intervention
Type i i Every 40,000 km Every 120,000 km
or 800 hours or 2,400 hours
LUBRICATION, CHANGING OIL, FILTERS AND CHECKING FLUIDS

1 Changing engine oil • •
1 Changing engine oil filter • •
2 Changing fuel filter * • •
3 Checking hydraulic brake system fluid level • •
5 Changing mechanical gearbox oil •
CHECKS IN THE ENGINE BAY
• Checking state of auxiliary drive belts •
• Changing auxiliary drive belts (1) •
CHECKS UNDER THE VEHICLE
7 Checking steering box rack covers • •
8 Checking wear of brake discs and shoes • •
6 Cleaning rear axle oil breather •
7 Checking steering column, articulation and linkage •
9 Checking steering box fixing •
10 Checking universal joints and propeller shaft fixing •
CHECKS IN THE CAB
• Checking parking brake travel • •
EXTERNAL CHECKS
11 Checking headlight adjustment •
DIAGNOSTICS
• Check-up engine EDC system with MODUS - IT 2000 - E.A.SY. •
ON-ROAD TESTS
• Functional testing on the road • •
(1) Replace every four years. Replace every 60.000 km under harsh conditions of use (dust and/or heat).
(*) If the “clogged filter” warning lamp lights up on the instrument panel, the filter must be replaced before the programmed replacement interval

Print 603.43.671
Extra plan operations (to be carried out possibly in combination with maintenance service)
EPI EVERY 80,000 km or 1,600 hours

- Changing the rear axle oil (1)
EP2 EVERY 240,000 km or, anyhow, every 5 years (or 4,800 hours)
- Changing the belt driving the alternator (2)
- Changing the automatic tensioner of the belt driving the alternator
- Replacing the power steering pump and alternator drive belt automatic stretcher
- Changing the pre-heating glow plugs
TI EACH YEAR - especially in early springtime

- Check state of pollen filters.
In the case of low mileage, change the filters once a year, early each spring.
T2 EACH YEAR - before the winter season

- Check coolant density.
- Check pre-combustion chamber glow plug operation.
T3 EVERY TWO YEARS

- Change brake fluid and bleed brake fluid system.
T4 EVERY THREE YEARS - even if there is no indication of the air filter clogging
- Change cartridge and clean air filter container. (1)
- Change engine coolant (2).
(1) In case of annual covered distances of less then 40,000 km, the rear axle oil shall be changed at least every two years.
(2) Early air cleaner obstruction is generally due to particular environmental conditions. For this reason it may need to be replaced when indicated by the
sensor regardless of the replacement interval also if not specifically stated.
(3) Paraflu11 needs to be diluted at 50% with water, while Paraflu FE is already diluted at 50% with water.

Print 603.43.671/A
F1C ENGINE VEHICLES

Standard Services Extra plan Time Operations
E i
Engine-oil
il E i
Engine M1 M2 EP1 EP2 EP3 T1 T2 T3 T4
Every Every Every Every Every Every year Every year
ACEA B5 40,000 km 120,000 km 240,000 km 240,000 km 240,000 km at the at the Every Every
Urania Daily (1) Engine F1A
or or or or or start of start of 2 years 3 years
800 hours 2,400 hours 4,800 hours 4,800 hours 4,800 hours spring winter
(1) IVECO recommend Urania Daily ACEA B5 SAE 5W30 for benefits in terms of “fuel economy”. IVECO have already introduced this lubricant with
new vehicles
D Average speed calculated at 50 km/h

D In the case of very low mileage or anyhow under 40,000 km/year, the engine oil and filter must be changed every
12 months.
D In case of urban use of the vehicle requiring repeated regeneration of the particulate filter (on the vehicles equipped
with such component), the replacement of the engine oil filter and engine oil might be required in advance of the
scheduled time. In this case, the need to carry out this out-of-schedule operation will be signalled by the vehicle
computer.
D In case of annual covered distances of less then 40,000 km, the rear axle oil shall be changed at least every two years.
D In case of annual covered distances of less then 40,000 km, the gearbox oil shall be changed at least every three years.
Inspection and/or maintenance interventions (F1C engine vehicles)

M1 M2
Typ off intervention
Type i i Every 40,000 km Every 120,000 km
or 800 hours or 2,400 hours
LUBRICATION, CHANGING OIL, FILTERS AND CHECKING FLUIDS

1 Changing engine oil • •
1 Changing engine oil filter • •
2 Changing fuel filter * • •
3 Checking hydraulic brake system fluid level • •
5 Changing mechanical gearbox oil •
CHECKS IN THE ENGINE BAY
• Checking state of auxiliary drive belts •
• Changing auxiliary drive belts (1) •
CHECKS UNDER THE VEHICLE
7 Checking steering box rack covers • •
8 Checking wear of brake discs and shoes • •
6 Cleaning rear axle oil breather •
7 Checking steering column, articulation and linkage •
9 Checking steering box fixing •
10 Checking universal joints and propeller shaft fixing •
CHECKS IN THE CAB
• Checking parking brake travel • •
EXTERNAL CHECKS
11 Checking headlight adjustment •
DIAGNOSTICS
• Check-up engine EDC system with MODUS - IT 2000 - E.A.SY. •
ON-ROAD TESTS
• Functional testing on the road • •
(1) Replace every four years. Replace every 60.000 km under harsh conditions of use (dust and/or heat).
(*) If the “clogged filter” warning lamp lights up on the instrument panel, the filter must be replaced before the programmed replacement interval

Print 603.43.671
Extra plan operations (to be carried out possibly in combination with maintenance service)
EP1 EVERY 80,000 km or, in any case, every two years (or 1,600 hours’ operation)
- Changing the rear axle oil.
EP2 EVERY 240,000 km or, anyhow, every 5 years (or 4,800 hours)
- Changing the automatic tensioner of the belt driving the alternator.
- Changing the pre-heating glow plugs.
EP3 EVERY 400,000 km (or 8,000 hours’ operation)

- Replacing the timing chains, chain stretchers, camshaft drive gears, pads.
- Replacing the exhaust gas catalyst (vehicles equipped with D.P.P. particulate filter).
TI EACH YEAR - especially in early springtime

- Check state of pollen filters.
In the case of low mileage, change the filters once a year, early each spring.
T2 EACH YEAR - before the winter season

- Check coolant density.
- Check pre-combustion chamber glow plug operation.
T3 EVERY TWO YEARS

- Change brake fluid and bleed brake fluid system.
T4 EVERY THREE YEARS - even if there is no indication of the air filter clogging
- Change cartridge and clean air filter container. (1)
- Change engine coolant (2).
(1) Early air cleaner obstruction is generally due to particular environmental conditions. For this reason it may need to be replaced when indicated by the
sensor regardless of the replacement interval also if not specifically stated.
(2) Paraflu11 needs to be diluted at 50% with water, while Paraflu FE is already diluted at 50% with water.

DIAGRAM OF CHECK AND/OR MAINTENANCE POINTS
Figure 1
109115

MAINTENANCE OPERATIONS
2. Replacing UFI Filters type fuel filter
NOTE After checking or changing parts, test the operation Figure 4
of the vehicle.
M1 SERVICE
1. Changing engine oil
1. Changing engine oil filter
Figure 2
109062
NOTE The figure refers to the F1A engine. 112722
Take out the dipstick (2). From underneath the vehicle, Disconnect chassis cable connection (6) from electronic unit
remove the soundproofing guard, and fit it back on after connection (7). Release connection (7) from support bracket
completing the operation. Remove the plug from the oil (8). Remove fastener (9), unthread electronic unit (4) and put
sump and drain the engine oil off into a special container. it away accurately in order that it is not damaged or soiled.
With tool 99360076 (1) disassemble oil filter (2). Loosen screw (3) and unthread fuel filter (1) upwards from
support (2). Mount new filter (1) in such a way that mark (→)
NOTE Before refitting the new cartridges, moisten the seal results to be aligned at the point where the ends of support
with engine oil. (2) join each other and tighten screw (3) at prescribed
torque. Check the conditions of seal rings (5); if they are
detected to be damaged, replace them. Mount electronic
Screw the oil filter (1) on by hand until it is in contact with the unit (4) into fuel filter (1) up to ledge in such a way that
mounting and then tighten by 3/4 of a turn (tightening torque fastener (9) is correctly fitted into the ring-shaped grooves
25 Nm). Screw the plug back on under the sump. of electronic unit (4). Connect connection (7) to bracket (8)
Pour oil into the engine through the filling-pipe (1) of the and connect connector (6) to connection (7).
required grade and quantity (see fluids table in the GENERAL
section).
3. Checking hydraulic brake system fluid level
2. Replacing Filtrauto type fuel filter
Figure 5
Figure 3
109063 52314
Check the level of brake fluid. If it is low, top it up (see fluids
Unscrew fuel filter container (1) and replace the cartridge, then table in the GENERAL section).
screw container (1) again and tighten it to 35±5 Nm.

• Checking state of auxiliary drive belts • Changing auxiliary drive belts

Visually check that the belts are not worn or This should be done as described in the ”ENGINE”
deteriorated, in which case replace them as described section.
in the ”ENGINE” section.
7. Checking steering box rack covers 6. Cleaning rear axle oil breather
Remove the soundproofing guard from underneath
the vehicle. Figure 7
If the covers are damaged at all, replace them as
described in the ”STEERING GEAR” section.
8. Checking wear of brake discs and shoes

If the wear is found to be too great, replace the brake
discs or shoes as described in the ”BRAKES” section.
• Checking parking brake travel
Check that the vehicle stays braked with a lever travel
of:
- five catches.
62882
If it does not, adjust it as described in the ”BRAKES” Take out the screws (1) and remove the brake caliper with
section. its brake linings from the mounting.M
M2 SERVICE NOTE The oil vent cleaning operations refer to rear axle
450517/2. As far as rear axles 450511 NDA R.S. -
NOTE The M2 service comprises some of the operations NDA R.G. are concerned, refer to Figure 11.
in the M1 service as well as the following
operations.
5. Replacing the mechanic and automatic 7. Checking steering column,

transmission gearbox oil articulation and linkage
Steering linkage
Figure 6 - Check that the nuts and screws securing the
clamps to the tie rods have not deteriorated
and are tightened to the required torque.
- The tie rods must not be damaged, likewise the
threaded portion must be sound.
Swivel heads
- Clean the swivel heads of the tie rods.
- This must be done with dry canvas or raw
cotton. Use no solvents.
- Check that the swivel heads, in their
components, have no points of corrosion, with
sections affected to a depth greater than 1 mm.
In particular, check the sheet metal cover close
to the rolled section.
- Check the protecting casing: it must be secured
to the body and to the pin of the joint with a
retaining ring and must not rotate.
- The casing must be neither damaged nor
deteriorated.
- Crush the protective casings by hand and check
that lubrication grease comes out.
102112
- Check that the nuts and split pins have not
A. Automatic transmission - B. Mechanic transmission deteriorated.
The lubrication oil should be drained off when it is warm.
Place a special container under the plug (1). Take out the
plug and drain off the oil.
Screw the plug back on. Unscrew the filler plug and pour 9. Checking steering box fixing
in lubricating oil of the required grade and quantity (see Remove the soundproofing guard from underneath
fluids table in the GENERAL section). the vehicle.
Fit the plug (2) back on. If there is any damage, refer to the ”STEERING
Remove the oil vapour vent and clean it thoroughly. GEAR” section.
After making the check, fit the soundproofing guard
back on.

10. Checking universal joints and propeller Figure 10

shaft flange fixing
Figure 8
10904
If an orientation error is found, proceed as follows:

52124 - open the engine hood;
- ad just the light beam:
The plates welded onto the propeller shafts are there for - horizontally, by acting on screw (2);
balancing. - vertically, by acting on screw (1).
If there are no plates, it is necessary to balance the shaft again.
Turning the propeller shaft and at the same time the sliding
sleeve in the opposite direction, check there is not too much
clearance between the splines.
Acting on the forks of the couplings (in the direction of the
arrows shown in the figure), check that the spiders are not OUT-OF-SCHEDULE MAINTENANCE
worn. Replace them if they are. EP1 service (every 80,000 km or 1,600 hours’
If there is any damage, refer to the ”PROPELLER SHAFTS” operation)
section. 6. Changing rear axle oil
NOTE In case of annual covered distances of less then

40,000 km, the rear axle oil shall be changed at least
11. Headlamp orientation check
every two years.
Figure 9
Figure 11
109065
46311
Place the vehicle, unladen and with the tyres inflated to the NOTE The oil change shown refers to rear axles NDA R.S.
prescribed pressure, on a flat surface in front of a clear wall - NDA R.G. - 450511.
at a distance of 10 m.
Draw two crosses (corresponding to the headlamp centres) The lubricating oil has to be drained off while it is hot.
on the wall. Place a container under the plug near the arrow; remove the
Set the headlamp control switch to ”0”, then turn the plug and drain off the oil.
low-beam headlamps ON. The distance between the crosses Screw the plug back on. Unscrew the plug (2) and pour in the
and points ”P” (corresponding to the headlamp inclination) prescribed quantity of lubricating oil (see fluids table under the
shall be 10 cm (1% as shown on the tag). GENERAL INFORMATION heading).
To get off I leak it some vapors oil (1) and to carefully clean it.

Print 603.43.671
Figure 12 EP3 service (every 400,000 km or 8,000 hours’

operation - only F1C engines)
1. Replacing the timing chains, chain

stretchers, camshaft drive gears,
pads
The belts shall be replaced as described in the
respective ”ENGINE” section.
• Replacing the exhaust gas catalyst

33123 (vehicles equipped with D.P.F.
particulate filter)
NOTE The oil change described refers to the Rear Axles The belts shall be replaced as described in the
450517/2. respective ”ENGINE” section.
The lubrication oil should be drained off when it is warm.

Place a special container under the plug (2). Take out the plug
and drain off the oil.
Screw the plug (2) back on. Unscrew the plug (1) and pour
in lubricating oil of the required grade and quantity (see fluids
table in the GENERAL section). T1 service (annually, at the beginning of spring)
Remove the oil vapour vent and clean it thoroughly.
(Shown in Figure 12). 13. Pollen filter check
Figure 13
EP2 service (every 240,000 km or 4,800 hours’

operation or, in any case, five years)
1. Replacing the camshaft drive belts
(only F1A engines)
The belts shall be replaced as described in the
NOTE Under heavy-duty conditions (excessive dust

and/or heat), the camshaft drive belt shall be
replaced every 120,000 km.
52307
• Replacing the water pump/ Act from inside the engine compartment to take out
alternator drive belt automatic protection cover (1) and remove pollen filter (2).
stretcher Check the pollen filter conditions: if the filter is clogged, it shall
The belts shall be replaced as described in the be replaced (by following the reverse order of the
respective ”ENGINE” section. detachment operations).
NOTE Excessive clogging of the pollen filters can cause a

reduction in the flow rate of air into the cab and
1. Replacing the precombustion therefore less ventilation. This will be highlighted
chamber engine plugs especially by a significant reduction in the efficiency
The belts shall be replaced as described in the of the windscreen defrosting function.

T2 service (annually, prior to the beginning of T4 service (every three years and, if possible,
winter) concurrently with a maintenance service)
12. Checking the antifreeze concentration in
the engine coolant
Figure 14
14. Replacing the air filter cartridge and
1
cleaning the container
Figure 15
109067
With the engine warm, the cooling system is in

overpressure, therefore take care when taking off
the cap (2).
Take off the cap (2) and draw off a sample of the coolant from 109068
the expansion tank (3) with the densimeter 99395858.
Release the retaining clips, then remove upper cover (1) and
Depending on the temperature of the liquid, check the replace the filtering cartridge.
percentage of antifreeze in the liquid on the scale of the Thoroughly clean the cartridge housing before fitting the new
instrument. The percentage has to be higher than 40% and cartridge into place.
must not exceed 50%.
If necessary, restore the percentage of antifreeze, bearing in
mind that the liquid needs to be replaced every 2 years.
NOTE For vehicles fitted with an additional heater, the

percentage of antifreeze must never exceed 50%.
12. Changing the engine coolant
Follow the procedure described in the respective
paragraph of the ”ENGINE” section (as far as filling
• Replacing the auxiliary heater fuel is concerned, refer to the table of the ”GENERAL
filter REMARKS” charter).
T3 service (every two years and, if possible,

concurrently with a maintenance service)
3. Changing the draining and braking

hydraulic system fluid
The fluid shall be changed as described in the
respective ”HYDROPNEUMATIC SYSTEM -
BRAKE” section (ad regards the amount of brake
fluid, refer to the filling and fuelling table in the
”GENERAL REMARKS” charter).
The brake fluid is poisonous and corrosive. In case

of accidental contact, wash immediately with water
and mild soap.


DAILY EURO 4 ELECTRIC/ELECTRONIC SYSTEM 1
Print 603.93.281
Print 603.93.281
SECTION 14
7600 Electric/Electronic system
Page
ABBREVIATIONS AND GRAPHIC SYMBOLS . 5
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 6
TECHNICAL CODES . . . . . . . . . . . . . . . . . . . . . 10
POWER NETWORK . . . . . . . . . . . . . . . . . . . . . 14
POSITIVE NETWORK (CBA) . . . . . . . . . . . . . . . 15
INSTRUMENT PANEL INTERCONNECTION

CENTRAL UNITS (CPL) “75002” . . . . . . . . . 17
- Fuses / remote control switches identification 19
- Internal electrical scheme . . . . . . . . . . . . . . . . 20
- Junction connectors . . . . . . . . . . . . . . . . . . . . 21
- Junction connector “L” . . . . . . . . . . . . . . . . . . 22
- Junction connector “M” . . . . . . . . . . . . . . . . . 23
- Junction connector “R” . . . . . . . . . . . . . . . . . . 24
- Junction connector “H” . . . . . . . . . . . . . . . . . 25
ENGINE OPENING CENTRAL UNIT (CVM)

“75001” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Internal electrical scheme . . . . . . . . . . . . . . . . 29
- Junction connectors . . . . . . . . . . . . . . . . . . . . 30
- Junction connectors “A” . . . . . . . . . . . . . . . . . 31
- Junction connectors “C” . . . . . . . . . . . . . . . . . 32
- Junction connectors “B” . . . . . . . . . . . . . . . . . 32
- Junction connectors “D” . . . . . . . . . . . . . . . . . 33
- Junction connectors “E” . . . . . . . . . . . . . . . . . 33
- Junction connectors “F” . . . . . . . . . . . . . . . . . 33
NEGATIVE NETWORK . . . . . . . . . . . . . . . . . . . 34
EARTH POINTS . . . . . . . . . . . . . . . . . . . . . . . . . 34
BATTERY (20000) . . . . . . . . . . . . . . . . . . . . . . . 37

2 ELECTRIC/ELECTRONIC SYSTEM DAILY EURO 4
Print 603.93.281/A
Page Page
BOSCH KCBI 14V 110A ALTERNATOR . . . . . . 38 FITTER CONNECTOR (72068) . . . . . . . . . . . . . 72

EV 12V - 2.3 KW STARTER MOTOR . . . . . . . . . 39 ELECTRONIC INJECTION EDC16 . . . . . . . . . . . 73
JUNCTION WELDS . . . . . . . . . . . . . . . . . . . . . . 40 - Particular features of engines Euro 4 . . . . . . . 73
WIRING HARNESS SECTION . . . . . . . . . . . . . . 42 - System to reduce pollutants at exhaust . . . . . 74
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
JUNCTION CONNECTORS . . . . . . . . . . . . . . . . 45 - E.G.R. (Exhaust Gas Recirculation) SYSTEM . . 75
- Bonnet - instrument panel junction (600/601H) 45 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
- Bonnet - instrument panel junction (600/601B) 46 - Main system components . . . . . . . . . . . . . . . . 75
- Bonnet - instrument panel junction (600/601D) 47 - E.G.R. valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
- Bonnet - instrument panel junction (600/601G) 48 - Modulator solenoid valve . . . . . . . . . . . . . . . . 75
- Bonnet - instrument panel junction (600/601A) 49 - Air flow rate meter (flow meter) . . . . . . . . . . 75
- Bonnet - instrument panel junction (600/601C) 50 D.P.F. (DIESEL PARTICULATE FILTER) CATALYST 76
INSTRUMENT CLUSTER (58919) . . . . . . . . . . . . 51 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
- Junction connector . . . . . . . . . . . . . . . . . . . . . 52 - Particulate filter (components location) . . . . . 77
- Display screen . . . . . . . . . . . . . . . . . . . . . . . . . 53 - Throttle valve assembly . . . . . . . . . . . . . . . . . 78
STEERING COLUMN SWITCH UNIT (54030) . 54 REPLACING THE COMPONENTS . . . . . . . . . . . 79
CENTRAL INSTRUMENT PANEL . . . . . . . . . . . . 55 - Replacing particulate filter . . . . . . . . . . . . . . . . 79
INSTRUMENT PANEL SWITCH ASSEMBLY (53807) 56 - Replacing flow meter . . . . . . . . . . . . . . . . . . . 80
OPTIONAL BOX . . . . . . . . . . . . . . . . . . . . . . . . 57 - Replacing rail pressure sensor in hydraulic
accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . 80
- Replacing delta-p sensor . . . . . . . . . . . . . . . . . 80
- OPT central unit Pin-Out . . . . . . . . . . . . . . . . 59
- Replacing engine oil . . . . . . . . . . . . . . . . . . . . 80
“CAN LINES” SYSTEM DESCRIPTION . . . . . . . . 60
- Replacing an injector . . . . . . . . . . . . . . . . . . . . 81
- “C” CAN line . . . . . . . . . . . . . . . . . . . . . . . . 61
- Electronic injection control . . . . . . . . . . . . . . . 82
- “B” CAN line . . . . . . . . . . . . . . . . . . . . . . . . . 62
- EDC system components . . . . . . . . . . . . . . . . 86
BODY COMPUTER - (86116) . . . . . . . . . . . . . . . 63
- Bosch EDC16 control unit . . . . . . . . . . . . . . . 88
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
- Control unit connection to the injection cable
- Black cab junction connector “LN” . . . . . . . . 66 on engine side (housing A) . . . . . . . . . . . . . . . 89
- Blue instrument panel junction connector “PF” 68 - Control unit connection to cab-bonnet
cable (housing K) . . . . . . . . . . . . . . . . . . . . . . 91
- Blue bonnet junction connector “AV” . . . . . 69
- Accelerator pedal sensor . . . . . . . . . . . . . . . . 93
FITTER CONNECTOR (61071) . . . . . . . . . . . . . 71

Page Page
- Brake pedal switches (53501) . . . . . . . . . . . . . 94 ABS 8/ESP 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
- Clutch pedal switch (42374) . . . . . . . . . . . . . . 94 - The ABS 8 system integrates the following
functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
- Preheat plug electronic centre
(F1A/F1C engine) . . . . . . . . . . . . . . . . . . . . . . 95 - The ESP 8 system, in addition to the EBS 8
system, incorporates the following functions . 115
- Preheat plugs . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Four crossed channel system (x) . . . . . . . . . . 116
- R.p.m. / timing sensors (F1C) . . . . . . . . . . . . . 96
- Electro-hydraulic modulator/control unit . . . . 116
- Timing sensor (stroke) (F1C) . . . . . . . . . . . . . 97
- Four parallel channel system (II) . . . . . . . . . . . 117
- RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
- Electro-hydraulic modulator/control unit . . . . 117
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . 99
- ABS 8 control unit PIN OUT (X - crossed channels, II
- Pressure regulator . . . . . . . . . . . . . . . . . . . . . . 100 - parallel channels) . . . . . . . . . . . . . . . . . . . . . 118
- Rail (pressure accumulator) F1C . . . . . . . . . . . 101 - ESP 8 control unit PIN OUT (X - crossed channels,
II - parallel channels) . . . . . . . . . . . . . . . . . . . . 119
- Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . 101
- PIN OUT of central unit ASR 8 (4 channels -X) 120
- Air temperature/pressure sensor . . . . . . . . . . 102
- (4 channels -II) . . . . . . . . . . . . . . . . . . . . . . . . 121
- Atmospheric pressure sensor . . . . . . . . . . . . . 103
- ESP (Electronic Stability Program) operation . 122
- Engine coolant temperature sensor . . . . . . . . 103
- Control strategy . . . . . . . . . . . . . . . . . . . . . . . 122
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 103
- Sudden obstacle . . . . . . . . . . . . . . . . . . . . . . . 122
- Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
- Sudden steering . . . . . . . . . . . . . . . . . . . . . . . 123
- Electromagnetic junction fan . . . . . . . . . . . . . . 105
- Vehicle running on a slippery road . . . . . . . . . 123
- Camshaft sensor (F1A) 48042 . . . . . . . . . . . . 106
- ASR deactivation strategies . . . . . . . . . . . . . . . 124
- Flywheel and rpm sensor . . . . . . . . . . . . . . . . 107
- Recovery strategy in case of component failure 124
- Characteristics of flywheel rpm and timing
system sensors . . . . . . . . . . . . . . . . . . . . . . . . 107 - Warning light legend . . . . . . . . . . . . . . . . . . . . 125
- Pressure regulator . . . . . . . . . . . . . . . . . . . . . . 108 - Installing the esp components . . . . . . . . . . . . . 125
- Rail (pressure accumulator) F1A . . . . . . . . . . . 109 - ESP system components and calibration . . . . . 126
- Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . 109 - Yaw sensor with built-in side acceleration

sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
- Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
- Longitudinal acceleration sensor . . . . . . . . . . . 127
- Air temperature / pressure meter . . . . . . . . . . 111
- Longitudinal acceleration sensor calibration . . 127
- Electromagnetic junction fan . . . . . . . . . . . . . . 112
- Steering angle sensor . . . . . . . . . . . . . . . . . . . 128
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
- Steering angle sensor calibration . . . . . . . . . . . 128
FUEL PUMP / FUEL LEVEL . . . . . . . . . . . . . . . . . . 114
- ESP control unit programming . . . . . . . . . . . . 129

Page Page
AIR BAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 - Drive side air bag module . . . . . . . . . . . . . . . . 148
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 - Passenger side air bag module . . . . . . . . . . . . 148
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . 130 - Spiral contact . . . . . . . . . . . . . . . . . . . . . . . . . 149
INTERVENTION LOGICS . . . . . . . . . . . . . . . . . . 132 IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
- Preliminary rules . . . . . . . . . . . . . . . . . . . . . . . 133 - Operation description . . . . . . . . . . . . . . . . . . 151
- Operations after an accident . . . . . . . . . . . . . 134 - Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
- Painting work . . . . . . . . . . . . . . . . . . . . . . . . . 134 - Body computer . . . . . . . . . . . . . . . . . . . . . . . . 152
- Health hazards . . . . . . . . . . . . . . . . . . . . . . . . 134 - Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
- Effects of over-exposure . . . . . . . . . . . . . . . . . 134 - Warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . 153
- Rules of safety in handling air bag modules . . . 135 IMMOBILIZER NEW PROCEDURES . . . . . . . . . . 154
- Air bag module scrapping . . . . . . . . . . . . . . . . 135 6AS 400 A O.D. VD AUTOMATIC TRANSMISSION 155
- Rules of safety in handling pretensioners . . . . 136 - Description of operation . . . . . . . . . . . . . . . . 155
- Scrapping pretensioners . . . . . . . . . . . . . . . . . 136 - Electronic management . . . . . . . . . . . . . . . . . 156
- Operations on system components . . . . . . . . 137 COMPOSITION OF THE SYSTEM . . . . . . . . . . . 157
- Removing and scrapping an activated air bag - System control unit . . . . . . . . . . . . . . . . . . . . 157
module and pretensioner from a vehicle . . . . 137
- Connector control unit PIN-OUT —
- Removing or scrapping an air bag module that has gearbox side (A) . . . . . . . . . . . . . . . . . . . . . . . 158
not been deployed from a reparable vehicle . 137
- Connector control unit PIN-OUT —
- Deployment of an air bag . . . . . . . . . . . . . . . . 138 vehicle side (B) . . . . . . . . . . . . . . . . . . . . . . . . 159
- Deployment of air bag modules and electronic - Gearbox actuator . . . . . . . . . . . . . . . . . . . . . . 160

pretensioners still on board of irreparable vehicles 139
- Clutch actuator . . . . . . . . . . . . . . . . . . . . . . . . 162
DE-ACTIVATING PASSENGER AIR-BAG . . . . . . 141
- Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . 164
- Electronic control unit . . . . . . . . . . . . . . . . . . 142
- Gear selector . . . . . . . . . . . . . . . . . . . . . . . . . 165
- Central unit Pin Out . . . . . . . . . . . . . . . . . . . . 143
REMOTE CONTROL SWITCHES /
SPIRAL CONTACT . . . . . . . . . . . . . . . . . . . . . . . 144 FUSES ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 166
PRETENSIONERS . . . . . . . . . . . . . . . . . . . . . . . . 145 - PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
- Operation principle . . . . . . . . . . . . . . . . . . . . . 145 - PTO engaging procedure . . . . . . . . . . . . . . . . 168
CURTAIN AIR BAG . . . . . . . . . . . . . . . . . . . . . . . 146 - PTO disengaging procedure . . . . . . . . . . . . . . 168
COMPONENT REPLACEMENT INTERVENTIONS 147 - Display screen . . . . . . . . . . . . . . . . . . . . . . . . . 169
- Electronic central unit . . . . . . . . . . . . . . . . . . . 147 DIAGNOSIS (CONNECTOR EOBD) . . . . . . . . . 171
CIRCUITS CARDS . . . . . . . . . . . . . . . . . . . . . . . . 171

Print 603.93.281
ABBREVIATIONS AND GRAPHIC SYMBOLS
Indicates a general warning II6 Connector between cables:

II = connector number
A Ampere 6 = cell number
kW KiloWatt
NB Note Well 7777 Cable colour code
m2 Identification of an earth point
V Volt
Ω Ohm Consult
60 O
Reed fuse on control box
Connection to a power earth point 4 = fuse number
5A
4
5A = capacity
59-60 = terminal identification
59 O
Connection to a signal earth point
720303C Code of connector between cables:

Electronic component or control unit
72030 = connector code
3C = cell identification co-ordinates
Base equipment Optional equipment
Optional electrical connection in a

Base electrical connection
base circuit chart
Connection to earth through metal

Connection to earth by cable
agglomerate
Cables symbol
No protection
Protection with continuous PVC tape
Protection with 30 mm spiral PVC tape
The symbol identifies a knot

GENERAL WARNINGS
General conditions for laying electric circuits
- Engine off
- Ignition switch off
- Handbrake engaged
- Neutral gear
- Fluids at normal level
Do not ever disconnect the system batteries and do not open the general current switch with the i.c. engine running.
! Do not start the engine without first connecting the batteries in a permanent manner.
- Before doing any work on the vehicle chock the wheels appropriately.
- Do not use quick chargers to start the engine. Starting must only be carried out with separate batteries or with the special
trolley.
- Make sure that the polarity on the battery terminals is correct when starting from an auxiliary trolley.
- The incorrect polarisation of the power voltage of electronic control units (for example incorrect polarisation of the batteries)
may lead to their destruction.
- When needing to disconnect the battery from the system, firstly always disconnect the battery negative cable that goes to
the engine from the negative terminal of the battery itself.
- Before connecting the battery to the system, make sure that it is well insulated.
- When seeking faults, insert a wander fuse between the battery negative terminal and the engine earth cable.
- Before removing any electrical and/or electronic components, disconnect the ground cable from the negative terminal of
the battery.
- Disconnect the battery from the system when charging it with external equipment.
- Disconnect the external charging equipment from the mains before removing its grippers from the terminals of the battery.
- Do not insert or remove the connector of electronic control units with the power on.
- With temperatures above 80 °ºC (drying ovens) remove the electronic control units
- During electric welding work disconnect the connectors of electronic control units.
Key storing procedures are affected by electromagnetic noise (mobile phones, etc.). Therefore, during key storing:
! 1. Pay attention that there are no noise sources in the cab or near keys.
2. Keys not inserted in panel must be at least at 1 metre distance.
Measurements in electronic control units, plug connections and electric connections to components may be carried
! out only on appropriate testing lines, with special plugs and sockets. Never use improper means such as metal wires,
screwdrivers, clips or the like. In addition to the danger of a short circuit, damage to the plug connectors may also result
and this would subsequently cause contact problems.

Concept of earth and electromagnetic compatibility

The electric system is traditionally a single-pole system. The body, the frame, the metal container of electromechanical
components act as equipotential return conductor to the generator, as any point of their metal structure or any negative terminal
not isolated is at the same reference potential or EARTH. This is why the earth has been chosen as reference to the whole system,
conventionally giving it the value of zero.
Due to obvious reasons of construction, in the negative network of the system there are various earth points located on the
vehicle in relation to the location of the components on the frame, engine and body.
On the other hand, ideally, all the equipment should be connected to only one earth point in order to provide them, particularly
for electronic devices, a clearly defined earth reference.
For the above-mentioned reasons it is necessary to distinguish the supply earth or system earth, characterised by strong direct
current intensity (> 1 A for electromechanical components), from the analogue earth, characterised by wave shapes at
determinate frequencies and very low current intensity (mA, µA) of electronic systems.
The definition of signal earth or analogue earth depends on the sensitivity of the electronic systems to EMC (electromagnetic
compatibility), as parasite signals emitted by the systems on board or outside the vehicle, induce failures and/or deterioration of
the systems themselves. The best solution for a signal earth is connection with the battery negative terminal.
In order to minimise both continuous and transient disturbance or interference generated by parasite radiation, it is of the utmost
importance to always bear in mind that the satisfactory efficiency of the reference plane or system earth depends on the excellent
conductivity characteristics (contact resistance tending towards zero) in each of its connection points.
Briefly, we can say that the earth understood as equipotential electrical conductor, i.e. as potential reference for all the
electric/electronic components on board, is subdivided into system earth and analogue earth.
Figure 1
6616
EARTH NETWORK
Ba. Battery - R. Loads - Rz. Frame impedance - M1, M2, M3. Earth

Practical advice
The negative cables connected to an earth point must be as short as possible and connected to one another in a ”star” connection,
trying to tighten them neatly and adequately.
Additionally, for electronic components the following instructions should absolutely be followed:
- Electronic control units must be connected to the system earth when they have a metal container.
- The negative cables of electronic control units must be connected to both a system earth point, for example the dashboard
earth (avoiding ”serial” or ”chain” connections), and to the negative terminal of the battery/ies.
- Though they are not connected to the system earth/battery negative terminal, analogue earths (sensors) must be perfectly
insulated. Therefore, particular care should be given to the parasite resistances of the terminals: oxidation, clinching defects,
etc.
- In the presence of jointing connectors the unscreened section d, near them, should be as short as possible.
- The cables should be laid on parallel with the reference plane, i.e. as near as possible to the frame/body structure.
- Additional electromechanical systems should be carefully connected to the system earth and must not be set at the side
of the cables of electronic components.
Figure 2
88039
SCREENING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT

C. Connector - d. Distance ! 0

Ultrasonic cable welding

In order to eliminate earth, supply, outer/inner lighting bridges between components, ultrasonic welding points have been used.
These are not easily identifiable as they appear along the cables inside the corrugated tube of the various harnesses and they are
isolated from the cables through heat-shrinking sheaths or insulating plastic.
Generally, the cables of the components converge on one side in the different welding points, while on the other only one cable
connects them with the earth or supply.
It is also possible to have several welding points connected to one another in which several cables converge on both sides of
the welding. In this case, the earth or supply cable will be connected to the last weld of the series.
Ultrasonic welding brings considerable advantages, including:
- reduction of electromagnetic interference outside the vehicle
- the almost total reliability of the electric system, due to elimination of the bridges, with lower possibility of faults.
Figure 3
A
B
4886 8576
ULTRASONIC WELDING
A. Wiring diagram - B. Technical layout
8577
CONNECTION BETWEEN COMPONENTS

A. Connection through bridges - B. Connection through ultrasonic welding point

TECHNICAL CODES
03000 Self-rectifying alternator with built in voltage regulator
08000 Starter motor
12006 Motor for adjustable mirrors
12010 Motor for locking right door
12011 Motor for locking left door
12012 Compressor for air conditioning system
12025 Power takeoff motor
12026 Motor, winch control
12027 Motor for opening or closing left side door lock
19005 Thermal starter
19010 Heater plug
20000 Starter battery
22001 Horn
22039 Bell for parking lights on signal
25003 Relay for switching on fog lights
25006 Brake lights relay
25014 Relay for enablement of parking lights with engine off
25023 Relay for disconnection of low beam lights with parking lights on
25104 Relay for switching off Retarder with ABS engaged
25209 Relay for switching off services during starting
25222 Relay for allowing connection of thermal starter
25223 Relay for allowing connection of thermal starter fuel tank with atmosphere
25307 Relay for controlling air conditioning compressor
25336 Relay for engine cooling electromagnetic joint
25337 Relay for disconnecting air-conditioning system compressor
25340 Relay, compressor operation, signal to EDC
25620 Relay for fuel filter clogged signal
25704 Relay for switching NC/NO signal for third steering axle
25705 Relay for enabling point switching on
25810 Relay for controlling diesel heating circuit
25811 Ignition timer relay (KSB)
25818 Relay for switching on heated windscreen
25837 Relay for connection of fuel pump
25858 Relay for EDC connection
25926 Relay for enablement of suspension lifting and stopping of suspension lowering function
25927 Relay for enablement of suspension lowering and stopping of suspension lifting function
25928 Relay, rear window heating
28002 Engine stopping electromagnet
30003 Multifunctional side headlight
30011 Fog light
32002 Front direction indicator
33001 Side direction indicator
33004 Side marker lamp
34000 Multifunctional rear light
34007 Stop light
34009 Rear fog lamp
35000 Number plate light
37001 Front dimensions light
39020 Ashtray light
39022 Courtesy light for cabin interior with adjustable spot light

39025 Lamp for lighting rear hatch

39026 Lamp for lighting side hatch
40011 Electronic tachograph
40030 Sender unit for electronic tachometer
40031 Sender unit for electronic tachograph
40046 Inductive type chassis height sensor (rear axle)
42035 Absolute pressure sensor
42102 Switch signalling handbrake applied
42350 Switch signalling body tilted
42351 Switch signalling air filter blocked
42354 Switch for air suspension system failure
42374 EDC clutch switch
42550 Switch signalling engine oil pressure
42552 Fuel filter clogged indicator switch
42608 Coolant pressure signalling 3-switch assembly
44031 Sender unit, fuel level indicator with w/lamp contact
44033 Insufficient brake fluid level gauge control
44036 Insufficient radiator coolant level gauge control
44037 Insufficient power assisted steering fluid level gauge control
44044 Engine oil low level indicator control
47034 Engine coolant temperature sensor (EGR)
47035 Engine coolant temperature sensor
47104 Switch for engaging engine cooling electromagnet coupling
47106 Switch for engaging diesel fuel heating
47109 Switch for connection of ignition timer (KSB)
47207 Switch/sender unit, engine water temperature indicator
48035 Engine rpm sensor
48042 Engine rpm sensor (on timing gear)
52005 Switch with built in w/l for heated rear view mirrors
52036 Switch with built in w/l for engaging windscreen heater
52082 Switch with built-in w/lamp, fog lights
52083 Switch with built-in w/lamp, hazard lights
52084 Switch with incorporated warning light for switching on rear differential lock
52090 Suspension levelling switch (ECAS)
52091 Switch with incorporated warning light for switching on rearscreen heating
52093 Switch for tail hatch locking safety
52310 Switch for adjustable mirrors
52312 Switch controlling headlamp alignment adjustment
52502 Ignition switch for services with starting
53004 Switch for headlamp washer
53041 Switch for checking EDC system
53051 Suspension lifting switch
53052 Suspension lowering switch
53300 Switch for driver’s side electric window
53302 Switch for passenger side electric window
53501 Switch signalling vehicle stopped
53503 Switch signalling reversing lights
53505 Rear differential lock engaged indicator switch
53509 Switch for switching on interior lights
53565 Switch for signalling brake pedal fully pressed
53590 Switch for bonnet open signal

54032 8 function steering column switch unit

58700 Led, battery charging failure
58701 Led, EDC failure
58702 Led, preheating on
58703 Led, ABS failure
58709 Trailer direction indicators ON LED
58710 Water in fuel pre-filter indicator LED
58713 Led, ECAS system failure
58715 Total power take off (PTO) ON indicator LED
58717 Led, Immobilizer on
58718 Brake system failure warning led
58719 Led per segnalazione freno a mano inserito
58720 Led, radiator water level
58722 Led, engine oil pressure (low)
58725 Led, air cleaner restriction
58728 Power steering fluid level w/lamp
58730 Engine oil level w/lamp
58735 Led for indicating rear differential lock on
58918 32-optical indicator panel
61002 3 diode holder container 3A (with + common)
61101 Diesel fuel heater resistor
61102 Rheostat for antipollution device (EGR)
61103 Variable resistance for ignition timer control (KSB)
61106 Windscreen heater resistor
61124 Resistance for rearscreen heating
64000 Electric windscreen washer pump
65000 Windscreen wiper unit
66005 Headlamp washer pump
66010 Headlamp washer timer
68000 Radio equipment
68001 Speaker
68013 Monitor for controlling reverse gear
68014 Camera for controlling reverse gear
72016 13-pole coupling for 12V connection to trailer
72027 38-pole coupling for connection with IVECO
78000 Solenoid valve for connection with atmosphere from fuel tank for thermal starters
78013 Pressure regulator solenoid valve
78015 Solenoid valve to cut out third pumping element
78208 Transmission total power take-off solenoid valve
78209 Solenoid valve for antipollution devices (EGR)
78233 Vehicle raising solenoid valve assembly
78247 Solenoid valve for electronic injection
78248 Solenoid valve for variable geometry turbine order
80000 Motor for right electric window
80001 Motor for left electric window
82000 Windscreen defrosting control unit
82010 Joint between cab-bonnet cable and climate control cable
84020 Outdoor temperature sensor
85000 Cigar lighter
85005 Electrically adjustable heated rear view mirror
85022 Engine cooling electromagnet coupling
85028 Locking device for rear differential

85036 Heated air-suspended seat (driver’s side)

85038 Heated air-suspended seat (driver’s opposite side)
85130 Immobilizer
85131 Volumetric sensor
85132 Antitheft device self-supplying syren
85150 4-channel methane control unit
85151 EDC injection pump
85152 Accelerator load sensor (EDC)
85156 Turbofan air pressure temperature sensor, (EDC)
85157 Pressure adjustment sensor
86002 Sensors for front brake shoe wear
86003 Sensors for rear brake shoe wear
86011 Electronic control unit, pre/after-heating system
86012 Electronic control unit for signalling water in fuel filter
86013 Sensor, water in fuel filter
86020 Antipollution device control unit (EGR)
86023 Vehicle raising/lowering control unit
86029 Electronic control unit for central door locking
86046 Electronic control unit for trailer lights control
86047 Electronic control unit for switching on total power takeoff
86060 Airbag control unit
86061 Air bag
86062 Pretightener
88000 ABS system electronic control unit
88001 ABS system sensor
86*** Engine oil level control
1-2 Parking sensors (Table no. 5)
3-4 Parking sensors (Table no. 5)
* Clutch actuator (Table no. 9A)
** Gears engagement actuator (Table no. 9A)
** Parking sensors central unit (Table no. 5)
*** Gearbox actuator selector (Table no. 9A)

14
Base - March 2006

Figure 4
POWER NETWORK
ELECTRIC/ELECTRONIC SYSTEM
107649
A. Instrument cluster - B. Key switch - C. Steering column switch unit - D. Interconnection central unit ”CPL” - E. Body Computer - F. Battery - G. Positive (+30)
DAILY EURO 4
distribution central unit ”CBA” - H. Alternator - I. (Engine) interconnection central unit ”CVM”.
Print 603.93.651
POSITIVE NETWORK (CBA)

Figure 5
107621
1. Positive connection central unit (CBA)
On battery terminal an interconnection central unit is positioned named ”CBA”. Its task is to provide + battery (+30) power
supply to the different functions of the vehicle.
To this unit there are connected one 6 mm2 cable, three 10 mm2 cables, one 35 mm2 cable, and one 50 mm2 cable.
There are present five fuses by:

- 150 A
- 70 A
- 70 A
- 50 A
- 500 A

Figure 6
107635
Fuse
Ref. Function Sect.
range
1 Positive +30 for alternator starter 500 50
2 Positive for engine opening central unit ”CVM” 150 35
3 Positive +30 for ”CPL” 70 10
4 Positive +30 for ”CPL” 70 10
5 Positive +30 for box OPT 50 6
6 Positive +30 for ”CPL” - OPT prearrangement - 10
* On cable no. 1 there is a 500 A fuse (not visible in figure).

INSTRUMENT PANEL INTERCONNECTION CENTRAL UNITS (CPL) “75002”

Figure 7
107624
107639

Figure 8
107669
Ref. Function Sect.

1 Positive from ”CBA” (fuse 70A) - connector B/A 10
2 Positive from ”CBA” (fuse 70A) - connector B/B 10
3 Positive from ”CBA” - OPT connector D 10

Fuses / remote control switches identification

Figure 9
107626
Maximum
No. Function
nominal current
F-12 Right hand dipped headlight 7,5A
F-13 Left hand dipped headlight - headlamp attitude rectifier 7,5A
F-31 Relay T08-T17 in CVM and BC 3A
F-32 Rotating-translating door 15A
F-33 Air heater / Cigarette lighter 15A
F-34 Socket 20A
F-35 ABS8 or ESP8. Telma 10A
F-36 Central locking 20A
F-37 Switches for stop lights and various loads under 15 5A
F-38 BC / Roof lamps internal relays power supply 10A
F-39 Car radio - chrono-tachograph 15A
F-40 Rh heated rear window 10A
F-41 Lh heated rear window 10A
F-42 Reverse lights switch 5A
F-43 Windscreen wiper 20A
F-44 AVAILABLE -
F-45 AVAILABLE -
F-46 AVAILABLE -
F-47 Driver window winder 25A
F-48 Passenger window winder 25A
F-49 ECU for climate control system, car radio, heated seats 15A
F-50 Airbag 5A
F-51 Chrono-tachograph 5A
F-52 AVAILABLE -
F-53 Instrument cluster, rear fog lights 7,5A
Maximum
Relay Function
nominal current
T-01 Right and left hand dipped headlights 20A
T-11 Heated rear window 20A
T-12 Cigarette lighter / socket / heater or climate control system 20A
T-13 Power release from key 50A

Internal electrical scheme

Figure 10
107660
** Junction between central unit ”CPL” and ”Body Computer” (internal lamellar junction)
*** Connector ”R” unused pins (18 pins)
Junction connectors
Figure 11
107665
FRONT VIEW
Ref. Function
1 Connector (**)
2 Connector ”M”
3 Connector ”R”
4 Connector ”H”
5 Connector ”D”
6 Connector ”B”
7 Connector ”L”

Junction connector “L”
Ref. Function Code

1 Positive for cigarette lighter 7721
2 Positive for socket 7721
3 - -
4 Positive for (rh & lh) door control assembly 8180
5 - -
6 - -
7 Positive for reverse headlamp 2226
9 - -
10 B Can line ”L” for parking sensors 6111
11 Positive +30 7772
12 - -
13 Positive for central locking 9076
14 - -
15 Positive for heated rear window 8021
16 - -
17 Positive for rh lateral window winder 8863
18 Positive +30 for cab roof lamps 7772
19 Positive +15 for parking sensors 8879
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 B Can line ”H” for parking sensors 6110
29 - -
30 Positive for lh lateral window winder 8863
32 - -

Junction connector “M”
Ref. Function Code

1 Positive +15 with the exclusion of users during start-up step 8849
2 - -
3 Positive +15 for air-conditioner central unit 8879
4 Positive +15 for radio 8879
5 B Can line ”H” for radio 6110
6 Positive +15 for air bag 8879
7 Positive +30 for radio 7772
8 Positive for tachograph 5156
9 - -
10 Earth 0000
11 - 8887
12 Positive for tachograph 8879
13 - -
14 Positive +15 for rh & lh window winders 8849
15 - -
16 - -
17 B Can line ”L” for radio 6111
18 - -
19 - -
20 - -

Junction connector “R”
Ref. Function Code

1 - -
2 Positive +15 to control the exclusion of ASR 8879
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 Headlamp attitude rectifier 9934
15 - -
16 - -
17 - -
18 Headlamp attitude rectifier 9935

Junction connector “H”
Ref. Function Code

1 Positive for headlight attitude electric motor 9935
2 Positive for headlight attitude electric motor 9934
3 Positive for lh dipped headlight 2231
4 - -
5 - -
6 - -
8 Positive for reverse gear 2226
9 - -
10 Positive +15 (with exclusion) for windscreen wiper remote control switches 8849
11 Positive for reverse gear on switch 2268
12 Positive for rh dipped headlight 2223
13 - -
14 Positive +15 to stop warning switch 8879
15 Positive for stop lights control 1176
16 - -
17 - -
18 - -
19 Positive +15 for central unit ESP8 8879
20 - -

ENGINE OPENING CENTRAL UNIT (CVM) “75001”

Figure 12
107623
1. Interconnection central unit ”CVM”
107622


Figure 13
107627

Maximum
Ref. Function nominal
current
F-0 Ignition glow plugs 60A
F-1 ABS8 or ESP8 40A
F-2 ABS8 or ESP8 30A
F-3 ECU ESV1 (automatic gearbox) 30A
F-5 Start-up switch 30A
F-6 Heated mirrors and windscreen 20A
F-7 Side marker lamps 20A
F-8 Heater or climate control system fans 30A
F-9 Windscreen washer 20A
F-10 Horn 7,5A
F-11 EDC16 (secondary loads) 10A
F-14 Right hand full beam headlight 7,5A
F-15 Left hand full beam headlight 7,5A
F-16 EDC16, T02, T14, Additional heater 5A
F-17 EDC16 (primary loads) 15A
F-19 Baruffaldi 5A
F-20 Fuel filter heater 25A
F-21 Fuel pump 15A
F-22 EDC16 (primary loads) 25A
F-23 Additional heater 10A
F-24 ECU ESV1 (automatic gearbox), PTO 15A
F-30 Left and right hand front fog lights 15A
IN CONTAINER, OUT OF CENTRAL UNIT
F-26 Trailer socket 10A
F-29 Air spring suspensions 40A
F-54 Air spring suspensions 40A
Maximum
Ref. Function
nominal current
T02 Right and left hand full beam headlights 20A
T03 Horn 20A
T05 Baruffaldi power supply 20A
T06 Heater / mirrors / windscreen 20A
T07 Side marker lamps 20A
T08 Heater or climate control system fans 20A
T09 EDC16 (main relay) 20A
T10 Fuel pump 20A
T14 Left and right hand front fog lights 20A
T17 Windscreen washer 20A
T19 Fuel filter heater 20A
T20 Diagnosis MODUS 20A
IN CONTAINER, OUT OF CENTRAL UNIT
T25 Windscreen wiper on/off 10/20A
T26 Windscreen wiper 1st / 2nd speed 10/20A

Internal electrical scheme

Figure 14
107645

Junction connectors
Figure 15
107646
REAR VIEW
Ref. Function
1 Connector ”A”
2 Connector ”D”
3 Positive ”+30” from ”CBA”
4 Connector ”F”
5 Connector ”B”
6 Connector ”C”
7 Connector ”E”

Junction connectors “A”
Ref. Function Code

1 Positive for windscreen washer pump 8886
2 - -
3 - -
4 Positive for lh front fog headlamps 2228
5 Positive for rh front fog headlamps 2228
6 Positive from Body Computer 8879
7 Positive for gear selector switch for semi-automatic gearbox 8110
8 Positive +15 for total power take-off 8879
9 - -
10 - -
11 Jumper with H7 of 75002 8849
12 Jumper with AV12 of Body Computer 8879
13 - -
14 Earth 0000
15 - -
16 - -
17 Positive for diagnostics connection joint (+) 7797
18 - -
19 - -
21 Positive for horns 1116
22 Positive for rh full beam headlight 2221
23 Jumper for Body Computer 8879
24 - -
25 Positive for lh full beam headlight 2219
26 Earth 0000
27 Positive +15 for horns 1116
28 - -
29 - -
31 Positive +30 for automatic gearbox central unit 7772

Junction connectors “C”
Ref. Function Code

1 Positive +30 for start-up 7772
2 Positive for diesel oil heating on control 8036
3 - -
4 Positive for electromagnetic clutch for air conditioning system 9993
5 Earth 0000
6 Positive +30 7772
7 - -
8 - -
9 Positive +15 8879
10 Main relay signalling cable for EDC 155
11 Earth 0000
12 (Not protected) direct positive on batteries 7777
13 - -
14 - -
15 - -
16 - -
18 Positive for EDC/MS6 system from main relay 7150
19 - -
20 - -
22 Water in pre-filter warning lamp 5530
23 Jumper between C23 and C12 7772
24 Positive +30 for automatic gearbox central unit 7772
25 - -
26 - -
27 - -
28 Negative for heated rear view mirrors switch 0000
30 Injection pump diesel oil flow actuator for EDC16 9156
31 Positive for EDC16 7150
32 - -
Junction connectors “B”
Ref. Function Code

A Positive +30 for ABS 7772
B Positive +30 for ABS 7772
C Positive +15 for air-conditioner 8849

Junction connectors “D”
Ref. Function Code

A Positive +30 for key switch 7772
B Positive +30 for automatic gearbox 7772
Junction connectors “E”
Ref. Function Code

A Positive for chassis cable 3390
B -
C Positive +15 for heated rear view mirrors 8830
Junction connectors “F”
Ref. Function Code

A Positive +30 for pre-heating 7772

NEGATIVE NETWORK
Figure 17
EARTH POINTS
Through a brown 50 mm2 cable, battery negative terminal is
connected to earth point (LM2) located at chassis left side on
the side member; from this point, a copper braid is connected
to engine block, near the starter (lm1). At point lm2 there are
connected the earth points relating to chassis cable.
107633
NEGATIVE PIN
Figure 16 Figure 18
107637 107636
ENGINE BLOCK BRAID (LM1) EARTH POINT ON LEFT HAND SIDE MEMBER (LM2)

Figure 19 In bonnet, in the vicinity of left front blinker there is located

earth point lm5 to which connected are:
- Central unit ”CVM”
- Lh headlamp
- Pre-heating remote control switch
- EDC
- Electromagnetic joint for engine cooling
- Heated pre-filter
- Remote control switch to enable air-conditioner com-
pressor to be put on
- Headlight washer pump
- Fuel filter clogged switch
107628
- Switch for engine bonnet opening
LH BONNET EARTH POINT (LM5) In bonnet, in the vicinity of right front blinker there is located
earth point lm4 to which connected are:
Figure 20
- Rh headlamp
- Windscreen washer pump
- Horn
- Windscreen wiper
- Compressor connected remote control switch (for
EDC)
- Air-conditioner compressor
- Heated windscreen
- Gearbox power take-off in switch
- Antitheft siren
- Air filter clogged switch
In the bonnet, under power-assisted brake there are two
107629
earth points present:
RH BONNET EARTH POINT (LM4) - lm3: central unit ABS - heated pre-filter central unit
- lm3/S: central unit ABS
Figure 21
107632
EARTH POINTS UNDER POWER-ASSISTED BRAKE

(LM3)
Cab interior left side Figure 22

- CPL
- Body Computer
- Central locking central unit
- Switch for the exclusion of ASR (symbol)
- Power central unit
- Height sensors (ECAS)
- Steering column switch unit (lm7/S)
- Gear selector for automatic gearbox (lm7/S)
Cab interior right side
- Emergency lights pushbutton
- Front fog lights (pushbutton) 107641
- Speed limit setting (pushbutton) CAB INTERIOR LEFT SIDE (LM7)

- Radio
Figure 23
- Windscreen electric defroster control assembly
- Air-conditioner central unit
- Pushbutton for heated rear window
- Heated mirrors switch
- Vehicle lifting/lowering pushbuttons (ECAS)
- Tachograph (lm6/S)
Loading platform central part (lm8)
- Clearance (rh / lh) front lights
- AIR BAG (central unit) lm8/S
- Switch for anti-twisting with gears engaged
107640
CAB INTERIOR RIGHT SIDE (LM6)
Figure 24
107642
CAB INTERIOR LEFT SIDE (LM7/S)

BATTERY (20000)
The battery shown below has a 12Vdc 110Ah 460 A power supply voltage and is installed on the left side of the engine
compartment near the EDC control unit.
Requirements
- Case and cover in polypropylethylene plastics PR. 50.100. Matt white case.
- C.S. plugs, blacK. Grids: positive and negative made of Pb Ca.
- Cover integral polypropylene
- Separator: envelope-type polyethylene
- Battery for “tropical duty” marked with red color.
- “Environmental precautions” plate according to Law no. 126 of 10/04/91 “Standards for user information”.
- Adhesive label with “Selective disposal” acc. to EEC Directive no. 93/86.
Figure 25
107621
Fast diagnosis
Defect Possible causes Remedy
Start defect 1. Low battery Check battery charge; if regular check
recharge circuit
2. Loose, oxidized or burnt out con- Recover
tacts
3. Starter circuit defective Cf. start section
Low voltage at component leads 1. Battery at half power Check battery charge; if regular check
recharge circuit
2. Oxidized connections Sand and replace
Electrolyte level often low 1. Over voltage Check recharge circuit and/or connec-
tion tightness

BOSCH KCBI 14V 110A ALTERNATOR

03000
Specifications for use

Figure 26
Vehicle electric system rated voltage: 12 V
Suitable for coupling with battery of any capacity
It must work with the battery connected.
Connection with inverted polarity is not allowed.
Operating specifications
Rated voltage 14 V
Rated current delivery 110A
Drive side direction of rotation clockwise
Maximum continuous speed ≤ 12.000 min-1
Storage temperature -40 °C / +110 °C
8649
WIRING DIAGRAM
Figure 27
8656
TECHNICAL VIEW

EV 12V - 2.3 KW STARTER MOTOR Figure 29

08000
Figure 28
74023 8642
WIRING DIAGRAM PERSPECTIVE VIEW

Figure 30
5
2
4
3
1
7 10
9
8
6 5260
PERSPECTIVE BLOWN-UP VIEW

1. Support - 2. Pinion engagement control electromagnet - 3. Pinion - 4. Pinion engament fork - 5. Rotor - 6. Frame -
7. Inductors - 8. Brush holder support - 9. Cover - 10. Screw
Fast diagnosis
Defect Possible causes Remedy

Low drawing torque 1. Low battery Recover
2. Oxidized or loose circuit connec- Check starter motor and battery con-
tions nections
3. Faulty brushes Check brush slide length and pressure
4. Field coils short circuited Replace coils
5. Rotor cut out or short circuited Replace rotor
6. Oval collector Grind correct or replace
Low drawing torque but engine does 1. Defective free wheel or electroma- Replace
not start gnet
Pinion disconnected 1. Worn toothed crown Recover

JUNCTION WELDS
Inside each cable there are ultrasound welds (see start of manual) joining between each other those cable which have similar
functions (positive, earth, various junctions, etc.).
In these pages, their location is described divided according to the cable to which the location is belonging to.
This description will be in the future integrated by the drawing of respective cable in order that their location can be identified
more easily.
INSTRUMENT PANEL CABLE

Weld A9 near central instrument panel switches shunt
Weld A30/A65 near central instrument panel switches shunt
Weld A43 near instrument panel cable central part
Weld A49/50 near tachograph
Weld A51/54 near the shunt towards CPL
Weld A78 near the shunt for climate control system
Weld A100 near instrument cluster shunt
Weld A101/102 near rh speaker shunt
CAB CABLE
Weld A15 near lh window bag shunt
Weld A21/a601 near central roof lamp shunt
Weld A/25 near (lh front) shunt for cable/bonnet junctions
Weld A26/A18/A700 near lh front shunt for cable / instrument panel junction, Body Computer (LN),
CPL (connector ”L”)
Weld A/600 near (rh) lateral hatch roof lamp shunt
Weld A/602 near (lh) driver roof lamp shunt
Weld A/603 near rh window bag shunt
BONNET CABLE
Weld A3 near CBA
Weld A4 near brake oil level sensor cable shunt
Weld A5/A32/A39/A53 near heated windscreen shunt
Weld A7/A8/A31/A36/A40 near heated windscreen shunt
Weld A13/A24/A44/A45/A22 near passage between bonnet and cab (cab side)
Weld A14/A64 near sensor shunt on DPF
Weld A17/A20 near passage between bonnet and cab (bonnet side)
Weld A19 near lh headlight shunt
Weld A33/A41 near IE cable shunt

Weld A34/A35 near switching on switch shunt

Weld A37/A38 near Telma (bonnet side) shunt
Weld A66 near junction for automatic gearbox (bonnet side)
Weld A67 near central unit CPL
Weld A70 near central unit EDC
Weld A77 near shunt for ECAS, lambda, additional heater (bonnet side)
TRUCK CHASSIS CABLE

Weld A6 near rear lights shunt
Weld A10 near fuel level transmitter shunt
VAN CHASSIS CABLE

Weld A6/A10 near lh clearance lateral headlamp shunt

WIRING HARNESS SECTION

Description
Engine cable
(van-truck) chassis cable
ABS probes cable
cab cable
instrument panel cable
bonnet cable
AIR BAG cable
doors cable
BONNET - INSTRUMENT PANEL - CAB - CHASSIS cables interface to each other through following connectors:
BONNET - INSTRUMENT PANEL cable

Connectors 600-601H 600-601B 600-601D
BONNET - CAB cable

Connectors 600-601G 600-601A
INSTRUMENT PANEL - CAB cable

Connectors 600-601C
BONNET-CHASSIS cable
Connectors C4 C2 C70
All junction connectors are on vehicle left side at interconnection central unit CPL.
The three BONNET - CHASSIS connectors are in engine opening on vehicle left side under front headlamp.
The two AIR-BAG connectors are in cab floor central part. They can be identified by cable yellow colour.

Figure 31
107643
instrument panel cable
AIR BAG cable
bonnet cable
cab cable

Figure 32
107644
ABS probes cable
Engine cable
chassis cable
doors cable

JUNCTION CONNECTORS
Bonnet - instrument panel junction (600/601H)
Figure 33
BONNET CABLE
107654
INSTRUMENT PANEL
CABLE
107655
Ref. Function Code

1 Positive for power take-off solenoid valve 9131
2 Positive +15 8879
3 Optical indicator to signal that power take-off on gearbox has been connected 6601
4 Positive for ”opening” solenoid valve for tilt body 9137
5 Positive for ”closing” solenoid valve for tilt body 9138
6 Negative for ”opening” solenoid valve for tilt body 9139
7 Positive (+15) to antitheft siren 9140
8 Signal from antitheft central unit to siren 9142
9 Negative for power take-off actuator 9136
10 Positive for power take-off actuator 9135
11 Automatic gearbox central unit pin 3 6141
12 Automatic gearbox central unit pin 5 6143
14 Positive for automatic gearbox gear selector 8110
15 Automatic gearbox Gear selector pin 3 White
16 Automatic gearbox Gear selector pin 4 Green
17 Positive for optical indicator for heated rear view mirrors 6652
19 Positive +15 for additional heater timer 8879
20 Positive +15 for central unit EDC pin K28 8051

Bonnet - instrument panel junction (600/601B)

Figure 34
BONNET CABLE
107656
INSTRUMENT PANEL
CABLE
107657
Ref. Function Code

2 Earth 0000
3 Earth 0000
4 Control for EDC from speed limiter pushbutton -
5 Positive for 3-level air-conditioner pressure switch and remote control switch to 8163
signal to EDC that compressor has been connected
6 Signal from external temperature sensor for air-conditioner 5532
7 Acceleration sensor earth (ESP8) 0050
8 Acceleration signal (from acceleration sensor) ESP8 9090
9 Positive to acceleration sensor (ESP8) 9091
10 Positive for differential locking system 8066
12 Yaw sensor reference signal (ESP8) 9094
13 Yaw sensor test signal (ESP8) 9093
15 Yaw sensor signal 9095
16 Lateral acceleration signal 9092
17 Yaw sensor earth 9096
18 - -
19 Positive for electromagnetic joint for air-conditioner 9993

Bonnet - instrument panel junction (600/601D)

Figure 35
BONNET CABLE
107656
INSTRUMENT PANEL
CABLE
107657
Ref. Function Code

1 Positive for diagnosis connector 7797
2 Positive for electronic tachograph transmitter 5514
3 Negative isolated from electronic tachograph transmitter 0058
4 Speed signal from electronic tachograph transmitter 5517
5 Reversed signal from electronic tachograph transmitter 5516
6 Positive for TELMA decelerator: first position 9913
7 Positive for TELMA decelerator: second position 9910
8 Positive for TELMA decelerator: third position 9916
9 Positive for TELMA decelerator: fourth position 9912
10 Positive for TELMA control switch 9911
12 Positive for EDC failure warning lamp 5180
13 Negative for optical indicator for differential locking on transfer box (from 6603
signalling switch)
14 Positive for horn 1116
15 Earth 0000
16 Air spring suspension control (lifting) 9981
17 Air spring suspension control (lowering) 8091
18 Earth for signal for tachometric sensor 0058
19 Signal from tachometric sensor 5517

Bonnet - instrument panel junction (600/601G)

Figure 36
BONNET CABLE
107656
INSTRUMENT PANEL
CABLE
107657
Ref. Function Code

1 Negative for rear door actuator 8902
2 Negative for optical indicator for hand brake engaged 6662
3 - -
4 Negative for fuel level transmitter 0000
5 Signal from fuel level transmitter 5557
6 Positive +30 7772
7 - -
8 Positive for clearance lights (van) 3325
9 Positive for clearance lights (van) 3324
10 Positive for rear door actuator 8901
11 - -
12 - 5164
13 Positive for lh front parking light, lh front clearance 3321
14 Positive for rh front parking light, rh front clearance 3320
16 - -
17 - -
18 - -
19 - -
20 - -

Bonnet - instrument panel junction (600/601A)

Figure 37
BONNET CABLE
107656
INSTRUMENT PANEL
CABLE
107657
Ref. Function Code

1 - -
4 Optical indicator TELMA (to Body Computer) 6604
5 Positive for rear fog headlamps 2283
6 Line ”K” for air spring suspensions 2294
7 Air spring suspension failure warning lamp (to Body Computer) 6008
8 Positive for plate light 3337
9 Positive for rh blinker 1125
12 Positive for stop rear signalling 1177
13 Positive for heated mirrors 8830
14 Positive for heated mirrors 8830
16 Positive for lh rear blinker 1120
17 Positive for rh rear blinker 3322
18 Positive for stop rear signalling 1172
19 Positive for lh rear parking light 3323
20 - -

Bonnet - instrument panel junction (600/601C)

Figure 38
107658
107659
Ref. Function Code

1 Positive +15 8879
2 - 5647
3 To Body Computer (instrument panel - PF - pin 23) 5159
4 External temperature sensor for air-conditioner 5532
5 External temperature sensor for air-conditioner 5532
6 - -
10 ”B” Can line H (parking sensors) 6111
11 ”B” Can line L (parking sensors) 6110

INSTRUMENT CLUSTER (58919)
Figure 39
107659
Position Warning lamps Colour Position Warning lamps Colour

1 Lh blinker green 17 EOBD yellow
2 Driver belt unfastened red 18 Air spring suspension failure red
3 Front fog lights green Engine coolant high
19 red
4 Full beam headlights blue temperature
20 Tachograph failure (symbol T) yellow
5 Parking lights green
21 * Programmed maintenance yellow
6 Tractor external light failure yellow
22 Fuel reserve yellow
7 Rear fog lights yellow
23 Generic failure yellow
8 Doors open red
24 Passenger airbag de-activated yellow
9 Rh blinker green
25 Differential locking connected yellow
10 Decelerator connected yellow
26 Air bag failure red
11 Glow plugs pre-heating yellow
Vehicle protection system
Water present in diesel oil 27 yellow
12 yellow failure
filter
28 Brake failure and EBD failure red
13 Engine coolant low level red
29 Parking brake red
14 Engine oil low pressure red
30 Failure yellow
15 EDC failure red
31 Function ESP/ASR yellow
16 Battery not being recharged red
* ”Modal” Version - Outer emergency handle locked by key

Junction connector
Figure 40
107651
REAR VIEW
Cable
Ref. Function
Code
1 Earth 0000
2 Positive +30 7772
3 Positive +15 8879
4 - -
5 “B” CAN Line L 6111
6 “B CAN Line” H 6110
7 Positive for headlight attitude rectifier (position C) 9935
8 Positive for headlight attitude rectifier 9934
9 Earth (to instrument panel switch assembly) 0000
10 - -
11 - -
12 - -
13 To instrument panel switch assembly 9086
15 - -
17 Positive for differential locking optical indicator 6603
18 Positive for EDC failure 5180
Where instrument cluster is replaced, reprogram by diagnosis tools.
A = 1÷9
B = 10 ÷ 18

Display screen
Figure 41
107620
Instrument Cluster: Magneti Marelli

Two versions are present of display screen mounted on instrument cluster:
- Modal version
- Comfort version
the two versions are different in display size and information displayed.
Modal Version:
this version has a smaller display screen and displays:
- total/partial KM
- consumption indication
- time
- headlamp attitude rectifier indication.
Comfort Version:
this version has a larger display screen with 14 characters that are used to display trip computer data, menu with relating messages
for settings/adjustments, activation/service messages, failure/warning messages. The display also displays:
- automatic gearbox indication
- time
- indication of danger owing to ice
- adjustable spanner symbol for “service”
- external temperature
- headlamp attitude rectifier indication
- total/partial KM.
Displaying messages on display screen:

Messages on display screen are divided into four different classes:
- High priority faults (8 display cycles)
- Low priority faults (4 display cycles)
- Information messages (4 display cycles)
- Feedback messages (1 display cycle)
- Messages driven by central unit (while their cause is persisting)
Longer messages are divided into lines with 14 characters appearing on display screen in order that these messages can be
displayed entirely.

STEERING COLUMN SWITCH UNIT (54030)

Figure 42
107650
Cable
Ref. Function
colour code
1 Windscreen wiper motor control (to Body Computer) 8880
2 Windscreen washer pump control (to Body Computer) 8886
3 Earth 0000
4 Signal earth (to Body Computer) 0050
5 Blinker control (to Body Computer) 1111
P1 6 Flashing control (to Body Computer) 8024
((Black)) 7 Parking lights control (to Body Computer) 3333
8 Horns 1116
9 Front fog lights control (to Body Computer) 2228
10 - -
11 Front fog lights control (to front fog lights on pushbutton) 2228
12 - -
1 Positive for Cruise Control 7155
2 Positive for Cruise Control 7155
P2 3 Slow down signal (SET-) 8157
((Black)) 4 Windscreen wiper reset input 8154
5 Electric pump for windscreen washer 8155
6 Supply (+30) for side lights switch 8156

CENTRAL INSTRUMENT PANEL

Figure 43
107647
Ref. Function
1 Hatchback locking
2 Rotating-translating door control
3 Self-levelling air spring suspensions
4 Load area illumination
5 Front fog lights
6 Emergency lights
7 Heated rear view mirrors
8 Heated rear window
9 Rear differential locking
10 Exclusion of ASR
11 Speed limiter in
Pushbutton arrangement may change depending on different preparations.

INSTRUMENT PANEL SWITCH ASSEMBLY (53807)

Figure 44
107652
Cable
Ref. Function
Code
1 Positive +15 3320
2 Earth (to Body Computer) 0000
3 - -
4 To instrument cluster (headlamp attitude) 9085
5 To instrument cluster (MODE +) 9086
6 To instrument cluster (MODE -) 9087
7 - -
8 - -
9 Earth (to instrument cluster (TRIP)) 0000
10 Air heater -
11 - -
12 - -

OPTIONAL BOX
Figure 45
107687
CENTRAL UNIT FRONT VIEW CENTRAL UNIT REAR VIEW

Ref. Component identification Function

1 T4 Remote control switch to release retarder with ABS in
2 F55 30A fuse for additional climate control system
3 T15 Remote control switch (at disposal)
4 T22 Remote control switch to enable compressor switching on
5 F25 10A fuse
6 T18 Remote control switch to set gearbox to neutral position (automatic gearbox)
7 T24 Remote control switch to enable PTO switching on
8 F28 30A fuse for positive for rear differential locking central unit
9 T23 Remote control switch to control air-conditioner compressor
10 T21 Remote control switch to warn that compressor for EDC is on
11 F27 20A fuse for positive for headlight wiper
12 T16 Remote control switch for headlight wipers
* Front view

OPT central unit Pin-Out
Cable
Ref. Function
Code
1 9911 Positive for decelerator control switch
2 - -
3 8879 Positive +15
4 9911 Positive for decelerator control switch
5 0000 Negative from central unit ABS
6 7772 Positive +30 for headlamp wipers from CBA
7 7777 Positive for headlamp wiper pump
8 0000 Negative from Body Computer
9 - -
10 8849 Positive +15
11 7772 Positive +30 for additional climate control system
12 7772 Positive +30 for additional climate control system
13 7772 Positive +30 for headlight wipers
14 7772 Positive +30 for headlight wipers
15 - -
16 - -
17 - -
18 - -
19 - -
20 7772 Positive +30 for remote control switch to warn that compressor is on (to EDC)
21 7772 Positive +30 for remote control switch to warn that compressor is on
22 0000 Earth for remote control switch to warn that compressor is on
23 - -
24 8163 Connection to 3-level pressure switch for air-conditioner
25 0000 Negative from EDC for remote control switch to enable compressor to be put on
26 - -
27 7772 Positive +30 for remote control switch to enable compressor to be put on
28 0000 Earth for remote control switch to enable compressor to be put on
29 0000 Negative from compressor control remote control switch
30 0000 Negative from remote control switch to enable compressor to be put on (30)
31 - -
32 0000 Connection to 3-level pressure switch for air-conditioner
33 8883 Positive for air-conditioner compressor control
34 9067 Positive for air-conditioner compressor control remote control switch
37 8887 Positive +15 for rear differential locking central unit
38 8887 Positive +15 for rear differential locking central unit
39 7772 Positive +30 for remote control switch to put gearbox in neutral position
(automatic gearbox)
40 - -
41 0000 Negative from automatic gearbox central unit
42 8888 Connection to starter
43 8888 Connection to start-up switch
44 7155 Positive for remote control switch to enable PTO to be put on
45 9131 Connection to total power take-off switching on central unit
46 0000 Earth
47 - -
48 0000 Earth

“CAN LINES” SYSTEM DESCRIPTION

The electrical / electronic system is characterised in the presence of two communication lines which manage vehicle electrical
system, directly controlling body functions, access, visibility, board information, comfort, etc.
The structure consists of two CAN communication networks to which all electronic central units present and instrument cluster
complete with display screen are connected.
A new central unit is also present: the Body Computer, which manages many functions present and communicates with both
CAN lines. For diagnosis, 38-pole connector is not present any more; on the contrary, a 16 pin connector is present named EOBD.
In particular, on CAN line named Ccan, connected are central units relating to vehicle systems and information for driver:
- Yaw sensor present with ESP8
- ABS
- Automatic gearbox
- EDC16
- Decelerator
- Digital tachograph
- Body Computer
This communication line is characterised in high speed data transmission relevant to electronic systems connected to it. It is
comparable to VDB line present on other vehicles.
Communication line named Bcan enables communication between Body Computer and the various central units employed for
the various board services. To this line connected is the instrument cluster, equipped with a display screen.
This communication line enables data transmission at a lower speed than above Ccan line.
Central units connected to this line:
- Body Computer
- Instrument cluster
- Radio and navigator
- Air Bag
- Rotating-translating door

Print 603.93.651
DAILY EURO 4
Figure 46
“C” CAN line
107653
1. Central unit EDC16 - 2. Digital tachograph - 3. Automatic gearbox central unit - 4. Decelerator - 5. Steering angle sensor (ESP8) - 6. Body Computer -
7. Alarm siren - 8. Additional heater - 9. Climate control system central unit - 10. Central unit WABCO - 11. Central unit ABS8/ESP8
61
Base - March 2006

62
Base - March 2006

Figure 47
“B” CAN line
107688
1. Rotating-translating door central unit (start of 2007) - 2. Air Bag central unit - 3. Body Computer - 4. Instrument cluster - 5. Radio / navigator - 6. Blue Tooth
DAILY EURO 4
Print 603.93.651
BODY COMPUTER - (86116)

Figure 48
107624
107673
1. Body Computer - 2. Central unit “CPL”

Description
The Body Computer is the central unit of the electrical system of vehicle under examination. Its task is to manage main functions
present.
Inside, it integrates “immobilizer” function; therefore, an external central unit is not present any more for this function.
Further, it manages:
- External and internal illumination
- Central door locking actuator controls, windscreen washers and wipers, front electric window winders, etc.
- Acquisition of switches and controls from steering column switch unit, pushbuttons, etc.
Inside, it integrates diagnosis connector EOBD (16 pins) for board diagnostics (previous diagnosis connector is not present any
more), it communicates with the two CAN lines present (Bcan, Ccan) and instrument cluster. It is mounted in the cab behind
interconnection central unit “CPL” and interfaces with it through a 20 pin lamellar connector located inside the component.
Figure 49
107668
A. Input signals - B. Output signals
It interfaces with vehicle system through three connectors: two connectors are located in front side and one connector is located
in rear side accessed by tilting the whole assembly through unscrewing special securing screws.
Front connectors:
- cab wiring harness (black) connector “LN”
- bonnet wiring harness (blue) connector “AV”
- diagnosis connector EOBD
Rear connector:
- instrument panel wiring harness (blue) connector “PF”
A closing resistance is present on “C” CAN line positioned in the vicinity of steering column switch unit inside instrument panel.

Figure 50
107664
1. Connector “CY” for junction with “CPL” (interior) - 2. Junction connector “AV” (bonnet) - 3. Diagnosis connector
“EOBD” - 4. Junction connector “LN” (cab) - 5. Junction connector “PF” (instrument panel)

Black cab junction connector “LN”

Figure 51
107661
Cable
Ref. Function
Code
1 - -
2 - -
3 - -
4 Central locking “H6” 0000
5 Positive for lh lateral blinker 1126
6 Positive for rh rear blinker 1125
7 Fuel level gauge “PIN 4” 5557
8 Positive for lh rear parking light 3323
9 Positive for rh rear parking light 3322
10 - -
11 Earth for roof lamp switching on 0003
12 Positive for plate light 3337
13 (Driver - passenger) central locking “PIN 1” 8180
14 - -
15 - -
16 - 8879
17 - 5164
18 Positive for lh rear blinker 1120
19 Positive for rh blinker 1124
20 Signal for hand brake optical indicator 6662
21 Fuel level gauge “PIN 3” 0000
23 - -
24 Line “K” for air spring suspension central unit 2294
25 Air spring suspension failure warning lamp 6008
26 Positive for rh rear fog light 2283
27 13-pole socket PIN 9 6120
28 Negative for illumination pushbutton with tools 0000
29 Side hatch roof lamp 4110
30 Cab interior roof lamp 4111
31 Positive for rh stop rear light 1172
32 Positive for rear roof lamp 7772
36 Central locking “C7” 0000

Cable
Ref. Function
Code
37 - -
38 - -
39 - 4112
40 Decelerator “TELMA” optical indicator 6604
41 Central locking “C2” 0000
42 Central locking “A2” 0000
43 Positive for lh rear fog light 2283
44 Positive for lh stop rear light 1177
45 - -
46 - 6606
47 - -
48 _ 6630
49 Roof lamp for side hatch illumination 4113
50 - -
51 - -
52 - -

Blue instrument panel junction connector “PF”

Figure 52
107662
Cable
Ref. Function
Code
1 - -
2 Parking lights (from steering column switch unit) 3333
3 Positive for instrument cluster 7772
4 Flashing remote control switch control (from steering column switch unit) 8024
5 Instrument cluster “B” CAN line L 6111
6 Instrument cluster “B” CAN line H 6110
7 Positive for blinkers (from steering column switch unit) 1111
8 Earth from instrument panel switches 0000
9 Earth (from steering column switch unit) 0050
10 Earth 0000
11 Positive for diagnosis connector 7797
12 Climate control system central unit line “K” 2296
13 - -
14 - -
15 - -
16 - -
17 - 0000
18 Positive for the illumination of the symbols of switches 3320
19 Earth 0000
20 Negative for cab roof lamp switch 0000
21 Positive for the illumination of the symbol of heated rear window on 6653
22 - 5647
23 Camera PIN B-1 (visual system for reverse gear) 5+59
24 Air Bag “B” CAN line H 6110
25 Air Bag “B” CAN line L 6111
26 - -
27 Positive (+15) 8849
28 Positive for windscreen wiper (from steering column switch unit) 8880
29 - -
30 Positive for windscreen washer pump (from steering column switch unit) 8886
31 Positive for instrument cluster (+15) 8879
32 Negative from heated rear window switching on pushbutton 0000
33 - -
34 Negative for emergency lights switching on (from pushbutton) 1113
35 Fog front headlamps power supply (from steering column switch unit) 2228
36 Negative for instrument cluster 0000

Blue bonnet junction connector “AV”

Figure 53
107661
Cable
Ref. Function
Code
1 Negative from fuel filter clogged sensor 5531
2 - 2663
3 Positive for general power-assisted units (+15) 8879
4 - -
5 For rh front blinker 1129
6 - -
7 “IMMOBILIZER” antenna PIN 2 8092
8 “IMMOBILIZER” antenna PIN 1 8092
9 Signal from sensor for engine water level gauge 5520
10 Electronic tachometer transmitter “PIN 3” 5517
13 - -
14 - -
15 - -
17 - -
18 - -
19 Fixed stop for windscreen wiper “PIN 2A” 8873
20 Negative for remote control switch to switch on headlight wipers 0000
21 Negative for automatic gearbox central unit “PIN 45” 0000
22 Line K for central unit ABS / ASR 2299
23 - -
24 Negative from brake liquid level sensor 6661
25 Generator charge optical indicator 7778
26 Line “K” for central unit EDC 16 2298
27 Negative for electronic tachometer transmitter “PIN 2” 0058
28 Positive for rh front blinker 1123
29 Control for remote control switch to insert windscreen wiper 1st/2nd speed 8879
30 Central locking antenna “PIN 1” -
31 - -
32 Signal from (front / rear) shoes wear sensors 6004
33 Negative from engine bonnet opening switch 5621
34 Signal for antitheft system 9142
35 - -
36 - -

Cable
Ref. Function
Code
37 Speed signal (from tachometer) for EDC / automatic gearbox 5517
38 External temperature signal (air-conditioner) 5532
39 Positive for rh front parking light - rh front clearance light 3320
40 Control for remote control switch to switch on windscreen wiper 8879
41 - -
42 - -
43 Central locking antenna “PIN 2” -
44 “C” CAN Line L — Steering angle sensor (PIN 1) - CAN line closing resistance
45 “C” CAN Line H - Steering angle sensor (PIN 3) - CAN line closing resistance
46 Positive for antitheft siren (+30)
47 Line K for additional heater
48 “C” CAN Line L - ABS / automatic gearbox / EDC16 2950
49 “C” CAN Line H - ABS / automatic gearbox / EDC16 8950
50 - -
51 - -
52 Positive for lh front parking light - lh front clearance light 3321

FITTER CONNECTOR (61071)

Figure 54
101564
Ref. Function
1 -
2 -
4 -
5 Hand brake in
6 -
7 Positive K58 (external lights)
8 Alternator charge (alternator signal L)
9 Clutch status (activated / not activated)
10 Reverse gear engaged (positive)
11 -
12 Cruise control (set +)
13 Cruise control (set -)
14 Cruise control (reset)
15 Cruise control (on)
16 -
17 Earth
18 Power take-off 1
19 Power take-off 2
20 Power take-off 3
Positioned in the cab near junction connectors - Air-Bags (at the bottom to the right)

FITTER CONNECTOR (72068)

Figure 55
101554
Ref. Function
1 Activating secondary speed limiter
2 Activating speed limiter
3 Selecting idling and 2 speeds
4 Vehicle speed signal
5 Positive +15 (key)
6 Power take-off activated
7 Horn activated
8 -
9 -
10 Engine rotation speed
11 -
12 -

ELECTRONIC INJECTION EDC16

Particular features of engines Euro 4
To observe emission limits Euro 4, engines E4 have following features:

- E.G.R. system present;
- D.P.F. filter (solid particulate trap with constant regeneration) present;
- new digital flow meter HFM6 (positioned after the air filter);
- air pressure sensor present (on the intake manifold after the intercooler);
- fuel electrical pump suitable to pressurise the circuit according to specifications Euro 4;
- vehicle wiring harness for central unit EDC16C39 new electrical scheme;
- throttle valve present driven by EDC central unit (positioned on the intake manifold after the intercooler).
Constant regeneration particulate trap is mounted on engine exhaust. Through data processing (engine rpm’s, H2O temperature,
oil temperature, lambda probe signal, etc.), the central unit calculates the quantity of particulate accumulated in filter and chooses
to increase exhaust gas temperature (through post-injection) in order to burn particulate accumulated inside filter.
Further, vehicles (for compliance with regulations Euro 4) differ from the ones of present production mainly in following
components:
- fitting with catalytic converter DPF (Diesel Particulate Filter) provided with exhaust gas temperature sensors,
- differential pressure (Delta-p) sensor for detecting DPF catalyst particulate filter clogging,
- fuel electric pump with different characteristics for boosting fuel system pressurisation,
- electrical wiring harness.

System to reduce pollutants at exhaust

Figure 56
105058
Exhaust gasses
Under-pressure tube
1. E.G.R. heat exchanger - 2. E.G.R. valve - 3. Engine coolant temperature sensor -

4. Engine rpm sensor - 5. Modulator solenoid valve - 6. Air filter - 7. Air flow rate meter (flow meter) -
8. Oil vapours recirculation tube - 9. Differential pressure (delta p) sensor - 10. Inlet exhaust gas temperature sensor -
11. Outlet exhaust gas temperature sensor - 12. DPF catalysed silencer - 13. Vacuum tank - 14. Vacuum unit fitting -
15. EDC 16 central unit - 16. Power-assisted clutch - 17. Throttle valve assembly - 18. Air pressure sensor.
General
To constrain exhaust emission values of pollutants such as nitrogen oxides (NOx), hydrocarbons (HC) and particulate (PM)
within limits requested by Euro 4 regulation, the engine was equipped with an EGR system paired to DPF catalysed silencer
for the post-treatment of above substances.

E.G.R. (Exhaust Gas Recirculation) SYSTEM

Operation Recirculated gas quantity regulation is through a mushroom
valve, pneumatically driven under under-pressure; the
E.D.C. 16 electronic central unit processes information from under-pressure, through calibrated section fitting, is taken
atmospheric pressure sensor, water temperature sensor, from the tube connecting the vacuum unit to power-assisted
engine rpm sensor, accelerator pedal potentiometer and brake.
drives modulator solenoid valve and throttle valve with Driving under-pressure modulated by the solenoid valve and
PWM signals, according to modes properly programmed in overcoming the force exerted by counteracting spring (1),
its memory. will lift membrane (2), connected to cut-off unit (3), which
Modulator solenoid valve, whenever driven by E.D.C. 16 moves upwards and enables the recirculation of burnt out
central unit, puts under-pressure power-assisted brake circuit gasses towards inlet manifold.
into communication with E.G.R. circuit. In E.G.R. circuit there
is set an under-pressure value depending on drive signal.
Such under-pressure acts on pneumatic valve E.G.R. 540746 Modulator solenoid valve
membrane calling and lifting the cut-off unit, which normally Modulator solenoid valve is an integrating part in E.G.R.
shuts out exhaust gas passage towards intake. system and power-assisted brake under-pressure tubes.
In this way, exhaust gasses, through the heat exchanger, are It is a proportional solenoid valve modulating E.G.R. valve
carried into throttle valve assembly chamber to be mixed to driving under-pressure depending on PWM signal generated
air from intercooler and flowed into intake manifold. by EDC 16 central unit.
During engine operation steps not requiring gas recirculation
(particulate filter regeneration, startup, cold engine, idling
rotation speed, load request, high elevation), the central unit
control signal to modulator solenoid valve is suppressed. The 85159 Air flow rate meter (flow meter)
solenoid valve closes the connection between
power-assisted brake under-pressure circuit and E.G.R.
circuit, and simultaneously restores atmospheric pressure Figure 58
into E.G.R. circuit.
Main system components
105060
E.G.R. valve 1. Connector - 2. Flow meter body - 3. Recirculated oil
Figure 57 vapours air inlet grid - 4. Power supply - 5. Earth - 6. Inlet
The flow meter is a heated film type flow meter and is placed
between turbocharger and intercooler.
Inside the flow meter, sucked in air temperature sensor is
built in.
Operation
Operation principle is based on a heated membrane put in
between a measurement channel through which inlet air
entering the engine is flowing.
The heated film membrane is kept at constant temperature
(about 120 °C, higher than incoming air temperature) by
heating resistance.
The air mass which runs through measurement channel
tends to take out heat from the membrane; therefore, to
105059 keep the membrane at constant temperature, the current
must run through the resistance.
E.G.R. valve is mounted on heat exchanger end. Absorbed current is proportional to air mass flowing to
To ensure higher efficiency and longer durability to the valve, engine; the current is measured by a Wheatstone bridge and
the valve is cooled by engine coolant from heat exchanger. signal obtained is sent to the electronic central unit.


Figure 59
105064

Description
and steam (H2O). On the contrary, if its temperature is lower, the filter is
Catalyst module is made up of a ceramic structure clogged, with negative effects, on counterpressure, on
impregnated with platinum, as platinum is a catalysing exhaust gasses generated by the filter.
compounds.
A differential pressure sensor (7), connected to D.P.F.

Print 603.93.651
DAILY EURO 4
Figure 60
Particulate filter (components location)
102393
1. Lambda probe - 2. Exhaust gas temperature sensor - 3. TO Pressure sensor (at filter inlet) - 4. Exhaust gas temperature sensor -
5. TO Pressure sensor (at filter outlet)

77
Base - March 2006


Figure 61
108399
1. Throttle valve - 2. Electrical actuator - 3. Throttle position signal - 4. Earth - 5. Positive - 6. PWM signal
Figure 62

Engine coolant
Hot exhaust gasses
105063
A. Inlet exhaust gasses - B. Cooled exhaust gasses - C. Coolant to heater -

D. Exhaust gasses from E.G.R. valve - E. Coolant coming in from cylinder head - F. Air from intercooler
The assembly of (normally open) throttle valve is mounted on inlet manifold. Its task is to regulate the flow rate of air coming
in from the intercooler that is to be mixed with exhaust gasses recirculated by E.G.R. valve according to a programmed
percentage.
The throttle valve is driven by an electrical actuator controlled by a PWM signal from central unit EDC 16.

REPLACING THE COMPONENTS
Replacing particulate filter
Particulate filter, as it is suggested by its name, has the task to filter particulate particles depositing between the pores of the ceramic
structure of which the filter is made up.
If the filter is maintained at a temperature over 530 ºC and with adequate oxygen content, some reactions, boosted by (Oxicat)
catalyst put before the filter, allow particles to burn, so keeping the filter indefinitely clean.
On the contrary, if its temperature is lower, the filter is forced to become clogged, with negative effects, on counterpressure,
on exhaust gasses generated by the filter.
To allow to “clean up” the filter at proper time intervals, temperature of exhaust gasses is artificially raised (up to 630 ºC) at filter
inlet by an hexothermic reaction which takes place in the catalyst put before the filter on exhaust line.
With a lag, after combustion dead point, such as to ensure filter non involvement with combustion, a small fuel quantity is injected
which vaporises in combustion chamber and, dragged by exhaust gas draught, is sent to the catalyst. The catalyst (made of noble
metals, mainly Platinum) boosts filter combustion through the catalyst itself, easily allowing to reach 630 ºC temperature. A
regulator of the central unit meters both post-injection and oxygen quantity (closing throttle valve) in order to maintain
regeneration optimal temperature.
The reaction can only take place if gas temperature at catalyst inlet is over 230 ºC. Proper engine management maps enhance
exhaust gas temperature increase when it is necessary to start up a regeneration.
E.G.R. system is of course shut out during regeneration in order to prevent post-injections vapours from being sucked into the
cylinder.
During vehicle run, the central unit processes plenty of information on filter status which are relevant to have correct filter
operation and reach duration targets.
In particular there are constantly counted and saved, on non volatile memory, following parameters:
- quantity of particulate accumulated in filter (regeneration is triggered if the quantity overflows preset values);
- quantity of ashes accumulated in the filter (not burning, so limiting filter accumulation capacity and consequently the
regeneration frequency);
- calculated drift of Oxidant Catalyst efficiency;
- quantity of fuel post-injected to activate and maintain the regeneration, which is important for assessing the danger of presence
of fuel in excess in engine oil;
- regeneration status: regeneration unnecessary, in progress, interrupted, resumed;
- miles covered and times from last complete regeneration.
Therefore, replacing particulate filter requires that all the parameter counters are reset, as:
- particulate quantity in filter is zero;
- quantity of accumulated ashes is zero;
- post-injected fuel quantity can be maintained if oil engine is not simultaneously refilled;
- all parameters about regeneration are to be reset, because there is an all new life cycle.
- if ashes counter is not reset, regeneration frequency will be greater than needed, consequently needlessly increasing fuel
consumption, and particulate filter thermal fatigue; and, in extreme cases, there will be a groundless request to refill engine
oil;
- if Oxicat ageing function is not reset, there is the risk of having unjustified quantities of post-injections;
- if post-injected fuel counter is not reset, there may be an early request to refill engine oil.

Replacing flow meter

In software, a function is present which is capable to rectify flow meter duration drift. In practice, while some manoeuvres (vehicle
deceleration with pedal released) are executed, the central unit performs a number of checks and determines some flow meter
reading rectification factors. It is a self-adapting process. Therefore, it is clear that replacing the flow meter involves resetting the
self-rectifying process.
Where the central unit is replaced, on the contrary, flow meter rectification coefficients are to be copied down from old to new
central units; where it is not possible, they are to be reset and self-learning process is started again.
Replacing rail pressure sensor in hydraulic accumulator

Rail pressure sensor can affect injector minimum flow rate correction accuracy, since minimum flow rate depends on both
injection times and hydraulic accumulator actual pressure.
Replacing delta-p sensor

During vehicle life time, the central unit makes some checks on filter differential pressure sensor drift, e.g., with engine stopped,
pressure value is the same upstream and downstream of filter.
So, some parameters are calculated and engine running values are consequently rectified.
Replacing delta-p sensor involves resetting the rectifications.
Replacing engine oil

During vehicle life time, the central unit counts up the quantity of post-injected fuel in order to activate and maintain regeneration.
A least fraction of this fuel (which is injected at a very long time after combustion, and consequently is not burning, i.e. is not
involved in combustion), through engine rings, comes into contact with lubrication oil and dissolves into it. Accumulated
post-injection quantity may increase, in case of loss of efficiency in Oxicat, the emissions at low temperature and, of course, impair
engine normal running.
The central unit is capable to calculate the limit quantity of fuel dissolved into oil and, consequently, to suggest oil refilling.
It is obvious that, if after engine oil refilling the function is not reset, the central unit will keep on counting the increase of oil fraction
in engine oil even with new oil and, sooner or later, groundlessly request to refill engine oil.

Replacing an injector
Figure 63
102394
1. Production date - 2. Series number - 3. Code - 4. Iveco component number - 5. IMA code -
6. Bosch code - 7. IMA code
On engines Euro 4 there is applied an injection flow rate individual rectification (I.M.A. - Injector Menge Abgleichung) [Injector
Quantity Offset].
It means that injectors are not assigned any more to classes (Min — Med — Max, or 01 — 02 — 03), but unavoidable flow rate
deviations from average design values are detected, during final check step on Bosch line, on each single injector and stored by
printing on injector magnet.
At Sofim Plant, I.M.A. code (7) is read from an on line automatic reading station, converted into bar code and printed on engine
identification label applied on the engine itself.
At Vehicle Production Plant, the central unit is programmed at the end of line automatically reading the label.
For interventions off production line (such as Service interventions) I.M.A. code (5) is used.
Therefore, it is necessary to take some precaution measures:
- injector mounting sequence is important and cannot be changed in service operations without reprogramming the central
unit;
- it is not possible to replace one or more injectors without reprogramming the central unit;
- where an injector is replaced, it is suggested to note down its code “before” mounting it, since it is problematic to read its
value on the vehicle.
It is obvious to conclude that, where the central unit is replaced, the central unit is to be reprogrammed with the I.M.A. codes
of the injectors that are mounted on the engine.
During engine running, the central unit makes some checks on injectors minimum flow rate. Under certain specified operation
conditions (deceleration with pedal released) an increasing (very small) fuel quantity starting from zero is injected and its effect
on engine rotation smoothness is observed. Injection start threshold is then detected and stored into the central unit. The process
is a self-learning process, and is carried out on each single cylinder.
Replacing an injector involves the need of resetting the rectification factors on cylinder considered.
Replacing all injectors extends the need of resetting to all the rectification coefficients.
Replacing the central unit requires to store the coefficients on new central unit.

EDC16 Checking quantity of fuel injected

Electronic injection control According to the signals from the sensors and the mapped
values, the control unit:
The system calculates injection on the basis of the
processing of the following parameters: - operates the pressure regulator;
- Engine rpm - varies the ”pilot” injection time to 2200 rpm;
- Engine coolant fluid temperature - varies the ”main” injection time.
- Intake air capacity - Checking idling adjustment
- Battery voltage The control unit processes the signals from the various
sensors and regulates the amount of fuel injected:
- Fuel pressure
- it operates the pressure regulator;
- Accelerator pedal position
- it varies the injection times of the electro-injectors.
Fuel pressure ranges from 400 to 1350 bars (1600 for F1
engines), according to engine rpm and load operating Within certain thresholds the speed takes account of the
conditions. battery voltage.
The lower pressure is compensated by longer injection Fuel cut-off in release phase
times and vice versa, always taking account of the loads In the phase of releasing the throttle pedal the control unit
required. actuates the following logic elements:
Up to 2800 rpm pre-injection is also carried out in order to - it cuts off supply to the electro-injectors;
reduce the typical noise of direct injection.
- it partially reactivates supply to the electro-injectors
Pre-injection advance angles, the distance between before reaching idling speed;
pre-injection and main injection and advance angles of main
injection vary according to the instantaneous engine - it operates the fuel pressure regulator.
operating conditions. Checking cylinder balancing on idling
System diagnosis is performed by means of diagnostic According to the signals received from the sensors, the
instruments (no Blink Code is used). control unit controls the regularity of the torque at idling
speed:
- it varies the amount of fuel injected into the single
Immobilizer recognition electro-injectors (injection time).
When the control unit receives the signal of the key on Checking regular engine rotation (anti-sawing)
”MAR” it communicates with the immobilizer control unit It ensures regular engine rotation at a constant rate while
to enable starting. increasing revs.
The control unit processes the signals received from the
Checking fuel temperature sensors and determines the amount of fuel to be injected via:
With the fuel temperature greater than 75°C, detected by - the pressure regulator;
the sensor on the fuel filter, the control unit operates the
pressure regulator to decrease the line pressure (injection - the electro-injector opening time.
times are not changed). If the temperature exceeds 90°C, Checking smokiness at exhaust on acceleration
the power is reduced to 60%.
from the air introduction meter and engine speed sensor, the
Checking engine coolant temperature control unit determines the optimum amount of fuel to
The control unit, depending on the temperature: inject:
- of the engine coolant, turbocharging air and fuel, - it operates the pressure regulator;
operates the electromagnetic fan (Baruffaldi) and - it varies the electro-injector injection time.
switches on the coolant temperature warning light.
Checking exhaust gas recirculation
accelerator pedal sensor, the control unit limits the amount
of air taken in, actuating partial suction of the exhaust gases.

Checking top speed limit Checking injection pressure closed cycle

Depending on the number of revs, the control unit actuates Depending on the engine load, determined by processing the
two action strategies: signals from the various sensors, the control unit operates
the regulator to obtain optimum line pressure.
- at 4250 rpm it cuts off the fuel, decreasing the
electro-injector opening time Over 5000 rpm it
deactivates the electro-injectors. Fuel supply
The fuel supply is calculated in relation to:
Checking regular rotation on acceleration - accelerator pedal position
Regular progression is assured in all conditions by the
- engine speed
control of the pressure regulator and the electro-injector
opening time. - quantity of air introduced.
The outcome may be corrected in relation to:
Preheat plug centre control
- the water temperature.
During:
Or to avoid:
- the start step
- noise
- the after start step
- smoke
the injection centre times the heater starter (or preheat
plugs for the F1 Engine) according to engine temperature. - overloading
- overheating
Checking activation of air-conditioning system
The control unit operates the air-conditioning compressor:
- switching it on/off when the relative switch is pressed;
- action of external devices (ABS), ABD, EDB
- momentarily turning it off (approximately 6 sec.) if the
engine coolant reaches the set temperature. - serious trouble decreasing the load or stopping the
engine.
Checking fuel pump After determining the mass of air introduced by measuring
Irrespective of the speed, the control unit: its volume and temperature, the control unit calculates the
corresponding mass of fuel to inject into the relevant cylinder
- supplies the auxiliary fuel pump with the key on MAR;
(mg per delivery) also taking into account the temperature
- cuts off auxiliary pump supply if the engine is not started of the diesel.
up within a few seconds. The mass of fuel calculated in this way is first converted into
volume (mm3 per delivery) and then into degrees of throw,
Checking diesel warming or duration of injection.
It times operation of diesel warming in relation to ambient
temperature. Correcting flow rate according to water temperature
A cold engine meets with greater resistance during
Checking cylinder position operation: friction is high, the oil is still very viscous, and the
various clearances are not yet optimized.
During each turn of the engine, the control unit recognizes In addition, the injected fuel tends to condense on the metal
which cylinder is in the power stroke and operates the surfaces that are still cold.
injection sequence for the appropriate cylinder. The fuel supply for a cold engine is therefore greater than for
a warm one.
Checking pilot and main injection timing
According to the signals from the various sensors, including
the absolute pressure sensor built into the control unit, the
control unit determines the optimum point of injection
according to internal mapping.

Correcting flow rate to avoid noise, smoke or overloading Engine starting

The behaviour that could lead to this kind of trouble is well During the first few turns of the engine, the timing and
known. cylinder no. 1 recognition signals (flywheel sensor and
The designer has therefore included special instructions in camshaft sensor) are synchronized.
the control unit to avoid it. The accelerator pedal signal is ignored on starting. Starting
delivery is set only according to water temperature, by a
De-rating special map.
When the control unit detects such speed and acceleration
In the event of the engine overheating, injection is modified, of the flywheel as to be able to consider the engine started
decreasing the delivery to a varying degree, in proportion to up and no longer driven by the starter motor, it re-enables
the temperature reached by the coolant. the accelerator pedal.
Turbine rpm setting Cold starting

(for the variable geometry turbo-compressor)
If even just one of the three temperature sensors (water, air
By changing its geometry, adjusted turbine speed is or diesel) records a temperature lower than 10°C, pre-post
monitored by the electronic centre via an electrical signal heating is activated.
feeding the compressed air actuator electro valve. Based on On inserting the key contact, the pre-heating indicator goes
signals from the accelerator pedal position and suction on and remains on for a period varying depending on
manifold air temperature/pressure engine rpm sensors, the temperature (air is heated by the pre-heating glow plugs that
electronic centre processes the field-back signal to properly are located on cylinder head for F1 engines), then it blinks.
modulate turbine actuator pilot electro valve opening. Thereafter, the engine can be started up.
When the motor is running this indicator light goes out, while
Injection timing electronic test the glow plugs continue to be powered for a certain length
The advance (start of delivery, expressed in degrees) may be of time (variable) for post-heating.
different from one injection to the next, also differentiated If, with the indicator light flashing, the engine is not started
from one cylinder to another. It is calculated, similarly to the up within 20-25 seconds (inattention time), the operation is
delivery, in relation to the engine load (accelerator position, cancelled so as not to run down the batteries pointlessly.
engine speed and air introduced). The pre-heating curve is also variable in relation to the
The advance is appropriately corrected: battery voltage.
Warm starting
- according to the water temperature. If the reference temperatures all exceed 10°C, when the key
And also to obtain: makes contact the indicator light comes on for
approximately 2 sec., for a short test, and then goes out. It
- lower emissions, noise and overloading; is now possible to start up the engine.
- better vehicle acceleration.
An extremely high advance is set on starting, depending on Run up
the water temperature. When the key makes contact, the control unit transfers the
Feedback from the start of delivery is supplied by the change information stored in memory when the engine was last
in impedance of the injector solenoid valve. stopped into the main memory (see After Run) and makes
a diagnosis of the system.
Speed governor
The electronic speed governor has both features of After run
governors: Whenever the engine is switched off with the key, the
control unit stays powered for a few seconds by the main
- idling and top speed relay.
- all speeds This makes it possible for the microprocessor to transfer
some data from the main memory (volatile) to a non-volatile
It is stable in ranges where conventional, mechanical memory, which can be erased and written over (EEPROM),
governors are imprecise. so as to make it available at the next start up (see Run Up).


- fault memory.
It is extremely important for this procedure not to be

! broken off, for example by switching off the engine with
the battery cut-out, or by disconnecting the battery
cut-out before 10 seconds have passed since switching
off the engine.
If this happens, the functioning of the system is ensured,
but repeated interruptions may damage the control
unit.
Cut - off
This function cuts off fuel delivery when the vehicle is
decelerating (accelerator pedal released).
Cylider balancing
Individual cylinder balancing contributes to increasing
comfort and handling.
This function permits individual, customized control over the
delivery of fuel and the start of delivery for each cylinder,
even differently from one cylinder to another, to
compensate for the hydraulic tolerances of the injector.
The differences in flow (delivery specifications) between the
various injectors cannot be evaluated directly by the control
unit. This information is supplied by Modus reading the bar
code of each injector at the time of assembly.
Synchronisation search
is anyhow able to recognize the cylinders into which the fuel
is to be injected.
If this occurs when the engine is already running, the
combustion sequence has already been acquired, so the
already been synchronized.
If this occurs when the machine is at a standstill, the control
unit energizes a single solenoid valve. Within at most 2 turns
of the crankshaft, injection will take place in that cylinder, so
the control unit just needs to get synchronized on the firing

EDC system components
Component
Ref. Description
code
1 58918 Tachometer on instrument cluster
2 58918 Revolution counter on instrument cluster
3 42374 Clutch pedal switch
4 53565 Brake pedal switches
5 85152 Accelerator pedal position sensor
6 47106 Fuel temperature sensor (on fuel filter)
7 47035 Coolant temperature sensor
8 85156 Air pressure and temperature sensors
9 48042 Timing system shaft sensor
10 85157 Fuel pressure sensor
11 48035 Engine shaft sensor
12 78247 Electrical injectors
13 25231 Glow plugs pre-heating central unit
14 - Throttle valve assembly
15 19010 Pre-heating glow plug
16 44030 Fuel electric pump (with level gauge)
17 78209 E.G.R. solenoid valve
18 12012 AC compressor
19 85159 Flow meter
20 58701 EDC warning lamp
21 54032 Cruise Control / PTO (optional) control
22 85130 Key for starting up with Immobilizer
23 72027 Diagnosis socket (EOBD) on Body Computer
24 78248 VGT control solenoid valve
25 85022 Fan electromagnetic joint

Figure 64
112286

Bosch EDC16 control unit

Figure 65
A
K
107683
PERSPECTIVE VIEW
A. Engine side injection cable connector - K. Bonnet/cab cable connector
Figure 66
107621
A. Central unit EDC

Control unit connection to the injection cable on engine side (housing A)

Figure 67
85708
85710
Cable
Pin Function
colour code
1 0000 Cylinder injector 3
6 - Throttle valve actuator
7 - Drive shaft sensor braided wire
8 0000 Rail pressure sensor negative
11 0174 Distributing shaft sensor negative (phase)
12 red Drive shaft sensor
13 5153 Boosting air pressure and temperature sensor power supply
15 - VGT solenoid valve
19 0000 Pressure regulator negative
20 7158 Distributing shaft sensor positive
23 0165 Boosting air pressure and temperature sensor negative
27 white Drive shaft sensor
28 5591 Rail sensor power supply
35 - Engine oil level signal
37 5151 Air flow meter air temperature signal (available with EGR)
39 - Engine oil level signal
40 5152 Boosting air pressure sensor signal
41 0150 Water temperature sensor negative
42 8153 Air flow meter signal
43 5591 Rail pressure signal
44 8151 Air flow meter negative (available with EGR)
49 9925 Pressure regulator
50 9160 Distributing shaft sensor signal (phase)
51 0150 Fuel temperature sensor negative

Cable
Pin Function
colour code
52 5592 Fuel temperature sensor signal
53 5151 Boosting air temperature sensor signal
58 5154 Water temperature sensor signal
60 8150 EGR solenoid valve
F Power seats
f Signal seats
- Pins not highlighted are not used

Control unit connection to cab-bonnet cable (housing K)
Figure 68
85708
85709
Cable
Pin Function
colour code
1 - +30 (main relay)
2 0000 Earth
4 0000 Earth
5 8150 +30 (main relay)
6 0000 Earth
8 0150 Accelerator pedal sensor negative (pin 5)
9 5157 Accelerator pedal sensor signal (pin 4)
10 - ∆p differential sensor
11 - Exhaust gas temperature sensor 1
12 0000 Coolant pressure switch
13 - Signal from power takeoff (if any) state selector
16 - Negative from power takeoff (if any) state selector
17 - Signal from brake pedal pressed for stop light ignition
25 2298 K line
27 5180 Exhaust gas temperature sensor 1
28 8051 +15
30 0157 Accelerator pedal sensor negative (pin 3)
31 5157 Accelerator pedal sensor signal (pin 6)
38 8155 Cruise Control (resume)
42 - Speed limiter button
45 5157 Accelerator pedal sensor power supply (pin 2)
46 5157 Accelerator pedal sensor power supply (pin 1)
48 5614 Engine speed sensor (revs counter)
50 - Exhaust gas temperature sensor 1
51 - Lambda probe
52 1310 To preheating spark plug actuation remote-control switch pin D1

Cable
Pin Function
colour code
54 7772 Positive for air-conditioner compressor switched on
56 8157 Cruise Control (set +)
57 0000 Auxiliary speed limiter (where available)
58 8150 Signal from clutch switch
61 - CAN L line
62 - CAN H line
64 8292 Lambda probe
68 8156 Fuel filter heating remote-control switch positive
70 - Compressor switching on
71 - EDC warning light negative
72 0155 Main relay (negative)
75 5517 Vehicle speed signal (tachometer)
77 8154 Cruise Control (off)
78 8156 Cruise Control (set -)
79 8167 Coolant pressure switch
80 8158 Brake pedal signal
81 5530 Water in fuel filter
90 - Positive for engine cooling electromagnetic joint control
91 - Fuel electric pump remote-control switch negative
92 0000 Pre-heating warning light negative
93 1311 To pre-heating spark plug actuation remote-control switch pin ST
- Pins not highlighted are not used

Accelerator pedal sensor injection system as an accelerator pedal position set by the
driver. (At the output of these potentiometers, a variable
A new sensor which incorporates two potentiometers (no
voltage is available which corresponds to the potentiometer
idling switch is provided) is available on the accelerator
resistance value.)
pedal. The ratio between the signals from the two
potentiometers is 2:1 (one potentiometer exhibits a twofold It is connected to the EDC control unit connector K pins
resistance value compared with the other). Both of these 9-30-45-31-8-46. The potentiometers are powered with 5
signals (V) are detected by the control unit that processes V voltage supplied by the control unit itself.
them according to stored threshold values and manages the
Figure 69
EDC 16
85714

Figure 70 Brake pedal switches (53501)

Two switches are present on brake pedal: one is directly
connected to pin KB0 of central unit, the other is connected
to central unit ESP8 at PIN 30.
003326t
1. Brake pedal switches
Clutch pedal switch (42374)

Figure 71
An N.C. switch connected to electronic centre pin K58 is
mounted on the clutch pedal.
The “clutch pedal actuated signal” is used by the centre to
identify gear condition selected and gear shifts.
In absence of the pedal pressed switch signal, the centre
disenables the Cruise Control function.
003327t
1. Clutch pedal switch

Preheat plug electronic centre Figure 72

(F1A/F1C engine)
EDC central unit effects the timing of the functioning of glow
plugs pre-heating central unit depending on engine
temperature, which, in turn, activates the glow plugs.
The preheat centre contains an “intelligent” remote control
switch that sends a feed-back to the control centre for
information on any preheat centre defect or plug earth shirt
circuit.
Preheat centre pin-out

31 - Mass
86 - Start switch (+15)
ST - EDC electronic centre (pin K93)
DI - EDC electronic centre (pin K52)
30 - Battery positive (+30)
G1 - Preheat plugs
G2 - Preheat plugs
G3 - Preheat plugs
003332t
G4 - Preheat plugs
PREHEAT CENTRE
Figure 73
Preheat plugs
CONTROL VALUES
With constant di 11V power supply:
- maximum current absorbed 18 A
- in 5” 11 ± 1,5 A
- in 30” 6 ± 0.9 A
- temperature after 7” 850°C
003331t
- torque 8-10 Nm
ELECTRICAL DIAGRM
Figure 74
75579
PREHEAT PLUS

R.p.m. / timing sensors (F1C)
Figure 75
88056
1. R.p.m. sensor - 2. Phonic wheel on drive shaft - 3. Timing sensor - 4. Phonic wheel on camshaft

Timing sensor (stroke) (F1C)
Figure 76
88264
88267
1. Phonic wheel on camshaft - 2. Identification slots - 3. Sensor

RPM sensor Figure 78

A phonic wheel is fitted on the drive shaft. As the sensor
detects existing teeth passing, it provides the central unit with
the signal that is necessary to determine engine r.p.m.’s.
The variation of the signal generated by the lack of some teeth
(synchronisation gap) occurring at each drive shaft turn is the
reference signal which enables the central unit to detect the
lead of the pair of pistons 1-4 with respect to PMS.
This signal is also used by the control unit to detect the engine
rotation speed, the duration of injection and to control the
rev counter.
87792
PHONIC WHEEL MOUNTING
Figure 79
Figure 77
87793
1. Phonic wheel
0003319t
TECHNICAL VIEW OF THE SOUND WHEEL AND

SENSOR
1. Sound wheel - 2. Sensor

Figure 80 RPM sensor

These are inductive sensors.
The flywheel sensor (48035) is connected at pins 27 and 12
of connector A of the control unit.
Timing sensor
A semiconductor layer, immersed in a magnetic field and
through which current flows, generates a potential difference
(called Hall voltage) at its ends.
If current intensity remains constant, the generated voltage
depends only on the magnetic field strength: periodical
variation of field strength is enough to obtain a modulated
electric signal.
RPM SENSOR AND CONNECTION CABLE
The smooth portion of the phonic wheel (distributing shaft
pulley) covers, while moving, the sensor, thus blocking the
Figure 81 magnetic field with resulting low output signal.
On the contrary, the sensor generates a high signal next to
the openings and when a magnetic field is available.
Phase sensor signals are acquired, and the engine position is
recognized according to the sequence of the phonic wheel
notches.
The mounting function makes it possible to identify signal
errors and interferences (if any).
The resulting signal is supplied to the processor that controls
the injection system.
The sensor (48042) is connected to the central unit at pins
A20/50/11.
SENSOR CONNECTOR AND WIRING DIRAGRAM
Figure 82
2
3 1
85712
TIMING SENSOR
1. Earth - 2. Signal output - 3. Power supply positive

Pressure regulator When solenoid (1) is not activated, the magnetic core is
moved to its rest position by preload spring (6).
When the engine control centre pilots the pressure
regulator via the PWM signal, solenoid (1) is activated, which In these conditions, cylinder (3) is in a position to offer
in its turn generates movement of magnetic core (2). maximum fuel passage cross-section.
Core movement causes cylinder (3) axial displacement by Control electro valve 78013 is connected to centre
fuel delivery partialization. connector A pins 19 and 49.
Figure 83
003386t
4
1 1
2 2
3
5
3 6
4
6
75574 75575
1. Solenoid - 2. Magnetic core - 3. Cylinder - 4. Fuel input - 5. Fuel output - 6. Preloiad spring - 7. Connector

Rail (pressure accumulator) F1C - high-pressure pump operation

The hydraulic accumulator is mounted in the cylinder head - electro injector opening.
on the side opposite aspiration.
On hydraulic accumulator there is located the fuel pressure
By its volume, it damps fuel pressure oscillations owing to: sensor.
Figure 84
88418
1. Rail - 2. Pressure sensor
Pressure sensor
Fitted to a rail end, it measures fuel pressure present to the purpose of determining existing fuel pressure. Pressure value is used
to control pressure and determine injection electric control duration (85157).
It is connected to the central unit at pins A 8/43/28. It is fed at 5 V.
Figure 85
VOLTAGE
4.8V
4.5V
0.5V
0.2V Minimum
0 bar PRESSURE 1500 bar
PRESSURE LIMITER OPERATING GRAPH

Air temperature/pressure sensor Figure 86

This component incorporates a temperature sensor and a
pressure sensor (85156).
It is fitted on the engine intake manifold and measures the
maximum flow rate of the intake air which is used to
accurately calculate the amount of fuel to be injected at each
cycle.
It is connected to the central unit on connector ”A”.
Pin 1 sensor - Pin A23 - earth -
Pin 2 sensor - Pin A53 - temperature signal
Pin 3 sensor - Pin A13 - 5V - supply -
Pin 4 sensor - Pin A40 - 0 ÷ 5V
pressure signal
Course of sensor in relation to the temperature
Temperature Resistance
8660
- 40 °C 48.50 kOhm
AIR FLOW METER
- 20 °C 15.67 kOhm
0 °C 5.86 kOhm
Figure 87
20 °C 2.50 kOhm
40 °C 1.17 kOhm
60 °C 0.59 kOhm
80 °C 0.32 kOhm
100 °C 0.18 kOhm
120 °C 0.11 kOhm
Course of sensor in relation to the pressure:
See graph opposite.
AIR FLOW METER CONNECTION
Figure 88
VOLTAGE
4.65V
0.4V
0.2 bar ABSOLUTE PRESSURE 2.5 bar
AIR FLOW METER OPERATING GRAPH

Figure 89 Atmospheric pressure sensor

This is integrated inside the control unit.
It measures the atmospheric pressure to correct the flow rate
in relation to the altitude.
Engine coolant temperature sensor

This is an NTC sensor located on the thermostat box.
It detects the temperature of the coolant fluid to give the
control unit information about the engine temperature
conditions.
The same signal is used (via CAN lines) to control the
instrument cluster where the gauge is present.
COURSE OF SENSOR RESISTANCE IN RELATION TO

TEMPERATURE
Figure 92
Figure 90
107689
TECHNICAL VIEW OF ENGINE COOLANT
TEMPERATURE SENSOR
A. Temperature sensor
Figure 91
Fuel temperature sensor
This is an NTC sensor located on the fuel filter.
It detects the temperature of the fuel to give the control unit
information about the fuel oil temperature conditions.
It is connected to pins 52 and 51 of connector A of the control
unit.
NTC
WIRING DIAGRAM

Injectors Figure 93
The solenoid valve controls the lift of the atomiser needle.
On the fuel inlet union a filter protects the injector for
impurities. The injector is constructively the same as
conventional ones, except that there is no needle return
spring.
Access to the injectors is gained by releasing the side
soundproof cover from the cylinder head. The fuel recovery
pipe has a quick coupling.
The injector comprises two parts:
- actuator - atomiser composed of pressure rod (1), pin (2)
and nozzle (3)
- control solenoid valve comprising a coil (4) and drive
valve (5).
10
1st phase: rest position
The coil (4) is not activated and the shutter (6) is in the closed 13
position.
The same fuel pressure acts in both the control area (7) and
in the pressure chamber (8), but as the shutter (6) is closed, 9
4
the needle (2) cannot be raised.
2nd phase: start of injection
11
The coil (4) is energised and causes the shutter (6) to move 5
upwards. 6
The fuel of the control volume (9) flows towards the backflow 14
duct (10) causing a drop in the pressure in the control area 7
(7). 12
At the same time, the pressure of the fuel in the pressure
chamber (8) causes the needle (2) to rise, resulting in fuel 12 1
injection to the cylinder.
3rd phase: end of injection
The coil (4) is not activated and makes the shutter (6) return
to the closed position, which re-creates a balance of forces
that makes the needle (2) return to the closed position and
consequently end injection. 15
Injectors (78247)
The solenoid valve is of the N.C. type. 2
The injectors are connected individually to the control unit at
the following pins: 8
- A16 / A47 cylinder 1 injector
- A1 / A46 cylinder 3 injector 3
INJECTOR WIRING DIAGRAM AND CROSS SECTION

1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilot
valve - 6. ball shutter - 7. control area - 8. pressure
chamber - 9. Control volume - 10. Backflow duct -
11. Control duct - 12. Supply duct - 13. Electrical
connection - 14. High pressure fuel inlet - 15. Spring

Electromagnetic junction fan Engine coolant temperature

The fan is provided with an electromagnetic junction Activated at over 96 °C and deactivated at under 84 °C
monitored by the electronic centre pin A39 that activated
Over supply air temperature
the junction remote control switch, to optimise water
cooling. Activated at over 75 °C and deactivated at under 65 °C
The electrical fan remote control switch is activated or Fuel temperature
deactivated by the centre according to the temperature of: Activated at over 20 °C and deactivated at under 10 °C
- the coolant
- over supply air
- the fuel
Figure 94
88064
ELECTROMAGNETIC JUNCTION TECHNICAL VIEW

1. Coil - 2. Connector

Figure 95 Camshaft sensor (F1A) 48042

A semiconductor layer, immersed in a magnetic field and
through which current flows, generates a potential difference
(called Hall voltage) at its ends.
If current intensity remains constant, the generated voltage
depends only on the magnetic field strength: periodical
variation of field strength is enough to obtain a modulated
electric signal.
The smooth portion of the phonic wheel (distributing shaft
pulley) covers, while moving, the sensor, thus blocking the
magnetic field with resulting low output signal.
On the contrary, the sensor generates a high signal next to
the openings and when a magnetic field is available.
Phase sensor signals are acquired, and the engine position is
recognized according to the sequence of the phonic wheel
notches.
The mounting function makes it possible to identify signal
errors and interferences (if any).
0003320t
The resulting signal is supplied to the processor that controls
the injection system.
1. Phase identification holes It is connected to PINs A20, A50, A11 of central unit EDC16.
Figure 96
0003321t
1. Distributing shaft pulley - 2. Sensor
Figure 97
2
1 3
85712 85713
PERSPECTIVE VIEW
1. Power supply positive - 2. Signal output - 3. Earth

Flywheel and rpm sensor Characteristics of flywheel rpm and timing

The F1A engine crankshaft sensor features a slatted sound system sensors
wheel on the crankshaft front. These are inductive sensors.
This features 58 (60-2) teeth and the sensor detects their The flywheel sensor (48035) is connected at pins 27 and 12
passage. of connector A of the control unit.
It is also used to control the electronic rev counter on the
instrument cluster.
The resistance at 20 °C is approx. ~ 860 Ohm.
Figure 99
SENSOR AND CONNECTION CABLE
Figure 100
Figure 98
0003319t
SENSOR CONNECTOR AND WIRING DIRAGRAM

TECHNICAL VIEW OF THE SOUND WHEEL AND
SENSOR
1. Sound wheel — 2. Crankshaft sensor

Pressure regulator When solenoid (1) is not activated, the magnetic core is
moved to its rest position by preload spring (6).
When the engine control centre pilots the pressure
regulator via the PWM signal, solenoid (1) is activated, which In these conditions, cylinder (3) is in a position to offer
in its turn generates movement of magnetic core (2). maximum fuel passage cross-section.
Core movement causes cylinder (3) axial displacement by Control electro valve 78013 is connected to centre
fuel delivery partialization. connector A pins 19 and 49.
Figure 101
003386t
4
1 1
2 2
3
5
3 6
4
6
75574 75575
1. Solenoid - 2. Magnetic core - 3. Cylinder - 4. Fuel input - 5. Fuel output - 6. Preloiad spring - 7. Connector

Rail (pressure accumulator) F1A - high-pressure pump operation

The hydraulic accumulator is mounted in the cylinder head - electro injector opening.
on the side opposite aspiration.
On hydraulic accumulator there is located the fuel pressure
By its volume, it damps fuel pressure oscillations owing to: sensor.
Figure 102
88418
1. Rail - 2. Pressure sensor
Pressure sensor
Fitted to a rail end, it measures fuel pressure present to the purpose of determining existing fuel pressure. Pressure value is used
to control pressure and determine injection electric control duration (85157).
It is connected to the central unit at pins A 8/43/28. It is fed at 5 V.
Figure 103
VOLTAGE
4.8V
4.5V
0.5V
0.2V Minimum
0 bar PRESSURE 1500 bar
PRESSURE LIMITER OPERATING GRAPH

Injectors Figure 104

The solenoid valve controls the lift of the atomiser needle.
On the fuel inlet union a filter protects the injector for
impurities. The injector is constructively the same as
conventional ones, except that there is no needle return
spring.
Access to the injectors is gained by releasing the side
soundproof cover from the cylinder head. The fuel recovery
pipe has a quick coupling.
The injector comprises two parts:
- actuator - atomiser composed of pressure rod (1), pin (2)
and nozzle (3)
- control solenoid valve comprising a coil (4) and drive
valve (5).
10
1st phase: rest position
The coil (4) is not activated and the shutter (6) is in the closed 13
position.
The same fuel pressure acts in both the control area (7) and
in the pressure chamber (8), but as the shutter (6) is closed, 9
4
the needle (2) cannot be raised.
2nd phase: start of injection
11
The coil (4) is energised and causes the shutter (6) to move 5
upwards. 6
The fuel of the control volume (9) flows towards the backflow 14
duct (10) causing a drop in the pressure in the control area 7
(7). 12
At the same time, the pressure of the fuel in the pressure
chamber (8) causes the needle (2) to rise, resulting in fuel 12 1
injection to the cylinder.
3rd phase: end of injection
The coil (4) is not activated and makes the shutter (6) return
to the closed position, which re-creates a balance of forces
that makes the needle (2) return to the closed position and
consequently end injection. 15
Injectors (78247)
The solenoid valve is of the N.C. type. 2
The injectors are connected individually to the control unit at
the following pins: 8
- A1 / A46 cylinder 3 injector 3
INJECTOR WIRING DIAGRAM AND CROSS SECTION

1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilot
valve - 6. Ball shutter - 7. Control area - 8. Pressure
chamber - 9. Control volume - 10. Backflow duct -
11. Control duct - 12. Supply duct - 13. Electrical
connection - 14. High pressure fuel inlet - 15. Spring

Air temperature / pressure meter Figure 106

This component incorporates a temperature sensor and a
pressure sensor.
It is fitted on the engine intake manifold (Figure 107) and
measures the maximum flow rate of the intake air which is
used to accurately calculate the amount of fuel to be injected
at each cycle.
It is connected to the control unit on pins A2 / A3 / A19 / A34.
Pin 1 sensor - Pin A23 ECU - earth -
Pin 2 sensor - Pin A53 ECU - temperature signal
Pin 3 sensor - Pin A13 ECU - 5V - supply
Pin 4 sensor - Pin A40 ECU - 0 ÷ 5V
pressure signal -
Course of sensor in relation to the temperature:
Temperature Resistance
- 40 °C 48.50 kOhm 8660
AIR FLOW METER
- 20 °C 15.67 kOhm
0 °C 5.86 kOhm
20 °C 2.50 kOhm
40 °C 1.17 kOhm
60 °C 0.59 kOhm
80 °C 0.32 kOhm
Figure 107
100 °C 0.18 kOhm
120 °C 0.11 kOhm
Course of sensor in relation to the pressure:
See graph opposite.
1
Figure 105
003323t
VOLTAGE
1. Air flow meter location

4.65V
0.4V
0.2 bar ABSOLUTE PRESSURE 2.5 bar
AIR FLOW METER OPERATING GRAPH

Electromagnetic junction fan Engine coolant temperature

The fan is provided with an electromagnetic junction Activated at over 96 °C and deactivated at under 84 °C
monitored by the electronic centre pin A39 that activated Over supply air temperature
the junction remote control switch, to optimise water
Activated at over 75 °C and deactivated at under 65 °C
cooling.
Fuel temperature
The electrical fan remote control switch is activated or
deactivated by the centre according to the temperature of: Activated at over 20 °C and deactivated at under 10 °C
- the coolant
- over supply air
- the fuel
Figure 108
003328t
ELECTROMAGNETIC JUNCTION TECHNICAL VIEW0 (F1A)

1. Coil

FUEL FILTER
Figure 109
8 1
7 6 5 4 3 2
107676
1. Positive for power supply - 2. Heater - 3. Water present sensor - 4. Filter clogged sensor - 5. Fuel temperature sensor -
6. Fuel temperature sensor - 7. Earth for heater - 8. Earth

FUEL PUMP / FUEL LEVEL

Figure 110
112287
1. Level sensor - 2. Level sensor - 3. Negative for fuel pump - 4. Positive for fuel pump

ABS 8/ESP 8
The ABS 8 system integrates the following functions:
- ABS - Antilock Braking System
It prevents wheels from being locked during braking, thus making it possible to avoid possible obstacles.
It prevents losing control of the vehicle when braking on a slippery surface (even on one side only → mu-split).
It also reduces the braking distance compared with the one with the wheels locked.
- EBD - Electronic Brake Force distribution
It supersedes and optimizes the function of current hydraulic brake correctors, by better controlling the braking force on
rear wheels.
It is implemented by adding a special software to the ABS, and comes into action within a given time interval prior to ABS
actuation.
It makes it possible to control any locking condition affecting the rear wheels compared with the front wheels, by optimizing
the braking force under different load, running and vehicle utilization conditions.
The ESP 8 system, in addition to the EBS 8 system, incorporates the following functions:
- ESP - Electronic Stability Program
It monitors the vehicle behaviour continuously (both along straight stretches and bends, when braking or accelerating).
It also monitors the driver’s actions: steering the wheel, pressing the brake pedal, accelerator position, and speed.
It is always active in the background, i.e. the ESP system compares the actual vehicle ride with the driver’s desired ride 50
times a second. It recognizes dangerous situations before the driver does.
The system considers the different possibilities of coming into operation. It brakes on every single wheel separately.
It operates on the engine control system.
- ASR — Acceleration drive control device
This system prevents driving wheel skid through quick action on the engine and brakes. It allows the vehicle to set off safely
and fast even on slippery roads or when one driving wheel is skidding. It also reduces the risk of understeering when you
accelerate too much when cornering.
- MSR — Engine braking torque control
This system avoids driving wheel drag due to the exhaust brake. It ensures vehicle stability when releasing on slippery roads
(e.g. snow, ice), and assists in keeping the path when cornering and shifting down, especially on slippery roads. It requires
a slight increase of revs number, through the CAN line.
- HHC — Hill holder control
This function allows the vehicle to be kept automatically locked (braked) until the clutch is closed and the driver
subsequently presses the accelerator pedal, thus preventing undesired vehicle motion.
The function is actuated automatically: the braking situation is detected by the sensor inside the modulator. When the brake
pedal is released, the vehicle will be kept for 2.5 seconds, thus allowing the driver/system to put the gear (and the vehicle
to be started). This ensures safe, easy start with any incline, regardless of the weight carried.
- HBA (Hydraulic Brake Assistant) — Hydraulic assistant in emergency braking
The main feature of the HBA function is to recognize an emergency braking situation followed by “automatic” increase
of vehicle deceleration.
Vehicle deceleration is only restricted to actuation of ABS control, thus taking the greatest advantage of the grip between
the tyre and the roadbed currently available. Therefore, ordinary drivers can now achieve braking distances which only
experienced drivers could achieve in the past.
If the driver reduces the braking intensity, vehicle deceleration is reduced depending on the reduction of the force applied
onto the pedal.
Therefore, the driver can control deceleration accurately after overcoming the emergency situation.
The extent of the braking request from the driver corresponds to the force applied onto the pedal. Such force is derived
from measuring the pressure in the brake pump.

Four crossed channel system (x)

Electro-hydraulic modulator/control unit
Figure 111
102113
1. Hydraulic accumulator - 2. Electro-hydraulic modulator - 3. Electronic control unit - A. ABS8 connector - B. ESP8
connector - MC1. LF/RR diagonal power supply (or FL/RR with ABS8/ESP8 systems) - MC2. RF/LR diagonal power supply (or
FR/RL with ABS8/ESP8 systems) - LF (or FL with ABS8/ESP8 systems). Left front axle output - RR. Right rear axle output - RF
(or FR with ABS8/ESP8 systems). Right front axle output - LR (or RL with ABS8/ESP8 systems). Left rear axle output

Four parallel channel system (II)

Electro-hydraulic modulator/control unit
Figure 112
102114
1. Hydraulic accumulator -- 2. Electro-hydraulic modulator -- 3. Electronic control unit -- A. ABS8 connector -- B. ESP8
connector -- MC1. Front axle power supply -- MC2. Rear axle power supply -- LF (or FL with ABS8/ESP8 systems). Left front
axle output -- RR. Right rear axle output -- RF (or FR with ABS8/ESP8 systems). Right front axle output -- LR (or RL with
ABS8/ESP8 systems). Left rear axle output

ABS 8 control unit PIN OUT (X - crossed channels, II - parallel channels)
Figure 113
102245
Pin (X) Pin (II) Function Cable

1 1 Earth 0000
2 2 Positive after fuse 7772
3 3 Positive after fuse 7772
4 4 Signal earth 0000
5 5 Front left sensor 5570
6 16 - -
7 7 Rear left sensor 5572
8 8 Rear right sensor earth 5573
9 9 Front right sensor earth 5571
10 10 Front right sensor 5571
11 11 Diagnosis K line 2299
12 12 - -
13 13 Decelerator deactivation with ABS system ON 0000
14 14 - -
15 15 CAN L line Green
16 6 Front left sensor earth 5570
17 17 Rear left sensor earth 5572
18 18 Positive after fuse (KL 15) 8879
19 19 Rear right sensor 5573
20 20 Stop signalling switch — brake lights 1176
21 21 - -
22 22 - -
23 23 - -
24 24 - -
25 25 - -
26 26 CAN H line White

ESP 8 control unit PIN OUT (X - crossed channels, II - parallel channels)

Figure 114
102246
Pin (X) Pin (II) Function Cable

1 1 Earth 0000
2 2 Positive after fuse (pump control motor power supply enable relay) 7772
3 3 Positive after fuse (valve lock power supply enable relay) 7772
4 4 Earth 0000
5 5 Front left sensor 5570
6 26 - -
7 7 Rear left sensor 5572
8 8 Rear right sensor earth 5573
9 9 Front right sensor earth 5571
10 10 Front right sensor 5571
11 11 Diagnosis K line 2299
12 12 - -
13 13 - -
14 14 CAN L line Green
15 15 Yaw / steering angle sensor earth 9096
16 16 Yaw sensor signal 9095
17 17 Longitudinal acceleration sensor 9090
18 18 Yaw sensor reference signal 9091
19 19 Voltage stabilization signal to the acceleration sensor 9091
20 20 Side acceleration sensor signal 9092
21 21 Side acceleration sensor signal earth 0050
22 22 Decelerator deactivation with ABS system ON 0000
23 23 - -
24 24 - 1199
25 25 - -
26 6 Front left sensor earth 5570
27 27 Rear left sensor earth 5572
28 28 Positive after fuse +15 8879
29 29 Rear right sensor 5573
30 30 Stop signalling switch (PIN3) 8158
31 31 Switch for the exclusion of ASR 8921
32 32 - -
33/34 33/34 - -
35 35 CAN H line White
36 36 Hand brake ON signal 6662
37 37 Yaw sensor test signal 9093
38/39/40 38/39/40 - -
41 41 Stop signalling switch (PIN1) 1176
42 42 - -
43 43 Reverse gear signal 2226
44/45 44/45 - -
46 46 Speed limiter or ASR failure warning light 6672

PIN OUT of central unit ASR 8

(4 channels -X)
Figure 115
102246
Pin Function Cable

1 Earth 0000
2 Positive after fuse 7772
4 Signal earth 0000
5 - -
6 Left rear sensor earth 5571
7 Right rear sensor earth 5572
8 Right rear sensor 5572
9 - -
10 Front sensor 5570
11 Diagnosis line K 2299
12 - -
13 De-activating the decelerator with ABS in 0000
14 CAN line L Green
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 Left rear sensor 5571
28 Positive after fuse for ABS (KL 15) 8847
29 Front sensor earth 5570
30 Stop signalling switch - Stop lights 1173
31 Switch to enable engine brake to be put on (ASR/ESP passive switch) 8800
32/33/34 - -
35 - White
36 - -
37 - -
38/39/40 - -
41 - -
42 - -
43 - -
44/45 - -
46 - -

(4 channels -II)
Figure 116
102246
Pin Function Cable

1 Earth 0000
4 Signal earth 0000
5 Left front sensor 5570
6 Left front sensor earth 5572
7 Left rear sensor 5572
8 Left rear sensor earth 5573
9 Right front sensor earth 5571
10 Right front sensor 5571
11 Diagnosis line K 2299
12 - -
13 De-activating the decelerator with ABS in 0000
14 CAN line L Green
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 Left front sensor earth 5570
27 - 5572
28 Positive after fuse (KL 15) 8879
29 Right rear sensor 5573
30 Stop signalling switch - Stop lights 1173
31 Switch for the exclusion of ASR 8921
32/33/34 - -
35 CAN Line H White
36 - -
37 - -
38/39/40 - -
41 - -
42 - -
43 - -
44/45 - -
46 - -

ESP (Electronic Stability Program) operation

The ESP function controls the vehicle’s stability and side dynamics.
The main goals of this function are as follows:
- to improve stability, especially in understeering and oversteering conditions;
- to reduce the braking distance in line change conditions and on slippery roads.
The ESP function evaluates the following driver’s requests:
- steering-wheel position;
- wheel revs number (speed);
- pressure on the brake pedal or accelerator position.
The ESP control unit microprocessor recognizes the specific manoeuvre and examines the vehicle’s behaviour:
- degree of yaw;
- wheel revs number;
- transverse acceleration.
The microprocessor assesses the running behaviour based on the data provided, and the ESP comes into operation by acting
on the brakes.
The hydraulic modulator controls brake pressure for every single wheel as quick as possible.
The ESP may, through engine management, reduce the number of revolutions of the engine itself, in order to withstand vehicle
deceleration.
The ESP system is always active in the background, i.e. it compares the actual vehicle ride with the driver’s desired ride 50 times
a second.
Control strategy
Sudden obstacle
Figure 117
102246
1) Acting on the steering-wheel suddenly: danger of understeering.

2) The ESP brakes the rear left wheel ⇒ the vehicle follows the steering command.
3) The driver countersteers: Danger of oversteering ⇒ The ESP brakes the front left wheel.
4) The vehicle recovers stability.

Sudden steering
Figure 118
101864
1) The vehicle risks skidding (oversteering): the ESP brakes the front right wheel.
3) The vehicle risks skidding (oversteering): the ESP brakes the front left wheel.
Vehicle running on a slippery road
Figure 119
101865
1) The vehicle risks skidding (understeering): the ESP brakes the rear right wheel and reduces the engine revs number.

ASR deactivation strategies

- Disabling any engine intervention of the ESP and ASR/MSR
(torque increase/decrease) over the entire speed range.
- Traction Control actuation enabled up to the speed of 60 k.p.h. (electronic locking of differential, with no reference to the
dragged wheels).
- Stability intervention (ESP) enabled over the entire speed range.
- ABS enabled over the entire speed range.
- EBD enabled over the entire speed range.
NOTE ASR deactivation is recommended when driving with the snow-chains mounted, or when the wheels sink into
gravel, sand, etc.
Recovery strategy in case of component failure
System failure
(warning light ON)
ESP/ASR ABS EBD
Broken component
Steering angle sensor X
Yaw sensor X
Brake light switch X X
1 or 2 wheel revs sensors X X
3 or 4 wheel revs sensors X X X
Electronic control unit X X X

Solenoid valve hydraulic unit X X X
Pressure sensor, ABS pump motor X X
NOTE If the warning lights are OFF, all the systems are working.

Warning light legend

Warning light ON: ESP/ASR/MSR not working. No action taken by the ESP/ASR on the engine or the brakes.
N.B. Warning light blinking = ESP/ASR coming into operation.
ABS not working
The front axle may get locked sooner than the rear axle. EBD recovery reduces the rear axle pressure.
EBD not working
No correction of the rear axle braking pressure: DANGER OF SPINNING THROUGH 180 DEGREES!
The warning light also warns the driver of low brake fluid level, hand brake ON, brake pads worn.
Installing the esp components
Figure 120
107690
1. Acceleration sensor - 2. Yaw sensor - 3. Steering angle sensor - 4. Electro-hydraulic modulator/control unit
NOTE Installation of the electro-hydraulic modulator/control unit is similar in ASB 8 systems, too.

ESP system components and calibration

Some modifications or repairs affecting the ESP system components require a calibration procedure.
The repair operations that require the above procedure are detailed as follows:
- Replacing the system’s braking apparatus electronic control unit (incorporated into the electro-hydraulic modulator).
- Replacing the steering angle sensor fitted into the steering wheel.
- Replacing the longitudinal acceleration sensor.
Yaw sensor with built-in side acceleration sensor
Figure 121
102115
It measures the motion of the vehicle around its own vertical axis (yaw) as well as the vehicle’s side acceleration.
These signals continuously inform the control unit about the vehicle’s behaviour.
The comparison between these signals and those from the driver (steering-wheel position, wheel spin number/speed and pressure
on the brake pedal/accelerator position) allows the ESP control unit to define the actions to be taken. The hydraulic unit controls
brake pressure as quickly as possible, separately for every single wheel.
Moreover, the ESP system may decrease the engine revs number by means of the engine control feature.
NOTE Replacing the yaw sensor requires no calibration.

Longitudinal acceleration sensor
Figure 122
102116
It measures the vehicle’s acceleration and deceleration changes.

These signals continuously inform the control unit about the vehicle’s behaviour.
The comparison between these signals and those from the driver (steering-wheel position, wheel spin number/speed and
pressure on the brake pedal/accelerator position) allows the ESP control unit to define the actions to be taken. The hydraulic
unit controls brake pressure as quickly as possible, separately for every single wheel.
Longitudinal acceleration sensor calibration
Figure 123
102111 112243
In a horizontal position, you will obtain the sensor “zero” condition through the diagnosis instrument, i.e. you will assign its
absolute zero position.
Carry out a road test, to make the control unit verify whether errors are still found. The vehicle is to be taken to a slight slope
and checked if it is kept braked for 2.5 seconds.

Steering angle sensor
Figure 124
102116
It measures the steering angle required by the driver.

The comparison between this signal and those from all the other sensors allows the ESP control unit to define the actions to be
taken. The hydraulic unit controls brake pressure as quickly as possible, separately for every single wheel.
Steering angle sensor calibration
Figure 125
102110 112243
With both the steering-wheel and the wheels in straight position (after checking toe-in), you will obtain the sensor “zero” condition
through the diagnosis instrument, i.e. you will assign its absolute zero position.
Carry out a road test, to make the control unit verify whether errors are still found. Drive along a straight road at a speed of
approximately 50 k.p.h. Steer to the right and then to the left several times, after making sure you do not endanger other drivers.
NOTE You need not oversteer to cause the ESP warning light to come on.

ESP control unit programming
Figure 126
102109 112243
Entering the variant codes: type of drive, engine, MTT, wheelbase, type of front and rear suspensions, height.
Easy compares the type of vehicle (PIC reading) with the control unit code, to avoid installation errors (single wheels instead
of dual), and downloads the variant codes into the control unit.
Clear the errors (if any) by means of the diagnosis instrument.
Carry out a road test. Drive along a straight road at a speed of approximately 50 k.p.h. Brake suddenly as if in an emergency,
after making sure you do not endanger other drivers: you should feel the system “respond” on the brake pedal. This test makes
the control unit verify whether errors are still found.
Replacing ESP central unit needs the longitudinal acceleration sensor calibration that was already described in previous page.
The steering angle sensor, in this case, is not to be calibrated as it has its own internal memory.

AIR BAG
General
The air bag is a passive safety device comprising one or two cushions which, in the event of a head-on crash, inflate automatically
setting themselves between the body of the occupants and the front structures of the cab.
The system is always integrated by seat belts with pretensioner, which are controlled by the air bag control unit, in the event
of head-on crashes.
The system does not cut in for front crashes at low speed, side crash, overturning or crashes from behind.
NOTE The air bag is complementary to the use of the seat belts and not in replacement of them.
Inflation of the bags without the restraint of the belts compromises the safety of the driver and passengers.
System components are connected to each other and to the rest of electrical system through a special wiring harness that can
be easily identified as it is provided with a yellow sheathe.
SYSTEM OPERATION
Device intervention sequence can be INDICATIVELY REPRESENTED as illustrated in following figure.
For convenience’s sake, drive side device only is shown: passenger side air bag operation is quite similar.
Represented diagrams are qualitative and are not concerning subject vehicle.
Diagram A: this diagram represents inflation pressure in cushion versus crash dynamics developing time.
Diagram B: this diagram represents body positions during a front crash with respect to steering wheel and air bag positions.
Below is events time sequence from the time of electrical pulse triggering off by electronic central unit.
Time “t1”
Time when inflation system is triggered off. Thereafter, inflation pressure starts rising in the cushion, which is still enclosed inside
module cover. The module is made up of a plastic layer located at steering wheel centre. Driver’s body is still in almost normal
position (Figure B, reference 1).
Time “t2”
Pressure inside still closed module rises until it reaches such a value that the cover is opened, cushion stuck out and inflation
started.
Driver’s body starts in this time period to move forwards and is placed between normal position taken during drive and the
position of the collision against the cushion (Figure B, reference 2).
At the time when the cushion is released from its shell, gas pressure slows rapidly down owing to the high inertia of the cushion.
At a certain time, pressure is drawn to take negative values.
Time “t3”
Cushion pressure takes back positive values because from this time the very inflation starts which will lead the cushion to
maximum expansion condition.
Time “t4”
Driver’s body impact against the cushion takes place (Figure B, reference 3).
Pressure inside the cushion rises because of pressure exerted on it by driver.
Time “t5”
Pressure in the cushion slows rapidly down owing to the presence of an air vent hole and the cushion deflates entirely to the
end of allowing driver high mobility (compatible with the rest of the vehicle).

Figure 127
107678

INTERVENTION LOGICS
The system is capable to cover a deceleration angle, according to vehicle longitudinal axis, of ? 30 degrees and intervenes if a
deceleration is reached which matches deceleration present when a front crash occurs at a speed of ~ 24 km/h against a fixed
barrier.
NOTE These values are just indicative and depend on various factors, including vehicle weight, etc.
Electronic central unit, if detecting a deceleration exceeding preset calibration curve, triggers off the reaction of a chemical
compound through electrical detonators.
Gas inflates the two cushions and activates the pretensioners which enable safety belts rolling up devices rewinding and locking.
Central unit is capable to detect this deceleration by two sensors, one electromechanical sensor and one electronic sensor, that
are placed inside it.
The cushions, made of a synthetic fibre, are respectively housed at steering wheel centre and at an opening of the instrument
panel in front of passengers.
- At each start-up operation, the central unit puts on the warning lamp and keeps it on for about 4 seconds, making a system
self-diagnosis operation.
- After each system activation, the central unit keeps fault warning lamp always on, on instrument cluster and the whole
system (central unit, belts and relating pretensioners, cushions and wiring harness) shall necessarily be replaced.
- The system does NOT need either any type of maintenance or any checks.

Rules of safety to be followed for operations on vehicles

fitted with the air bag system supplied to us by the supplier. NOTE The assembly or disassembly of components may
ONLY be carried out by competent and authorised
personnel.
The following rules must absolutely be followed The failure to follow the instructions given below may
! when doing any work concerning vehicles fitted with involve unwanted activation of the system, personal
safety system with air bag. injury or unnecessary system repair. IT IS STRICTLY
PROHIBITED TO DISASSEMBLE AIR BAG
MODULES STRIPPING THEIR COMPONENTS.
Preliminary rules
Remember that air bag modules are devices to be

! handled with care. Their use, transport and storage All the system components have been specifically designed
are ruled by the following procedures. to work on vehicles of a specific brand and type. Therefore,
air bags cannot be adapted, re-used or installed on other
vehicles than the one for which they have been designed and
manufactured.
Before starting any body repair work, welding, work requiring
the removal of air bags or of the control unit, it is necessary
to: NOTE Any attempt to re-use, adapt or install them on a
- move the ignition key to “STOP” and remove it different type of vehicle may cause serious or lethal
harm to the occupants of the vehicle in the event of
- always disconnect the battery, i.e.: disconnect the two a crash.
terminals from their post and isolate them taping
appropriately
- wait for at least 10 minutes before proceeding
- disconnect the control unit connector.
Store the modules with the cover upwards in a key-lockable
metal cabinet. The cabinet, to be used for this purpose only,
must not be used for storing other types of material, especially
if inflammable.
All the connectors used and wired on air bag modules contain
a short circuit clip. Up to the moment in which the air bag
modules are connected to an appropriate source of energy,
there is no possibility of undue activation of the units.
A system component not activated during an accident is to
be considered still “active”.
Therefore, undeployed components to be removed from
vehicles (due to faults, guarantee expiry or other causes) must
be returned to the special centre through the procedure
described below.

Operations after an accident Painting work

No particular rules of safety are to be followed for painting
NOTE If any component of the safety system is damaged work followed by oven drying, as the modules and
following an accident, it should be replaced. pretensioners have been designed in such a way that they will
Do not attempt to repair the control unit, clock not be damaged heating the outer surfaces of the vehicle
spring or air bag modules. with normal paint drying systems.
It is prohibited to use naked flames near the modules.
All electronic control units (including the air bag system)
should always be removed if their temperature in certain
Accidents with or without deployment of the air bag device environments may reach or exceed 85 °C.
Some system components should be inspected whether the
system has been activated or not. These components are:
- steering column;
Health hazards
- steering column support;
The precautions to be taken when handling deployed air
- electronic control unit and modules retaining area; bags are the following:
- clock spring; - use protective polyethylene gloves and safety goggles;
- dashboard (in the passenger’s air bag area). - after touching triggered air bags, wash your hands and
The component must be replaced in the presence of the parts of the body exposed with soap and water.
distortion, breakage and flexure.
Accidents with the deployment of the air bag device
If the vehicle has undergone a head-on crash involving the Effects of over-exposure
total deployment of the system, the following components
must be replaced: There is no potential hazard of exposure to the propellants
as the system is completely sealed.
- air bag modules;
The propellant mixture is in the solid state, therefore
- pretensioners; inhalation is impossible even in the event of breakage of the
- electronic control unit; gas generator cartridge.
- clock spring. Should any gas come out there is not health hazard.
The harness and connectors should be inspected for signs of Avoid any contact with the skin and do not swallow the
burns, melting of the outer insulation or damage due to propellant.
excessive heat. In the event of:
Any signs of damage on the clock spring in the control unit - contact with the skin wash immediately with soap and
retaining area and on the air bag modules call for the water;
replacement of the damaged components.
- contact with the eyes: wash immediately with running
water for at least 15 minutes;
- inhalation: take the person outdoors immediately;
- swallowing: induce vomit if the person is conscious.
Always call a doctor for all the above conditions.

!

Rules of safety in handling air bag modules Any spare parts should be stored in their original packing and
temporary storage should follow the same procedure as for
Under normal conditions the driver’s and passenger’s air bag
are activated by the electronic triggering device during the an undeployed air bag removed from the vehicle, i.e. a
crash. The gas developed (mainly nitrogen) under these key-lockable metal cabinet must be used, especially for this
conditions is not harmful. purpose (metal, shock resistant cabinet with grilles to allow
natural ventilation inside). The cabinet must have special
Personnel carrying out operations on the device fitted on warning notices (DANGER EXPLOSIVES - NO NAKED
vehicles must absolutely adhere to the rules of safety given FLAMES - NOT TO BE OPENED BY UNAUTHORISED
below. PERSONS).
Personnel operating on these devices must be suitably trained
and follow the precautions given below:
- In open (exploded) air bag removal and replacement
Air bag module scrapping
operations handle only one air bag at a time and for
removal use polyethylene gloves and protective goggles. The air bag modules fitted on the vehicle must not be
scrapped with the vehicle itself, but removed beforehand and
- Always rest the air bag module with the opening lid and then deployed as described in the following pages.
pre-split groove facing upwards. Do not put anything on
top of this lid. Air bag units must not be scrapped without firstly deploying
them.
- Afterwards wash your hands carefully with neutral soap
and in the event of contact with the eyes of residual If the air bag module has not been activated during a crash,
powder, rinse immediately with running water. the device is to be considered as still charged.
- Before starting work on the system, disconnect the two All unexploded material MUST NOT BE ACTIVATED and
battery cables (firstly the negative one) isolate the should be sent to a specialised centre with the following
terminals with insulating tape and wait at least 10 minutes wording on the delivery note:
before proceeding. - AIR BAG DEVICE CONTAINING EXPLOSIVE
- The metal components of an air bag that has just been CHARGE TO BE DEACTIVATED
deployed are very hot. Avoid touching these The devices must absolutely be shipped in the same package
components for 20 minutes from the time of air bag in which the spares are received and if this is not available it
deployment. is possible to ask the SPARES division for the package only.
- Do not carry out repairs on air bag modules. Send all Clearly in the case of replacing air bag devices the original
faulty modules to the supplier. Do not heat the air bag packing should be kept intact for sending the undeployed
module for example by welding, hammering, drilling, device.
mechanical machining etc.
For FOREIGN MARKETS follow local regulations.
- Never install on the vehicle air bags that have been
dropped or show signs of any type of damage.
- It is prohibited to keep air bags together with inflammable
material or fuel.
- The gas generators must not come into contact with
acids, greases and heavy metals. Contact with these The failure to follow the procedures listed here may
substances may cause the formation of poisonous, ! cause undue activation of the air bag units and
harmful gas or explosive compounds. personal injury. Undeployed air bag units must NOT
be disposed of through the usual refuse disposal
- Never use naked flames near air bag devices and system channels. Undeployed air bag units contain harmful
components. substances for the health and may cause personal
injury if the sealed container which contains them is
damaged during disposal.

Rules of safety in handling pretensioners

In the event of a head-on crash, the driver’s and passenger’s After every crash in which the pretensioner has been
pretensioners are activated an instant before the air bag ! activated, the belt is unserviceable and must be
modules. replaced.
The personnel that intervenes on the devices must be suitably

trained and observe the following precautions:
Scrapping pretensioners
- When handling activated pretensioners, i.e. when the Undeployed pretensioners (not fitted on the vehicle) to be
propellant has already been triggered, use protective scrapped must firstly be deployed; those not activated but
gloves and goggles. fitted on the vehicle must be removed and not scrapped
- At the end of operations wash your hands carefully with with the vehicle.
neutral soap and in the event of contact of residual If the pretensioner was not activated during a crash, the
powder with the eyes, rinse immediately with running device is to be considered as still active; proceed as
water. described i this manual.
- Disconnect the two battery cables (firstly the negative
one) isolate the terminals with insulating tape and wait at
least 10 minutes before proceeding.
- During activation the pretensioner develops heat; it is
therefore necessary to wait at least 10 minutes after
deployment, before touching them.
- During transport or handling, pretensioners should be
protected from shocks or falling; pretensioners that have
been knocked or dropped must not be used and must be
returned to the supplier stating the reason.
- Pretensioners should not be carried by the belt.
- Pretensioners must be protected from sparks and naked
flames; they should not contact surfaces for over 6 hours
with temperatures above 100 ºC .
- The gas generator propellant that is not burnt is
inflammable, therefore, the parts of the generator should
never be taken to pieces, damaged or tampered with.
- It is prohibited to store pretensioners with inflammable
materials or fuel.
- The gas generators must not come into contact with
acids, greases and heavy metals. Contact with these
substances may cause the formation of poisonous,
harmful gas or explosive compounds.
- Belts with pretensioners may only be stored in
key-lockable places or cabinets, ventilated and away from
naked flames and sources of heat.

Operations on system components Removing or scrapping an air bag module that

At the end of every operation on the system, it must be has not been deployed from a reparable
checked using Modus, I.W.T. or other diagnostic tools. vehicle
During assembly, the air bag components are labelled with a Do not cut cables or tamper with the connector
sticker with a removable part stating the date of installation between the vehicle harness and the air bag module.
of the system and components. The removable part is !
The connector contains a safety circuit.
detached and the information on it is filed together with the
system check report supplied by Modus, by the workshop that
installed the components.
After 10 years from installation, unless the components are
replaced before that time, a new air bag system (cable and If the connector is cut or removed from the air bag unit, the
components) should be installed. As mentioned previously, safety device is disabled and this could cause unforeseen
the data concerning the components and the date of system activation with serious consequences for the physical
installation are to be filed. integrity of people.
Air bag systems have a reserve power unit in the control unit.
Removing and scrapping an activated air bag This must be deactivated disconnecting the two battery
module and pretensioner from a vehicle terminals and waiting for at least 10 minutes before doing any
work on any components of the air bag.
Always wear gloves and safety goggles for handling an When handling an air bag module, always keep the bag and
activated air bag or pretensioner. Wash the hands and outer cover away from the body. When positioning an active
exposed skin immediately with neutral soap and water after air bag on a bench or other surface, always place the bag and
handling the components of an air bag module or its cover upwards, not on the resting surface and away from
pretensioner. In the case of exposure to secondary products, people. Never put any object near an active air bag as it
immediately rinse the eyes with running water. The failure to would become a bullet in the event of deployment.
comply with these instructions may result in injury.
To remove and scrap an already activated air bag module and
pretensioner:
1. Follow the instructions given in this manual for removing
activated air bag module and pretensioners.
Always keep active, undamaged, air bag modules and
2. Disconnect the air bag module and pretensioner pretensioners in a cool, dry, locked and safe place.
mechanical fastenings.
!
Do not expose to naked flames or temperatures
3. Disconnect the component connector from the air bag above 150 ºC. Do not cut, drill, braze weld an air bag
harness. module or its components with electric current.
Never expose an air bag module or pretensioner to
4. Place the air bag module and pretensioner in a special electric currents. The failure to comply with these
sealed polythene bag. instructions may damage the unit, cause fire, cause
5. Send to the authorised collection/disposal centre. unforeseen deployment and serious harm to
persons.
6. Dispose of, recycle or scrap deployed air bag modules
and pretensioners in the appropriate manner.
The residues left by combustion of the propellant require
Active, damaged air bag modules and pretensioners (e.g.
some consideration. They are mostly concentrated in the
breakage of the electrical connection) must be kept away
generator body or in small quantities in the bag. These
from corrosive or oxidising substances. The failure to comply
residues may contain copper or chloride (e.g. potassium
with these instructions may cause fire, and/or serious harm
chloride). If the propellant is based on sodium azide or
to persons.
potassium nitrate, the combustion residues are highly alkaline
and corrosive. Always wear appropriate protection for the
eyes and skin. Deployed air bags should always be stored in
dry, suitably ventilated places.
NOTE The air bag modules and pretensioners have an
energy reserve. This decive gives the electric pulse
needed to deploy the bag if the battery or cables are
damaged during the crash before the sensor activates
the gas generator.

Figure 128 Deployment of an air bag
A Remote activation
General instructions
1. The deployment procedure can be carried out in a
suitably identified and enclosed open area away from
potentially inflammable materials, fluids or other
substances and from persons. Place the air bag module on
a firm surface and clamp it closely.
C1 2. Clean the area on which the module is placed from
materials and bits (glass, instruments, pieces, etc.) which
could be thrown out during deployment.
Lb
3. Make sure that connector C2 is disconnected from the
remote deployment device (10 m).
4. Connect the electrical connector C1 specified by the
C2 vehicle manufacturer to the air bag module
5. Connect connector C2 to the remote deployment
device.
L 6. Connect the remote deployment device to a 12 V circuit
or equivalent device.
7. Make sure all persons are under shelter.
C2 8. Wear accident prevention goggles and protective
clothing.
9. Press the double deployment button
B 10. After deploying an air bag module, let it cool before
touching it (about 20 min.).
11. Dispose of, recycle or scrap activated air bag modules
according to the cases, as described in the corresponding
chapters.
+12V 8663
REMOTE DEPLOYMENT OF AIR BAG MODULES

C1 = air bag module connector
C2 = Connector to remote deployment device
(connector for air bag with circuit clip; counterparts with
male pins on air bag side)
Lb = bridle length - approx. 1 m
L = general cable, safety distance 10 m
A. Enclosed area
B. Remote deployment device

Deployment of air bag modules and electronic 13. Press the double activation button to deploy all the air
pretensioners still on board of irreparable bag modules and pretensioners at the same time.
vehicles 14. After deploying the air bag modules and pretensioners
This procedure is followed when the vehicle with one or always let them cool before touching them (about 20
more active air bags needs to be scrapped. This procedure min.).
applies whether the air bag and/or pretensioner system is still
intact or not. 15. Once the modules and pretensioners have been
It is advisable to deploy the explosive charges on the vehicle deployed the vehicle can be scrapped - by squashing or
directly connecting the electric connector of the single crushing - and/or recycled depending on the cases.
module to the remote deployment system.
Figure 129
The deployment procedure must be carried out
! away from other persons in a suitably identified ABP ABG
area. Check that no type of object has been left
near the modules and pretensioners and make sure C1 C1
that there are no inflammable liquids in the vicinity.
No-one should remain on board during Lb Lb
deployment and remember to close the vehicle
doors. Personnel should stay under shelter (e.g.
behind a wall, vehicle, etc.) to protect themselves C2 C2
from any objects that may be thrown. Leave the
generators and modules to cool after deployment Lb
(wait at least 20 min.). The failure to follow these C1 C2
instructions may result in serious physical harm.
PTG
General instructions
1. Follow all the WARNINGS, PRECAUTIONS and safety
instructions given in this manual.
2. Take the vehicle to the area foreseen.
3. Remove all materials and bits (glass, instruments, pieces,
etc.) around the air bag cover and check that there are L
no inflammable fluids in the immediate vicinity.
4. Disconnect the two battery cables (firstly the negative C2
one) and wait at least 10 minutes before proceeding.
5. Use a connection bridle (L = approx. 1 m) with specific
terminal connector for electrical connection with the
module to be deployed.
6. Reach the electrical connection of the module in +12V
8664
question (air bag or pretensioner) following the
instructions given in this manual.
LAYOUT FOR DEPLOYING EXPLOSIVE CHARGES ON
7. Disconnect connector C1 of the air bag module or THE VEHICLE, SINGLE DEPLOYMENT
pretensioner.
8. Check that connector C2 is disconnected from the
ABG = driver’s air bag
remote deployment device.
ABP = passenger’s air bag
9. Connect electric connector C1 of the air bag module or C2 = connector to remote deployment device
pretensioner to the connection bridle of the remote C1 = specific connector to explosive charge
deployment device. L = general cable, safety distance 10 m
Lb = bridle length
10. Connect connector C2 to the remote deployment PTG = driver’s pretensioner
device.
A. Remote deployment device
11. Make people go to a safe place.
12. Connect the remote deployment device to a 12 V circuit
or equivalent device.

Figure 130
107679

Air bag system includes following components:

1. drive side air bag module
2. passenger side air bag module
3. diagnosis connector (EOBD) on Body Computer
4. electronic central unit
5. air bag failure warning lamp on instrument cluster
6. safety belts with passenger side electronic control pretensioner
7. safety belts with drive side electronic control pretensioner
8. safety belts with central electronic control pretensioner
9. lh/rh lateral sensor
10. lh/rh curtain air-bag
DE-ACTIVATING PASSENGER AIR-BAG

Passenger air-bag can be disabled from instrument cluster menu directly by the driver.
Air-bag central unit will send a message through “B” Can line to instrument cluster which activates a yellow warning lamp and
a message on display screen (comfort). If passenger air-bag is enabled, the warning lamp will flash on going on and then go off.

Electronic control unit

The electronic control unit is located on the floor at the side of the driver’s seat between the gearshift lever and the parking brake
lever; it is supplied at 12 Volt by a key-operated device, but it is still in a condition to be able to work for about 200 msec after
a power cut off.
This is possible due to the presence of a buffer condenser inside which accumulates electric energy for normal operation of the
control unit and generate the signal for triggering the explosive capsule.
This way system operation is guaranteed if the crash causes a power system failure (for example damage or breakage of the
battery, power cable cut-off etc.).
The control unit must be directed with the arrow printed on the sticker facing the vehicle direction of travel. This is
! absolutely necessary as it determines the direction in which the deceleration sensor reads the values for defining the
crash condition and thus triggering the air bag.
Figure 131
A
B
73792
PERSPECTIVE VIEW OF THE ELECTRONIC CONTROL UNIT WITH TWO CONNECTORS

A. Black - B. Brown

Central unit Pin Out
Figure 132
A B
73791
CONNECTOR B WITH BROWN COLOUR CONNECTOR A WITH BLACK COLOUR

Pin Function Pin Function
1 “B” Can line L 1 Lh lateral sensor “-”
2 “B” Can line H 2 Lh lateral sensor “+”
3 ---- 3 Rh lateral sensor “-”
4 ---- 4 Rh lateral sensor “+”
5 ---- 5 ----
6 ---- 6 ----
7 ---- 7 ----
8 ---- 8 ----
9 ---- 9 Lh pretensioner “-”
10 ---- 10 Lh pretensioner “+”
11 ---- 11 Rh pretensioner “+”
12 Positive for power supply 12 Rh pretensioner “-”
13 ---- 13 ----
14 ---- 14 ----
15 ---- 15 ----
16 Earth 16 ----
17 Central pretensioner “+” 17 Lh curtain air-bag “+”
18 Central pretensioner “-” 18 Lh curtain air-bag “-”
19 ---- 19 Rh curtain air-bag “-”
20 ---- 20 Rh curtain air-bag “+”
21 Positive for driver air-bag “+” 21 ----
22 Negative for driver air-bag “-” 22 ----
23 Negative for passenger air-bag “-” 23 ----
24 Positive for passenger air-bag “+” 24 ----

SPIRAL CONTACT
It is a part which is installed on steering column switch unit and used to enable the connection cables of the cushion on steering
wheel to follow steering wheel rotation without risks of breakage.
The device is made up of two caps: lower cap is fixed to steering column switch unit by three screws, while upper cap is made
integer to steering wheel through two add-ons inserted on upper side.
Inside the two caps, connection cables are wound up in a spiral shape in order that they are enabled to follow movements.
Spiral contact is also equipped with a device which automatically locks spiral contact rotation when spiral contact is removed
from steering wheel; this is done in order to prevent upper cap, that is not constrained any more, from freely rotating, so causing
the cables to unexpectedly unwind or wind up and creating consequent risks of cable breakage.
On steering wheel mounting operation, the device is automatically locked.
- Where spiral contact is disconnected/reconnected, it must be made sure that it is remounted on the steering
! column switch unit in the same position it was removed.
- Where spiral contact is replaced, if it is provided as a spare apart from steering column switch unit, then spiral
contact must be installed with wheels perfectly aligned, because this is new device corresponding position.
Figure 133
107680

PRETENSIONERS
Pyrotechnic device that can be electrically activated by a signal from central unit, it is an integrating part of safety belts rolling up
device, so that a single component is created which is fixed to vehicle pillar.
In the case of a crash having a certain extent, it intervenes in such a way that it recovers the unavoidable stretch of the belts caused
by the action exerted by body weight and it keeps the body adherent to seat back.
At the end of intervention, the belt remains locked, so highlighting that device intervention has occurred.
Operation principle
At the time when a determined deceleration of the vehicle occurs, the electronic sensor, that is placed in control central unit,
sends a signal which ignites gas generator pyrotechnic charge (detonator).
Propellant combustion develops a gas the pressure of which generates a force pushing rack piston upwards.
Rack piston upward movement rotates gear wheels, which reverse tape rotation direction, so winding back the tape by a few
centimetres.
After every crash, the belt becomes unusable: therefore, it must be replaced.
! The charge for driver side pretensioner is connected to central unit on pins A9/A10.
The charge for passenger side pretensioner is connected to central unit on pins A11/A12.
The charge for central pretensioner is connected to central unit on pins B17/B18.
Figure 134
107681
107682

CURTAIN AIR BAG

Figure 135
A
107677
107686
A. “Curtain” air bag - B. Side crash sensor
On door pillars, two air bags named “curtain” air bags are provided. These devices intervene in case of a side crash. For this
purpose, two (lh & rh) sensors are present which detect the occurrence of this event.
For the connections of these components, see central unit pin-out and relating electrical scheme.

COMPONENT REPLACEMENT Figure 136

INTERVENTIONS
Electronic central unit
To remove the central unit, the following is needed:
- observing safety rules;
- disconnecting battery cables (first negative cable, then
positive cable) and isolating them by applying an adhesive
tape on pins (Figure 136);
- waiting for at least ten minutes before resuming
operations;
- removing the protection under which central unit is
located;
- operating using a small screwdriver on connector stops
locking connector fastening levers and rotating the levers
inwards;
- disconnecting the connectors from central unit;
- unscrewing the three screws which fasten central unit to
8547
floor (Figure 137).
ISOLATING THE BATTERY CABLES
Figure 137
8549
REMOVING THE CENTRAL UNIT

Drive side air bag module Passenger side air bag module
For removing air bag module, the following is needed: For removing air bag module, the following is needed:
- observing safety rules; - observing safety rules;
- disconnecting battery cables (first negative cable, then - disconnecting battery cables (first negative cable, then
positive cable) and isolating them by applying an adhesive positive cable) and isolating them by applying an adhesive
tape on pins; tape on pins;
- waiting for at least ten minutes before resuming - waiting for at least ten minutes before resuming
operations; operations;
- unscrewing the screws located at steering wheel rear - unscrewing the screws fastening instrument panel upper
side, and, in order to be able to gain access to each screw, coating (including the screws that are present near
rotating the steering wheel in such a way that you can central air diffusers);
always operate from steering column upper half-shell
- removing the coating;
side;
- disconnecting module cable connector from air bag
- lifting the module by just what needed to be able to
cable;
disconnect the connector that is placed at the centre of
the module; - unscrewing the four screws, two per side, which fasten
module support bracket to body and removing the
- removing the module from steering wheel.
module.
Not activated air bag modules, after they have NOTE Where passenger side cushion is not present as
! been removed, must be put back into a special it is optional, on relating connector there is since
locked cabinet with the plate resting on the plane. vehicle production mounted a specific
resistance for simulating the charge (R = 2.15
Ohm + 0.35).

Spiral contact For remounting the spiral device, the following is needed:
For removing the spiral contact, the following is needed: - making sure that wheels are aligned;
- removing the drive side air bag module; - if spiral device has not to be replaced, after taking off
either adhesive tape or the clamp previously mounted,
- aligning the wheels and keeping them in such position
remounting the spiral device without rotating the upper
throughout the operation;
cap, then screwing the three fastening screws;
- unscrewing the nut which fixes the steering wheel to
- where a new spiral device is mounted, after fixing it to
steering column;
steering column switch unit, tearing off plastic tab locking
- always with the vehicle having the wheels aligned, the upper cap and checking that the upper cap is not
marking the position between steering wheel hub and rotating;
steering column;
- connecting air bag cable connector to spiral device cable
- taking out the steering wheel paying attention not to and fixing spiral device cable to steering column through
unthread spiral contact cable; suitable clamp;
- mounting the two half-shells of steering column fixing
them to their support plate through special screws;
Make sure that steering wheel removal has - cautiously entering the cable, to be connected to drive
! caused spiral device upper cap lifting. Where side air bag module, into special slit on steering wheel
upper cap rotates, it has to be locked by taking it hub;
outwards; if a click is heard, it will mean that the
locking has occurred. - mounting the steering wheel making previously marked
references match;
- tightening the nut, fixing the steering wheel, at prescribed
torque.
- removing steering column lower half-shell by unscrewing
the three fastening screws;
NOTE Where steering column switch unit is replaced,
- operating from inside, removing steering column upper it must be replaced by a steering column switch
half-shell by unscrewing the two fastening screws; unit comprehensive of spiral device.
- cutting the clamp fixing spiral device cable to steering
column and disconnect spiral device cable connector
from air bag cable;
- unscrewing the three screws fastening spiral device to
steering column switch unit and removing it.
Spiral device must be removed without rotating

! the upper cap, locking spiral device position by
either a clamp or some adhesive tape.

150
Base - March 2006

Figure 138
IMMOBILIZER
1. Instrument cluster - 2. Central unit EDC 16 - 3. Body Computer - 4. Antenna on start-up switch
DAILY EURO 4
107684
Print 603.93.651
Operation description
Immobilizer present on Daily E4 differs from previous one in some features:
- “Immobilizer” central unit is not present any more, but this function has been integrated inside Body Computer;
- the warning lamp has a different symbol;
- a display screen is present where messages relating to the system are displayed (COMFORT).
Signal received from the “transponder” from the key is sent to connector AV to pins 8 and 7. Body Computer communicates
with central unit EDC 16 through “C” Can line and, if the signal is acknowledged, start-up enabling is sent to central unit EDC.
By rotating start-up key, engine lock is only de-activated if protection system acknowledges the code that was transmitted by
the key.
Body Computer through “B” second Can line communicates with instrument cluster, where Immobilizer warning lamp is present
(change of symbol with respect to previous version).
- warning lamp on: key not acknowledged;
- warning lamp off: key acknowledged.
A warning lamp on after approximately two seconds from vehicle start-up not necessarily means system failure but can mean
a particularly low charge status in battery.
Where such event occurs, in order to make a system test, vehicle must be stopped and engine put off. Rotate the key again:
warning lamp will go on and shall go off after approximately 1 second.
Where warning lamp remains on after this test too, repeat the operation keeping engine stopped up for more than 30 seconds.
if the problem persists, comply with provided prescriptions appearing on display screen (if any).
Emergency procedure
It is necessary to enter “PIN code” only operating on accelerator pedal as described below:
- Insert the key to ride position.
- EDC warning lamp, after ~ 2 seconds, starts flashing rapidly.
- Press accelerator pedal and keep it pressed for ~ 15 seconds.
- EDC warning lamp starts flashing slowly.
- When the number of flashings is matching “PIN code” first figure, fully press down accelerator pedal, then release it again.
(While this pressing operation is performed, EDC warning lamp remains off).
- Go on with reading and performing relating pressing operation on accelerator pedal for remaining four “PIN code” figures.
- At the end of the sequence, if entered code results to be correct and no failure is present in the system, EDC warning lamp
stops flashing: operation terminated correctly.
- Start up the vehicle.
Keys
- New key memorization procedure (centralized by Iveco)
- New type of key with trasponder (with or without wireless control)
- You can memorize min 1 up to max. 8 keys

Body computer
Figure 139
112242
1. “EDBD” diagnosis connector - 2. “AV” connector
Capable to communicate with central unit “EDC” through “CAN line”.

Central unit main tasks are:
acknowledging that the key was entered into the switch and rotated,
activating and reading the secret code issued by “Transponder”,
managing code check and processing,
communicating with central unit “EDC”,
storing any failures,
making system diagnosis.
AV/7 - AV/8 antenna signal input (Transponder)

Figure 140 Warning lamp

Placed on instrument cluster, it acquaints the driver of system
correct operation or possible failure.
Inserting the key to ride position, central unit makes a system
test putting on the warning lamp and keeping it on for a time
of about “1 second”.
If it goes off after said time, it means that the key was
acknowledged and system is working. On the contrary, if it
behaves in a different way, it means that key was not
acknowledged (star-up not possible).
107620
A B
A. Immobilizer warning lamp - B. EDC failure warning lamp
Antenna
It is mounted coaxial to key switch and has the task of:
- supplying “Transponder” for sending the secret code;
- receiving the signal from “Transponder” and sending it
to central unit.
It is connected to Body Computer to connector AV/7 - AV/8.
Figure 141
112288

IMMOBILIZER NEW PROCEDURES
Storing new keys into Body Computer - Send out a fax to Iveco with key VIN and PN.
- Keys arrive programmed by Iveco but it is necessary to
have them acknowledged through diagnosis tool.
Old keys can be stored later
Storing radio commands Through diagnosis tool
Replacing Body Computer (readable) Through diagnosis tool: keys need not to be learnt again
Replacing Body Computer (not readable) with remote Through remote services: to reset the plan (instrument
services cluster), Programmed Maintenance keys and/or radio
commands need to be learnt again
Replacing Body Computer (not readable) without remote - BC already programmed by Iveco is sent and it will be
services necessary to have old keys acknowledged on new Body
Computer.
- Rewrite maintenance plan.
Information stored in old B.C. are lost
Replacing EDC16 No particular procedure: as soon as new EDC is connected,
it is automatically configured by Body Computer
Replacing key switch - Order a kit complete with switch and two keys to be
programmed at Iveco.
- Workshop shall just store the keys into Body Computer
by Easy.
Programmed maintenance is a function of display screen in version COMFORT.

6AS 400 A O.D. VD AUTOMATIC TRANSMISSION
Description of operation
The gear engaging system of the 6 AS 300 VD gearbox is a combination of a traditional system of the mechanic type and an electric
one.
Below are the main components of the system:
1) electronic control unit;
2) gear selecting/engaging actuator;
3) gear shift lever;
4) clutch actuator;
5) display/buzzer.
In the manual mode, the first gear is used to start the vehicle.
In the automatic mode, you just need to act on the selection lever (A/M): the gear is selected directly by the control unit.
The electronic control unit picks up all the signals required to meet the safety conditions and the parameters programmed in the
same. It also drives the electric actuating motor(s) for gear selection/engagement and clutch control.
The information required for driving is in any case made available to the driver by means of the display.
NOTE To ensure correct management of the gearbox and the other auxiliary functions provided for by the system, the
control unit is interfaced (CAN line) with the other electric and electronic system fitted to the vehicle.

Electronic management
Figure 142
112289
1. Digital tachograph - 2. Buffer (located inside Instrument Cluster - 3. Instrument Cluster - 4. Body Computer -
5. Switching on reverse lights - 6. IMMOBILIZER central unit - 7. Central unit ABS8/ASP8 - 8. Central unit EDC - 9. Gears
lever - 10. Pushbutton board - 11. Central unit gearbox - 12. PTO - 13. Clutch actuator - 14. Gearbox actuator

COMPOSITION OF THE SYSTEM
System control unit

The electronic control unit receives the signals from the sensors/switches: the management and control of the system under
the different operating conditions of the gearbox are based on the above signals.
It is interfaced with other electronic systems available on the vehicle, such as EDC and ABS, through CAN communication lines.
A - Connector on the gearbox side
B - Connector on the vehicle side
Figure 143
90135
Through the connection with the EDC 16 system, the gearbox control unit is able to detect the position of the accelerator pedal
and also the engine revs number.
Connection with the ABS8/ESP8 control unit is used to prevent the “UP” gear shift at bends and also control driving under poor
grip conditions in case of mode “A” driving.
The new ABS system controls “smart” warning lights incorporated into the on-board panel. These warning lights come on to
indicate braking system failure.
NOTE The “Brake” signal, upon start-up, comes directly from the EDC control unit. The reverse gear signal is direct.
Figure 144
101870
Position of the electronic control unit

Connector control unit PIN-OUT — gearbox side (A)
Figure 145
101869
Pin Function
1 Electric motor positive (gearbox actuator selector pin 6)
2 Electric motor negative (gearbox actuator selector pin 1)
3 Electric motor positive (clutch actuator pin 3)
4 Electric motor negative (clutch actuator pin 6)
5 Electric motor positive (gear engaging gearshift actuator pin 6)
6 Electric motor negative (gear engaging gearshift actuator pin 1)
11 Sensor direction signal (clutch actuator pin 4)
12 Sensor speed signal (clutch actuator pin 2)
13 Clutch actuator pin 5 sensor voltage signal (5 V)
15 Sensor direction signal (gear engaging gearshift actuator pin 4)
16 Sensor voltage signal, 12 V (gear engaging gearshift actuator pin 3)
17 Sensor voltage signal, 12 V (gearbox actuator selector pin 3)
18 Sensor direction signal (gearbox actuator selector pin 4)
33 Earth (clutch actuator pin 1)
35 Sensor speed signal (gear engaging gearshift actuator pin 5)
36 Earth (gear engaging gearshift actuator pin 2)
37 Earth (gearbox actuator selector pin 2)
38 Sensor speed signal (gearbox actuator selector pin 5)

Connector control unit PIN-OUT — vehicle side (B)
Figure 146
101871
Pin Function
1 Earth
2 Earth
3 Earth
4 Battery positive
5 Battery positive
6 Battery positive
7 Earth
8 Earth
9 KL 30
14 PTO actuation request signal (option)
17 CAN C “H” line
18 CAN C “EDC” line
28 CAN C “EDC“ line
29 CAN “L” line
33 Free
37 Free
38 Free
39 KL 30
40 CAN L --- ZF LINE
41 CAN H --- ZF LINE
43 KL 15
44 Hand brake in signal
45 Signal to Body Computer
46 PTO status signal
47 PTO in signal
49 ”Gearbox in neutral position” remote control switch control
51 Speed signal
52 Diagnosis line K (heater, Body Computer)

Gearbox actuator
The function of the gear actuator is to continuously exchange information with the electronic control unit for gear selection
and engagement.
It is made up of two electric motors, control cylinders, and respective sensors.
Figure 147
90139
Position of actuator
Figure 148
101872
1. Gear engaging electric motor - 2. Gear selection electric motor

Figure 149
101873
Wiring diagram
Pin Function
1 Electric motor negative
2 Earth
3 Sensor voltage signal
4 Sensor direction signal
5 Sensor speed signal
6 Electric motor positive
Characteristics of electric motor
Voltage 12 V
Output 95 W
Torque 0.72 Nm (at 125 °C)
nmax 5400 r.p.m.

Clutch actuator
It is made up of the following:
- a cylinder acting on the clutch engaging/disengaging lever;
- a position sensor that detects the clutch lever stroke, by informing the electronic control unit of the actuating cylinder
position and the clutch plate wear.
Figure 150
90137
Figure 151
90138
1. Actuating cylinder - 2. Electric motor - 3. Vehicle electric wiring junction block

Figure 152
101873
Wiring diagram
Pin Function
1 Earth
2 Incremental sensor speed signal
3 Electric motor positive
4 Incremental sensor direction signal
5 Sensor voltage signal
6 Electric motor negative
Characteristics of electric motor
Max. torque 0.65 Nm

No-load revs number 5800 r.p.m.
Output 80 W (0.3 Nm - 2,500 r.p.m.)

Accelerator pedal Figure 153

To detect the engine idling position and allow the clutch to
be engaged when the vehicle is about to start, the N.O.
switch, incorporated into the position sensor, is used, with
the pedal released.
This signal reaches the EDC electronic control unit and is
sent, through the CAN VDB (Vehicle Data Base) line, to the
gearbox control unit.
The “kick-down” function can be actuated during running, in
the automatic mode.
When the pedal is pressed down almost fully (98%), e.g.
101877
when overtaking, the system will automatically shift down by
one speed, thus making it possible to use the deflecting
torque at its best.
In practice, if the accelerator pedal is pressed fully down, the
vehicle will ride at a running speed with a higher gear shift.
Figure 154
101878
Figure 155
101879

Gear selector
Figure 156
108873
Gear selector is an electronic component placed in the cab at driver side.

It is interfaced with gearbox central unit through CAN communication line in order to signal that the driver is going to select
and engage a gear.
PIN FUNCTION
1 KL 15
2 GROUND
3 CAN L
4 CAN L
5 -
6 -

REMOTE CONTROL SWITCHES / FUSES ASSEMBLY

Figure 157
107627
System power supply is ensured by an assembly of fuses located in engine opening in interconnection central unit at highlighted
positions.
F3 — is connected to central unit pin B4
F4 - is connected to central unit pins B5 and B6
F18 - Central unit power supply
F24 — Automated gearbox services
Where one or two of these fuses is burnt, gearbox functionality is not impaired. Failure of fuse F24 only prevents gearbox from
operating (clutch movement, gear selection and engagement are inhibited).
Accelerator pedal sensor
Accelerator pedal position is provided to gearbox central unit through proper communication line by electronic central unit
EDC, which learns the position thanks to load transmitter directly mounted on accelerator pedal.
Engine rpm sensor
The sensor is mounted at engine flywheel.
Engine rotation speed values are transmitted to electronic central unit EDC, which through proper communication line transfers
them to gearbox central unit.
Vehicle speed sensor
The sensor transmits pulses to electronic tachograph / tachometer.
The signal is duplicated by sensors ABS/ESP present on the wheels.

PTO
There is one pushbutton only, which is used for inserting and disconnecting PTO.
PTO can only be engaged with gearbox in neutral position and engine on.
PTO can be used both in STATIONARY and NON STATIONARY conditions.
In NON STATIONARY conditions valid are following conditions:
- First gear can be put in and vehicle moved.
- Once started, with vehicle moving, gear cannot be shifted any more;
- PTO can be disengaged with gearbox in both gear and neutral position.
- Depending on signal coming in to Pins, self-implementing device acknowledges if it is working with either a mechanical or
automated gearbox. If it is working with a mechanical gearbox, signal comes in from clutch pedal.
Figure 158
101880
1. EDC control unit - 2. Gearbox control unit - 3. Clutch actuator electric motor - 4. PTO actuator motor -
5. PTO ON switch - 6. PTO ON warning light - 7. PTO control unit - 8. PTO actuation switch - A. Gearbox side -
B. Vehicle side.

PTO engaging procedure

To engage power take-off, following operations must be preformed: Put on engine with gearbox in neutral position.
1) press the PTO button;
2) wait at least 0.5 seconds;
3) release the PTO button.
NOTE - The PTO will be actuated only if the PTO button is kept depressed for more than 0.5 seconds.
- The PTO button will be ignored until the next 5 seconds have elapsed.
PTO disengaging procedure

To disengage the power take-off, the following operations must be carried out:
1) press the PTO button;
2) wait at least 0.5 seconds;
3) release the PTO button.
NOTE - The operation will be carried out only if the PTO button is kept depressed for more than 0.5 seconds.
- The PTO button will be ignored until the next 5 seconds have elapsed. • In the event that the power take-off
is not disengaged within 5 seconds, the operator may carry out the operation again, by pressing the button
again.

Display screen
Figure 159
0051594t
Display screen, positioned on instrument panel, allows to display all information necessary for system correct use, as, for example:
Mode: manual or automated, and, in both cases, gear ratio entered;
Reverse gear / neutral (R/N) position;
Signalling faults:
- ”SERVICE: gearbox failure”
- ”SERVICE: serious gearbox failure” (associated to sound warning)
- ”SERVICE: clutch excessive temperature” (associated to sound warning)
- ”Gearbox failure in SERVICE mode” (message that can only be displayed at Assistance Network)

Alarm is integrated in Body Computer central unit; it is optional.

Where alarm is to be mounted at Assistance, the following is needed:
1. PROGRAMMING THE BODY COMPUTER

2. INSTALLING THE SIREN
3. INSTALLING ENGINE BONNET SWITCH
4. Storing radio commands into Body Computer central unit
Body Computer manages alarm.

Alarm controls vehicle perimetral portion (doors and bonnet switches), and also any battery and siren disconnections. BC directly
controls external siren. It also activates inserted alarm LEDs, activates blinkers and transmits all information to Instrument Cluster
via B-CAN for managing VPS (Vehicle Protection System) warning lamp on the dashboard.
Body Computer controls and diagnoses alarm siren, receives input from vehicle alarm system and also provides siren condition.

DIAGNOSIS (CONNECTOR EOBD)

The vehicle that is described in this section has a number of differences with respect to previous version. 30-pole diagnosis
connector located on vehicle right side in front of passenger was replaced by a 16-pin connector.
It is placed on vehicle left side near interconnection central unit CPL.
This connector is placed on Body Computer (it is a part of the component). Therefore, connection cables are not present as
necessary connections are directly implemented on Body Computer printed circuit.
To be connected to it will be available diagnosis tools.
Figure 160
112244
Diagnosis connector “EOBD”
PIN FUNCTION
1 free
2 free
3 positive +15
4 earth
5 signal earth
6 B Can line ”H”
7 line ”K” EDC
8 line ”K” ABS/ESP, Tachometer
9 free
10 free
11 line ”K” for climate control system
12 free
13 line ”K” for suspensions, retarder
14 B Can line ”L”
15 free
16 positive +30

Figure 161
108874
A. IT 2000 - B. Modus - C. EASY - D. Body Computer - E. Diagnosis connector EOBD

Circuit cards
Page
CARD 1: POWER NETWORK . . . . . . . . . 175
CARD 2: CAB INTERIOR COMPONENTS 176
CARD 3: WINDOW WINDERS -

ELECTRIC MIRRORS . . . . . . . . . . 177
CARD 4: CAB INTERIOR COMPONENTS 178
CARD 5: VARIOUS LOADS . . . . . . . . . . . . 179
CARD 6A: TELMA DECELERATOR . . . . . . . 180
CARD 6B: DIFFERENTIAL LOCKING -

HEATED REAR WINDOW AND
WINDSCREEN . . . . . . . . . . . . . . 181
CARD 7A: AIR SPRING SUSPENSION . . . . . 182
CARD 7B: ADDITIONAL HEATER -

POWER TAKE-OFF . . . . . . . . . . . 183
CARD 8: CRUISE CONTROL -

CLIMATE CONTROL SYSTEM . . 184
CARD 9A: AUTOMATIC GEARBOX . . . . . . 185
CARD 9B: ESP 8 . . . . . . . . . . . . . . . . . . . . . . 186
CARD 10: EXTERNAL ILLUMINATION . . . . 187
CARD 11A: ASR . . . . . . . . . . . . . . . . . . . . . . . . 188
CARD 11B: CAMERA . . . . . . . . . . . . . . . . . . . 189
CARD 12: EXTERNAL ILLUMINATION . . . . 190
CARD 13A: AIR BAG . . . . . . . . . . . . . . . . . . . . 191
CARD 13B: ABS8 . . . . . . . . . . . . . . . . . . . . . . . 192
CARD 14A: EDC 16 . . . . . . . . . . . . . . . . . . . . . 193
CARD 14B: EDC 16 . . . . . . . . . . . . . . . . . . . . . 194
CARD 15B: CAB INTERIOR COMPONENTS 195
CARD 16: ”CAN” LINES . . . . . . . . . . . . . . . 196


Card 1: Power network
107694

Card 2: Cab interior components
107695

Card 3: Window winders — Electric mirrors
107696

Card 4: Cab interior components
107697

Card 5: Various loads
107698

Card 6A: Telma decelerator
107699

Card 6B: Differential locking - Heated rear window and windscreen
107700

Card 7A: Air spring suspension
112226

Card 7B: Additional heater - Power take-off
112227

Card 8: Cruise control - Climate control system
112228

Card 9A: Automatic gearbox
112229

Card 9B: ESP 8
112230

Card 10: External illumination
112231

Card 11A: ASR
112232

Card 11B: Camera
112233

Card 12: External illumination
112234

Card 13A: AIR BAG
112235

Card 13B: ABS8
112236

Card 14A: EDC 16
112237

Card 14B: EDC 16
112238

Card 15B: Cab interior components
112239

Card 16: “CAN” lines
*
*
* Tachograph / * *Parking sensors 112240

Iveco Daily Euro 4

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DAILY EURO 4

expert22 для http://rutracker.org

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Danger for persons

Danger of serious damage for the vehicle

NOTE It indicates an additional explanation for a piece of information.

Print 603.93.651 I Base - March 2006

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

Base - March 2006 II Print 603.93.651

Product 50 = Vehicle chassis;

Product 50 = Vehicle chassis;

Product 50 = Vehicle chassis;

Print 603.93.651 III Base - March 2006

Base - March 2006 IV Print 603.93.651

Print 603.93.651 V Base - March 2006

Base - March 2006 VI Print 603.93.651

Further, following warnings are to be compulsorily observed for electronic components:

1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR

Print 603.93.651 VII Base - March 2006

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Base - March 2006 VIII Print 603.93.651

Print 603.93.651 — 1st edition

Section Description Page Revision date

Print 603.93.651 Base - March 2006

Front and rear suspensions 8

Wheels and tyres 9

Pneumatic system - Brakes 11

Bodywork and chassis frame 12

Print 603.93.651 Base - March 2006

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

ALPHANUMERICAL CODING FOR

Print 603.93.651 Base - March 2006

Base - March 2006 Print 603.93.651

Print 603.93.651 Base - March 2006

Single disk 10” 1/2 • • o o • • • • o o • •

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

Base - March 2006 Print 603.93.651

REAR AIR SUSPENSIONS V V V V V V V V

Print 603.93.651 Base - March 2006

ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION

MARKET VEHICLE (V.M.)

STANDARD VEHICLE (V.C.B.)

A LIGHT ROAD VEHICLES

Base - March 2006 Print 603.93.651

VANS AND DERIVATIVES

Print 603.93.651 Base - March 2006

29 L10 D (•) - 29 L12 D (•) - 29 L14 D (•) -

35 S12 CC (•) - 35 S 14 CC (•) - 35 S18 CC (•) -

35 S12 CCR (•) - 35 S14 CCR (•) - 35 S18 CCR(•)

Base - March 2006 Print 603.93.651

35 C10 CA (•) - 35 C12 CA (•)

29 L10 V (•) - 29 L12 V (•) - 29 L14 V (•)

29 L10 SV (•) - 29 L12 SV (•) - 29 L14 SV (•)

VENDOR 35 S12 CV (•) - 35 S14 CV (•)

5 COMBI 29 L14 C (•) - 35 S14 C (•)

35 S14 ((•)) - 35 S18 (•)