14+ +electric Electronic+System

DAILY ELECTRIC/ELECTRONIC SYSTEM 1
Print 603.93.281
Print 603.93.281
SECTION 14
7600 Electric/Electronic system
Page
ABBREVIATIONS AND GRAPHIC SYMBOLS . . . 7
GENERAL CONDITIONS FOR LAYING ELECTRIC

CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . 8
TECHNICAL CODES . . . . . . . . . . . . . . . . . . . . . . . 9
POWER NETWORK . . . . . . . . . . . . . . . . . . . . . . . 13
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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- Power network assembly . . . . . . . . . . . . . . . . 14
- Positive network . . . . . . . . . . . . . . . . . . . . . . . 15
- Negative network . . . . . . . . . . . . . . . . . . . . . . 17
- Earth points on the vehicle . . . . . . . . . . . . . . . 19
CONCEPT OF EARTH AND ELECTROMAGNETIC

COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . 20
- Practical advice . . . . . . . . . . . . . . . . . . . . . . . . 21
- Ultrasonic cable welding . . . . . . . . . . . . . . . . . 22
MAIN COMPONENTS OF POWER

NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- BOSCH KCBI 14V 110A Alternator . . . . . . . . 23
- EV 12V - 2.3 kW Starter motor . . . . . . . . . . . 24
- Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Interconnection center . . . . . . . . . . . . . . . . . . 27
- General remote control switch (T.G.C.) . . . . . 28
ONBOARD CABLES . . . . . . . . . . . . . . . . . . . . . . . 29
- Components of the injection system (E. 8140) 29
- Engine cable . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8140.43C ID/TCA (.11) ENGINE HARNESS . . . . . 30
8140.43S UNIJET (.13) ENGINE HARNESS . . . . . . 32
INJECTION CABLE - V.G.T (.15) . . . . . . . . . . . . 34
Print 603.93.281 Base - May 2004

2 ELECTRIC/ELECTRONIC SYSTEM DAILY
Print 603.93.281/A
Page Page
F1A UNIJET (.10 - .12) ENGINE HARNESS . . . . 36 - Connection between cab/bonnet cable and
self-levelling suspension cable . . . . . . . . . . . . . 64
F1A UNIJET WITH EDC16 (.10 - .12 - .14) ENGINE
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37/1 - Connection between cab/bonnet cable and
self-levelling suspension cable . . . . . . . . . . . . . 65
F1C UNIJET WITH EDC16 (.10 - .12 - .14) ENGINE
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37/3 - Connection between cab/bonnet cable and total
power takeoff cable . . . . . . . . . . . . . . . . . . . . 66
INJECTION CABLE - F1A (.10 - .12) WITH AND WI-
THOUT EGR . . . . . . . . . . . . . . . . . . . . . . . . . . 38 - Connection between cab/bonnet cable and total
power takeoff cable . . . . . . . . . . . . . . . . . . . . 67
TRUCK CHASSIS CABLE . . . . . . . . . . . . . . . . . . . 40
- Connection between cab/bonnet cable and
A.B.S. PARALLEL CABLE . . . . . . . . . . . . . . . . . . . 42 antitheft cable . . . . . . . . . . . . . . . . . . . . . . . . . 68
AIR-BAG CABLE WITH ONE-CONNECTOR CON- - Connection between cab/bonnet cable and
TROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 antitheft cable with central door locking . . . . 69
AIR-BAG CABLE WITH TWO-CONNECTOR CON- - Connection between cab/bonnet cable and right
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TROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 door cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
VAN INTERIOR DOME LAMP CABLES 1/2 . . . . 48 - Connection between cab/bonnet cable and left
door cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
VAN INTERIOR DOME LAMP CABLES 2/2 . . . . 50
- Connection between cab roof lamp and left
TRUCK INTERIOR DOME LAMP CABLES . . . . . 52 front clearance light cable . . . . . . . . . . . . . . . . 72
JUNCTION CONNECTORS . . . . . . . . . . . . . . . . 53 - Connection between cab roof lamp and right

front clearance light cable . . . . . . . . . . . . . . . . 73
- Connection between cab/bonnet cable and injection
cable (Unijet) . . . . . . . . . . . . . . . . . . . . . . . . . 53 - Connection between cab/bonnet cable and fog
lamp cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
- Connection between cab/bonnet cable and air bag
cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 - Connection between right tail light cable and
rear roof lamp cable . . . . . . . . . . . . . . . . . . . . 75
- Connection between cab/bonnet cable and rear
differential lock cable . . . . . . . . . . . . . . . . . . . 55 - Connection between frame cable and side
clearance lights cable . . . . . . . . . . . . . . . . . . . 76
- Connection between cab/bonnet cable and cable
for tachometer . . . . . . . . . . . . . . . . . . . . . . . . 56 - Connection between cab/bonnet cable and ABS
cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
- Connection between frame cable and right tail
lamp cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - Connection between cab/bonnet cable and
ABS cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
- Connection between frame cable and right tail
climate control system cable . . . . . . . . . . . . . . 79
- Connection between frame cable and left tail
- Connection between frame cable and left tail
- Connection between cab/bonnet cable and roof
lamp cable inside cab . . . . . . . . . . . . . . . . . . . 61 VENDOR-DERIVED BUS VERSION . . . . . . . . . . 82
- Connection between cab/bonnet cable and 13 - General Information . . . . . . . . . . . . . . . . . . . . 82

pin current socket cable or rear door opening/
closing cable (van) . . . . . . . . . . . . . . . . . . . . . 62 - Perspective view of Vendor-derived Bus
version interior lighting harness . . . . . . . . . . . 83
- Connection between cab/bonnet cable and
brake wear/air cleaner clogged cable . . . . . . . 63 - Diagnostic connector . . . . . . . . . . . . . . . . . . . 84
Base - May 2004 Print 603.93.281/A

Revi - February 2005
Page Page
RELAY AND FUSE HOLDER SUPPORT . . . . . . . 86 - Four crossed channel system (x) . . . . . . . . . . 132/3
- Identification of fuses . . . . . . . . . . . . . . . . . . . 87 - Electro-hydraulic modulator/control unit . . . . 132/3
- Identification of relays/diode holders . . . . . . . 88 - Four parallel channel system (II) . . . . . . . . . . . 132/4
OPTICAL INDICATORS . . . . . . . . . . . . . . . . . . . 89 - Electro-hydraulic modulator/control unit . . . . 132/4
- Interface bride with the new tool with 32-way - ABS 8 control unit pin out . . . . . . . . . . . . . . . 132/5
connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
- ESP 8 control unit pin out . . . . . . . . . . . . . . . 132/6
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . 91
- ESP operation . . . . . . . . . . . . . . . . . . . . . . . . . 132/7
- Warning lights assembly . . . . . . . . . . . . . . . . . 91
- Control strategy . . . . . . . . . . . . . . . . . . . . . . . 132/7
- Instrument assembly . . . . . . . . . . . . . . . . . . . . 92
- ASR deactivation strategies . . . . . . . . . . . . . . . 132/9
- Connector assembly (cable input side view) . 94
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- Recovery strategy in case of component failure 132/9
SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 98
- Warning light legend . . . . . . . . . . . . . . . . . . . 132/10
STALK UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
- Installing the ESP components . . . . . . . . . . . 132/10
- Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
- ESP system components and calibration . . . . 132/11
- Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . 104
- Yaw sensor with built-in side acceleration
ELECTRONIC SYSTEMS . . . . . . . . . . . . . . . . . . . 105 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132/11
- Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 - Steering angle sensor . . . . . . . . . . . . . . . . . . 132/13
- System components . . . . . . . . . . . . . . . . . . . . 106 - ESP control unit programming . . . . . . . . . . . 132/14
- Key teaching procedure . . . . . . . . . . . . . . . . . 109 6AS 300 VD AUTOMATIC TRANSMISSION . . . 132/15
ABS/EBD/ABD . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 - Description of operation . . . . . . . . . . . . . . . 132/15
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 - Electronic control . . . . . . . . . . . . . . . . . . . . . 132/16
SYSTEM WITH 4 CROSSED CHANNELS (X) . . 116 COMPOSITION OF THE SYSTEM . . . . . . . . . . . 132/17
- Location of components . . . . . . . . . . . . . . . . . 117 - System control unit . . . . . . . . . . . . . . . . . . . 132/17
- Sensor on phonic wheel . . . . . . . . . . . . . . . . . 118 - Connector control unit pin-out —

gearbox side (A) . . . . . . . . . . . . . . . . . . . . . . 132/18
- Electrohydraulic control unit/modulator . . . . . 119
- Connector control unit pin-out —
- Electrohydraulic modulator . . . . . . . . . . . . . . . 120 vehicle side (B) . . . . . . . . . . . . . . . . . . . . . . . 132/19
SYSTEM WITH 4 PARALLEL CHANNELS (11) . 125 - Gearbox actuator . . . . . . . . . . . . . . . . . . . . . 132/20
- Electrohydraulic control unit/modulator . . . . . 126 - Clutch actuator . . . . . . . . . . . . . . . . . . . . . . . 132/22
- Electrohydraulic modulator . . . . . . . . . . . . . . . 127 - Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132/24
- Pressure increase . . . . . . . . . . . . . . . . . . . . . . 127 - Accelerator pedal . . . . . . . . . . . . . . . . . . . . . 132/26
- Electronic control unit . . . . . . . . . . . . . . . . . . 132 - PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132/27
ABS 8/ESP 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132/1 - Diagnosis instruments . . . . . . . . . . . . . . . . . . 132/30
Print 603.93.281/A Base - May 2004

Page Page
- MODUS - IT 2000 - E.A.S.Y. connection . . . 132/31 - Clutch pedal switch . . . . . . . . . . . . . . . . . . . . 155
- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 132/32 - Electromagnetic junction fan . . . . . . . . . . . . . . 156
ELECTRONIC INJECTION SYSTEM . . . . . . . . . . 133 - Preheat plug electronic centre

(F1A/F1C engine) . . . . . . . . . . . . . . . . . . . . . . 157
- Common rail . . . . . . . . . . . . . . . . . . . . . . . . . . 133
- Preheat plugs . . . . . . . . . . . . . . . . . . . . . . . . . 157
- Common rail (F1A) . . . . . . . . . . . . . . . . . . . . 135
EDC MS6.3 / EDC16 . . . . . . . . . . . . . . . . . . . . . . . 158
- Hydraulic system (Common Rail - F1A) . . . . . 136
- Electronic injection control . . . . . . . . . . . . . . . 158
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . 137
- Bosch MS6.3 control unit . . . . . . . . . . . . . . . . 162
- Camshaft pulley and timing sensor . . . . . . . . . 137
- Control unit connection to the injection cable on
- Flywheel and rpm sensor . . . . . . . . . . . . . . . . 138 engine side (housing A) . . . . . . . . . . . . . . . . . 163
- Control unit connection to cab-bonnet cable
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- Flywheel and camshaft sensor specifications . . 139
(housing B) . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
- Pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
- EDC system components . . . . . . . . . . . . . . . . 165
- Electric pump . . . . . . . . . . . . . . . . . . . . . . . . . 140
- Blink Code (up to chassis no. 5383302/
D187233) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
- Common Rail 8140.43B - 8140.43S -
- High pressure pump . . . . . . . . . . . . . . . . . . . . 142 8140.43N - EDC MS6.3 . . . . . . . . . . . . . . . . . 167
- High-pressure pump (F1A engine) . . . . . . . . . 143 - F1A Common Rail . . . . . . . . . . . . . . . . . . . . . 168
- Pressure regulator . . . . . . . . . . . . . . . . . . . . . . 144 - EDC16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
- Pressure regulator (F1A) . . . . . . . . . . . . . . . . . 145 - Bosch EDC16 control unit . . . . . . . . . . . . . . . 170
- Rail (pressure accumulator) . . . . . . . . . . . . . . 146 - Control unit connection to the injection cable
on engine side (housing A) . . . . . . . . . . . . . . . 171
- Rail (pressure accumulator - F1A) . . . . . . . . . 147
- Control unit connection to cab-bonnet cable
- Flow limiters . . . . . . . . . . . . . . . . . . . . . . . . . . 148 (housing K) . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
- Pressure limiter . . . . . . . . . . . . . . . . . . . . . . . . 148 - Accelerator pedal sensor . . . . . . . . . . . . . . . . 175
- Fuel pressure sensor . . . . . . . . . . . . . . . . . . . . 148 - Camshaft sensor (F1A) . . . . . . . . . . . . . . . . . . 176
- Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 - Injection cable F1A (.10 - .12) . . . . . . . . . . . . . 177
- Fuel outlets unit . . . . . . . . . . . . . . . . . . . . . . . 150 - Injection cable F1A (.14) . . . . . . . . . . . . . . . . 177/1
- Air flow meter . . . . . . . . . . . . . . . . . . . . . . . . 151 - Joint connector . . . . . . . . . . . . . . . . . . . . . . . . 178
- Atmospheric pressure sensor . . . . . . . . . . . . . 153 - Diagnostic connector . . . . . . . . . . . . . . . . . . . 179
- Engine coolant temperature sensor . . . . . . . . 153 - Diagnostic connector pin description table . . 180
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 153 - High-pressure pump (F1A engine) . . . . . . . . . 181
- Brake pedal switches . . . . . . . . . . . . . . . . . . . . 155 F1C ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
- Injection cable F1C (.14 - .17) . . . . . . . . . . . . . 183
Base - May 2004 Print 603.93.281/A

Page Page
- Connection between cab/bonnet cable and - Air mixing gear motor . . . . . . . . . . . . . . . . . . 211
injection cable . . . . . . . . . . . . . . . . . . . . . . . . . 184
- Re-circulation gear motor . . . . . . . . . . . . . . . . 212
- R.p.m. / timing sensors . . . . . . . . . . . . . . . . . . 185
- Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 213
- Timing sensor (stroke) . . . . . . . . . . . . . . . . . . 186
- Safety pressure switches . . . . . . . . . . . . . . . . . 213
- RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
SYSTEM SELF-DIAGNOSTICS . . . . . . . . . . . . . . . 214
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . 188
- Diagnostics through blink code . . . . . . . . . . . . 214
- High-pressure pump . . . . . . . . . . . . . . . . . . . . 189
- Blink codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
- Pressure regulator . . . . . . . . . . . . . . . . . . . . . . 190
AIR BAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
- Rail (pressure accumulator) F1C . . . . . . . . . . . 191
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
- Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . 191
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- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
- Air temperature/pressure sensor
(without EGR) . . . . . . . . . . . . . . . . . . . . . . . . 193
- Preliminary rules . . . . . . . . . . . . . . . . . . . . . . . 218
- Atmospheric pressure sensor . . . . . . . . . . . . . 194
- Operations after an accident . . . . . . . . . . . . . 219
- Engine coolant temperature sensor . . . . . . . . 194
- Painting work . . . . . . . . . . . . . . . . . . . . . . . . . 219
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 194
- Health hazards . . . . . . . . . . . . . . . . . . . . . . . . 219
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
- Effects of over-exposure . . . . . . . . . . . . . . . . . 219
- Brake pedal switches . . . . . . . . . . . . . . . . . . . . 196
- Rules of safety in handling air bag modules . . . 220
- Clutch pedal switch . . . . . . . . . . . . . . . . . . . . 196
- Air bag module scrapping . . . . . . . . . . . . . . . . 220
- Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
- Rules of safety in handling pretensioners . . . . 221
- Electromagnetic junction fan . . . . . . . . . . . . . . 198
- Scrapping pretensioners . . . . . . . . . . . . . . . . . 221
CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . 199
- Operations on system components . . . . . . . . 222
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
- Removing and scrapping an activated air bag
module and pretensioner from a vehicle . . . . 222
- Operating logic . . . . . . . . . . . . . . . . . . . . . . . . 200
- Removing or scrapping an air bag module that has
- Electronic control unit . . . . . . . . . . . . . . . . . . 205 not been deployed from a reparable vehicle . 222
- Outside air temperature sensor . . . . . . . . . . . 206 - Deployment of an air bag . . . . . . . . . . . . . . . . 223

- Inside temperature sensor . . . . . . . . . . . . . . . 207 - Deployment of air bag modules and electronic
pretensioners still on board of irreparable vehicles 224
- Blown air temperature sensor . . . . . . . . . . . . 208
- Electronic control unit . . . . . . . . . . . . . . . . . . 225
- Evaporator temperature sensor . . . . . . . . . . . 208
- One-connector electronic control unit pin-out 226
- Required temperature potentiometer . . . . . . 208
- ECU pin-out to the two connectors . . . . . . . 229
- Ventilation control potentiometer . . . . . . . . . 209
- Electronic fan control module . . . . . . . . . . . . 210
Print 603.93.281/A Base - May 2004

Page Page
- Drivers air bag module . . . . . . . . . . . . . . . . . . 230 VB TECHNIEK PNEUMATIC SUSPENSIONS . . . . 267
- Clock spring . . . . . . . . . . . . . . . . . . . . . . . . . . 231 - Vehicles with braking system without ABS . . . 269
- Passenger’s air bag module . . . . . . . . . . . . . . . 233 - Vehicles with ABS system . . . . . . . . . . . . . . . . 270
- Pretensioners . . . . . . . . . . . . . . . . . . . . . . . . . 234 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . 271
- Driver’s/passenger’s pretensioner . . . . . . . . . . 235 - Electronic Control Unit (35C - 40C - 45C) . . 271
- Centre passenger’s pretensioner . . . . . . . . . . . 236 - Electronic control unit (60C - 65C - 50C) . . 272
DOOR-BLOCKER WITH ANTI-THEFT - Level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 273

PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 237
- Brake action compensator . . . . . . . . . . . . . . . 274
- General information . . . . . . . . . . . . . . . . . . . . 237
ROTATING SLIDING DOOR . . . . . . . . . . . . . . . . 275
- System components . . . . . . . . . . . . . . . . . . . . 238
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- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . 276
- Arrangement of components . . . . . . . . . . . . . 240
- Electronic center . . . . . . . . . . . . . . . . . . . . . . . 276
MAIN COMPONENTS OF THE SYSTEM . . . . . . 241
- Optical and sound warnings . . . . . . . . . . . . . . 278
- Remote-control key . . . . . . . . . . . . . . . . . . . . 241
- Sound device . . . . . . . . . . . . . . . . . . . . . . . . . 278
- Electronic central control unit (ECU) . . . . . . . 243
- Description and operation . . . . . . . . . . . . . . . 279
- Arrangement of the switches . . . . . . . . . . . . . 245
- Emergency operation . . . . . . . . . . . . . . . . . . . 280
- Electronic volumetric-detection module . . . . . 248
- Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
- Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
- Description of opening . . . . . . . . . . . . . . . . . . 281
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
- Description of closing cycle . . . . . . . . . . . . . . 282
- Error code table . . . . . . . . . . . . . . . . . . . . . . . 252
- Operating diagram . . . . . . . . . . . . . . . . . . . . . 283
AIR SUSPENSIONS ECAS . . . . . . . . . . . . . . . . . . . 253
ELECTRONIC TACHOGRAPH . . . . . . . . . . . . . . . 284
- WABCO electronically controlled air
suspensions (ECAS) . . . . . . . . . . . . . . . . . . . . 254 - Removing the lower dashboard cover . . . . . . 284
- Vehicles with braking system without ABS . . . 256 - Electronic tachograph control unit housing
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
- Vehicles with ABS system . . . . . . . . . . . . . . . . 257
- Assembling the tachograph control unit support
- Electronic Control Unit . . . . . . . . . . . . . . . . . 258 on the dashboard . . . . . . . . . . . . . . . . . . . . . . 285
- Level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 260 - Removing the instrument cluster module . . . . 286
- Pneumatic supply unit . . . . . . . . . . . . . . . . . . . 261 - Operations on gearbox . . . . . . . . . . . . . . . . . 288
- Brake action compensator . . . . . . . . . . . . . . . 262 - Operation in bonnet . . . . . . . . . . . . . . . . . . . . 289
- Chassis lifting . . . . . . . . . . . . . . . . . . . . . . . . . . 264 CIRCUIT CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . 291
- Chassis lowering . . . . . . . . . . . . . . . . . . . . . . . 265
- Chassis leveling . . . . . . . . . . . . . . . . . . . . . . . . 266
Base - May 2004 Print 603.93.281/A

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
IWT IVECO Wiring Tester
V Volt Consult
Ω Ohm
60 O
cardiagn.com
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
Print 603.93.281 Base - May 2004

GENERAL CONDITIONS FOR LAYING ELECTRIC CIRCUITS

- Engine off
- Ignition switch off
- Handbrake engaged
- Neutral gear
- Fluids at normal level
GENERAL WARNINGS
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.
cardiagn.com
- 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.
- During connection, tighten the nuts of the connectors (temperature, pressure sensors, etc.) only with the specified tightening
torque.
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.
Base - May 2004 Print 603.93.281

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
cardiagn.com
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
Print 603.93.281 Base - May 2004

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
cardiagn.com
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
Base - May 2004 Print 603.93.281

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
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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
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)
Print 603.93.281 Base - May 2004

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
cardiagn.com
86060 Airbag control unit
86061 Air bag
86062 Pretightener
88000 ABS system electronic control unit
88001 ABS system sensor
Base - May 2004 Print 603.93.281

POWER NETWORK
General
Never disconnect the battery from the system with the engine running.
! When needing to disconnect the battery from the system, always firstly disconnect the earth cable on the engine from
the battery negative terminal.
Before connecting the battery to the system, make sure that the system is well insulated.
Disconnect the battery from the system when charging it.
The purpose of the electric system is to generate, regulate, store and distribute the energy needed to make the vehicle
components work.
For this reason the supply of the base electric system is ensured by a generator (14V, 50 - 110A alternator) and a 12 V, 110
Ah battery.
The battery is located in a special compartment on the left front side of the bonnet.
Figure 1
cardiagn.com
Earth points
m4 m6
ms3
m1
ms8
m2 m3
ms7 m7
m5
7389
EARTH POINTS
m1. Engine earth - m2. Frame earth - m3. Bonnet power earth - ms3. Bonnet signal earth - m4. Bonnet right side earth
m5. Bonnet left side earth - m6. m7. Cab inside earths - ms7. Cab inside signal earth - ms8. Air bag signal earth
Print 603.93.281 Base - May 2004

Power network assembly

Figure 2
A m6 B C D m7 E F G
cardiagn.com
8633
I H m3 m2 m1
POWER NETWORK ASSEMBLY
A. Control box - B. Instrument cluster with warning lights - C. Ignition switch - D. Stalk unit - E. Relay/fuse holder Support
- F. Starter motor - G. Earth cables of frame and tail lighting components - H. Battery - I. Alternator
Figure 3 A m6 B C D m7 E F
73720
I H m3 m2 m1 O N M L G
POWER NETWORK ASSEMBLY WITH TELMA SPEED LIMITER
A. Control box - B. Instrument cluster with warning lights - C. Ignition switch - D. Stalk unit - E. Relay/fuse holder Support
- F. Starter motor - G. Earth cables of frame and tail lighting components - H. Battery - I. Alternator - L. Relays -
M. Electromagnets - N. Ground point - O. Ground cable for Telma speed limiter
Base - May 2004 Print 603.93.281

Positive network Figure 4

The battery positive terminal is connected through a 50 mm2
cable to terminal 30 of the starter motor. Two 16 mm2 and
one 6 mm2 cables are also connected to the battery positive
terminal cable. The first two cables are connected to
alternator and interconnection central unit, while the other
cable feeds 60A fuse for pre-heating glow plugs central unit.
At the terminal of the battery positive cable in vehicles with
ABS a 6 mm2 cable connects the 40A fuse that supplies the
ABS electronic control unit.
In the vehicles that are provided with a cab/bonnet cable
preset for various options, a 4 mm2 cable is also connected
to battery positive cable pin; via ultrasound weld, it feeds key
switch, 38-pole diagnosis connector and instrument panel
with warning indicators.
8627
CONNECTIONS TO BATTERY POSITIVE TERMINAL
cardiagn.com
Figure 5
8628
CONNNECTION OF STARTER MOTOR TERMINAL 30

TO BATTERY POSITIVE TERMINAL
Figure 6
8629
POSITIVE NETWORK CONECTION TO ALTERNATOR
Print 603.93.281 Base - May 2004

Figure 7
In the immediate vicinity of the battery, there is the control
box; this has the task of providing the battery + supply,
through internal bridges to the different electric functions of
the vehicle.
A 6 mm2 cable and a 10 mm2 cable are connected to it;
through ultrasonic welds they supply certain components and
part of the fuses and relays located on the support on the
lower left part of the dashboard.
In particular, the components and electric functions supplied
by the 6 mm2 cable are:
- interior lighting, radio-receiver, cigar lighter
- services cut-off relay during starting
- headlamp washer
- 13-pin current socket
8630 - socket for converter
CONTROL BOX AND ITS CONNECTIONS
The 10 mm2 cable supplies:
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Figure 8 - ignition switch (base vehicle)
- stalk unit (exterior lights and hazard warning)
- stop lights
- horns
- EDC switching on relay
- instrument cluster with warning lights
- modus diagnostics enable relay
- heated fuel filter
- climate control system
- door locking
Lastly, a 2.5 mm2 cable can be connected to the control box

which supplies fuse 33 (20A), where applicable, of the
relay/fuse holder support relating to the additional heater
8631
control unit.
RELAY/FUSE HOLDER SUPPORT
Figure 9
15/A 30
50 15
8632
POSITIVE NETWORK CONNECTION TO IGNITION

SWITCH
Base - May 2004 Print 603.93.281

Negative network Figure 11

The battery negative terminal is connected to with a brown
50 mm2 cable to the earth point m1 to be found on the
left-hand side of the crankcase, next to the starter motor.
From this point, two copper braids are connected to earth
points m2 on the front of the left sidemember and m3, on the
bonnet under the vacuum servobrake. At m3 the wirings
concerning the frame and engine are connected. Near m3,
there is another earth point, called ms3 which, through a 2.5
mm2 cable performs the signal earth function for the ABS
electronic control unit.
A 6 mm2 cable also connects the battery cable pin to the
ultrasound weld on which the earth cables of immobilizer
electronic central unit, EDC system function control switch, m1
EDC electronic central unit and diagnosis connector
converge.
cardiagn.com
8622
EARTH POINT ON ENGINE
Figure 10 Figure 12
m2
8623 8624
EARTH POINT ON FRAME EARTH POINT ON LOWER BONNET (m3-ms3)
Print 603.93.281 Base - May 2004

Figure 13
Earth point m4 to which the components concerning the
front and right side lighting, windscreen wiper, windscreen
washer, windscreen washer pump and air cleaner clogged
signal switch are connected, is located in the bonnet near the
right front direction indicator.
Earth point m5 to which the components concerning the left
front lighting and the fuel oil heating device are connected,
is located near the left front direction indicator.
m4
Earth points m6 and m7 are respectively located on the right
and left of the cab, near the upper hinges of the doors. To
these are connected the components in the dashboard (stalk
unit, instruments, warning lights, switches), in the doors,
where applicable (power window switches, motors for power
window/door locking, rear-view mirror aiming) and in the
upper part of the cab (roof lamp, front clearance lights).
8625
Near m7 earth point, there is the ms7 signal earth; from here,
a 1.5 mm2 cable is connected to an ultrasound weld towards
EARTH POINT ON BONNET RIGHT-HAND SIDE which the signal earth cables of cab/bonnet cable electronic
components like steering column stalk and instrument panel
cardiagn.com
Figure 14 with warning indicators for diagnosis converge.
Lastly on the floor panel, next to the handbrake lever, there
is an earth point (ms8) specific for the air bag electronic
control unit.
m5
8626
EARTH POINT ON BONNET LEFT-HAND SIDE

Figure 16
Figure 15
m7
m6
7379 ms7 7380
EARTH POINT ON CAB RIGHT-HAND SIDE EARTH POINT ON CAB LEFT-HAND SIDE
Base - May 2004 Print 603.93.281

Earth points on the vehicle

Figure 17
m6 m7
ms7
m3
ms8
m4 ms3
m3
m5
m1
m2
7390
Earth connection Location Components concerned

Left crankcase Battery negative terminal-connection to
cardiagn.com
m1
earth points m2 and m3
8634
m2 Front part of left sidemember Connection to earth point m1
8635
m3 Lower bonnet Connection to earth point m1 -

ms3 (under vacuum power steering) components on frame and engine -
electronic ABS control unit
8636
m4 Bonnet Fuel oil heating resistance - air cleaner

m5 (near right and left side direction indicator) clogged signal switch - front and side lights
- windscreen washer pump
8637
m6 Cab inner right side Stalk unit - windscreen electric demister

control unit - cigar lighter- ashtray light -
hazard warning light switch - radio-receiver
unit
7395
m7 Cab inner left side Instrument cluster with warning lights -

front clearance lights - headlamp aiming
control - relays on relay/fuse holder support
- interior lighting
7396
ms7 Cab inner left side Instrument cluster with warning lights - stalk
unit - low engine coolant fluid level indicator
control - transmitter for electronic
tachograph
7397
ms8 Centre floor Air bag electronic control unit
8638
Print 603.93.281 Base - May 2004

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.
cardiagn.com
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 18
6616
IDEAL EQUIPOTENTIAL EARTH NETWORK

Ba. Battery - R. Loads - Rz. Frame impedance - M1, M2, M3. Earth
Base - May 2004 Print 603.93.281

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.
cardiagn.com
Figure 19
88039
SCREENING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT

C. Connector - d. Distance ! 0
Print 603.93.281 Base - May 2004

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 20
cardiagn.com
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
Base - May 2004 Print 603.93.281

MAIN COMPONENTS OF POWER

NETWORK 03000
BOSCH KCBI 14V 110A Alternator
Specifications for use

Figure 21
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
cardiagn.com
8649
WIRING DIAGRAM
Figure 22
8656
TECHNICAL VIEW
Print 603.93.281 Base - May 2004

EV 12V - 2.3 kW Starter motor Figure 24

Figure 23 08000
74023 8642
WIRING DIAGRAM PERSPECTIVE VIEW

Figure 25
5
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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 connecĆ Check starter motor and battery conĆ
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 electromaĆ Replace
not start gnet
Pinion disconnected 1. Worn toothed crown Recover
Base - May 2004 Print 603.93.281

Battery
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 (Ref. A of figure).
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 26
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A
73721
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 conĆ 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 connecĆ
tion tightness
Print 603.93.281 Base - May 2004

Ignition switch 52502

Figure 27 Figure 28
30
0
II
50 15/A 15 1171 1125

SWITCHING SEQUENCE
WIRING DIAGRAM 0. Stop - I. Drive - II. Starting
Figure 29
cardiagn.com
0
115º
I
44º
II
15/A 30
50 15
8654
PERSPECTIVE VIEW WITH ASSOCIATED CONNECTIONS AND KEY ROTATION TECHNICAL LAYOUT
Cable colour
Position Under current Live circuit Terminal Function code
0 30 - 30 Supply 7777
I 30 -15 Services 15 Services 8887

30 - 15/A Users
15/A User cut-off relay during 8850
starting
30 - 15 Services
II 30 - 50 Starting 50 8888
Starting
Base - May 2004 Print 603.93.281

Interconnection center
This is a shunt center distributing battery positive power via internal jumpers.
Figure 30
cardiagn.com
8630
PERSPECTIVE VIEW OF THE JUNCTION BOX AND ASSOCIATED CONNECTORS AND THEIR SURFACE WITH
CONTACT BLADES
Figure 31
73722
VIEW OF THE ENGINE COMPARTMENT LOCATION
Print 603.93.281 Base - May 2004

General remote control switch (T.G.C.)

The general remote control switch is installed in vertical position to the vehicle chassis near the battery using special mounting
brackets. The remote control switch closing is controlled by switch 53008 and the associated relay to energize TGC from inside
cab 25226.
Figure 32
cardiagn.com
73717
GENERAL REMOTE CONTROL SWITCH
Base - May 2004 Print 603.93.281

ONBOARD CABLES Figure 33

Components of the injection system (E. 8140)
1. Injector 1
2. Injector retainer screw and bracket 2
3. Injector retainer screw and bracket 3
4. Rail sound-absorbing protection (pressure
accumulator)
4 8
5. High pressure pipe 5 9
6. Pump backflow pipe 6
7. High pressure pump 7
8. Thermal starter supply pipe
9. Fuel outlets unit
COMPONENTS OF THE INJECTION SYSTEM
cardiagn.com
Figure 34
4
Components of the injection system
5
1. Thermal starter supply pipei 1
2. Brackets
6
2
3. Brackets 7
4. Connection pipe with intercooler 3
8
5. Thermal starter
9
6. Piping
7. After warming solenoid valve
8. Intake manifold
9. Boosting air pressure sensor
COMPONENTS OF THE FUEL SUPPLY SYSTEM -

INJECTION
Figure 35
Engine cable
All engine cabling is in one bundle assembly.
In case of need replace the entire bundle assembly and not
individual cables or cable sections.
CABLE ON ENGINE
Print 603.93.281 Base - May 2004

8140.43C ID/TCA (.11) ENGINE HARNESS

Figure 36
cardiagn.com
74002
Base - May 2004 Print 603.93.281

Figure 37
WELDING 8140.43C
cardiagn.com
74003
Component
Description
code
00000 Ground
03000 Self-rectifying alternator with incorporated voltage regulator
08000 Starter motor
12012 A/C compressor
19005 Thermostarter
28002 Engine shutdown solenoid
42550 Engine oil low pressure indicator switch
44044 Low engine oil level indicator control
47030 Transmitter for engine water temperature thermometer
47104 Engine cooling electromagnetic coupling
47105 Diesel oil heating switch
47109 Spark advance variator switch (KSB)
48035 RPM sensor
61103 Variable resistance for spark advance variator (KSB)
70066 40A one-way fuse holder
72030 Engine service harness connector to cab/hood harness
78000 Solenoid valve for fuel tank connection to atmosphere
85022 Electromagnetic coupling for engine cooling
86011 Pre-post-heating electronic control unit
Print 603.93.281 Base - May 2004

8140.43S UNIJET (.13) ENGINE HARNESS

Figure 38
cardiagn.com
74008
Base - May 2004 Print 603.93.281

Component code Description

00000 Ground
03000 Self-rectifying alternator with integrated voltage regulator
08000 Starter motor
72030 Engine service harness connector to cab/hood harness
78000 Solenoid valve for fuel tank connection to atmosphere
cardiagn.com
Print 603.93.281 Base - May 2004

INJECTION CABLE - V.G.T (.15)

Figure 39
cardiagn.com
I
74010
Base - May 2004 Print 603.93.281


85150 EDC center
I Connection to hood cab cable
47035 Coolant temperature sensor
78015 Radialjet pump control electro valve
85157 Fuel pressure sensor
78247 Electrical injection electro valve
48042 rpm sensor on distributor
78013 Pressure adjustment electro valve
47106 Fuel heat on switch
85156 EDC blower air pressure sensor
61101 Fuel heat resistor
cardiagn.com
Print 603.93.281 Base - May 2004

F1A UNIJET (.10 - .12) ENGINE HARNESS

Figure 40
cardiagn.com
74267
Base - May 2004 Print 603.93.281


00000 Ground
08000 Starter motor
C1 Engine service harness connector to cab/hood harness
cardiagn.com
Print 603.93.281 Base - May 2004

37/1 ELECTRIC/ELECTRONIC SYSTEM DAILY
F1A UNIJET WITH EDC16 (.10 - .12 - .14) ENGINE HARNESS

Figure 40/1
cardiagn.com
101861
Revi - February 2005 Print 603.93.281/A

DAILY ELECTRIC/ELECTRONIC SYSTEM 37/2

08000 Starter motor
cardiagn.com
Print 603.93.281/A Revi - February 2005

F1C UNIJET WITH EDC16 (.10 - .12 - .14) ENGINE HARNESS

Figure 40/2
cardiagn.com
101862


08000 Starter motor
42608 Three-level pressure switches
C60 Three-level pressure switch cable joint with cabin/hood cables
cardiagn.com

INJECTION CABLE - F1A (.10 - .12) WITH AND WITHOUT EGR

Figure 41
cardiagn.com
74268
Base - May 2004 Print 603.93.281


85150 EDC center
D 85156 EDC blower air pressure sensor
19010 Preheat plug
25231 Plug insert centre
70064 1-way fuse holder
cardiagn.com
* 85159 Environment air temperature and pressure sensor for EDC
* 78209 EGR electro valve
D Without EGR
* With EGR
Print 603.93.281 Base - May 2004

TRUCK CHASSIS CABLE

Figure 42
cardiagn.com
74017
Base - May 2004 Print 603.93.281

Figure 43
WELDING
cardiagn.com
74018
Component
Description
code
22000 Horn
34000 Multifunctional rear floodlight
35000 License plate light
40032 Transmitter for tachometer and tachograph
42351 Air filter clogged sensor
44031 Fuel oil level indicator transmitter with contact for min. level indicator
44033 Brake fluid low indicator control
47106 Diesel olio heating switch
53503 Backup light switch
61101 Diesel oil preheating resistor
85151 EDC injection pump
86002 Front wheel pad wear indicator sensors
86003 Rear wheel pad wear indicator sensors
86012 Water-in-fuel-filter indicator sensor
C2-C4 Chassis harness connector to cab/hood cables
C3 Chassis harness connector to side clearance lights
M2 Ground
Print 603.93.281 Base - May 2004

A.B.S. PARALLEL CABLE

Figure 44
cardiagn.com
74015
Base - May 2004 Print 603.93.281

Figure 45
WELDING
cardiagn.com
74016
Component
Description
code
70060 40A one-way fuse holder
72048 Cab-hood harness to ABS harness connector
88000 ABS electronic control unit
88001 ABS sensor
Print 603.93.281 Base - May 2004

AIR-BAG CABLE WITH ONE-CONNECTOR CONTROL UNIT

Figure 46
II
cardiagn.com
74021
Base - May 2004 Print 603.93.281


86060 AIRBAG control unit
86061 Passenger airbag ć Driver airbag
86062 Passenger pretensioner ć Central pretensioner ć Driver pretensioner
II Dashboard harness connector
cardiagn.com
Print 603.93.281 Base - May 2004

AIR-BAG CABLE WITH TWO-CONNECTOR CONTROL UNIT

Figure 47
II
cardiagn.com
74022
Base - May 2004 Print 603.93.281


86060 AIRBAG control unit
86061 Passenger airbag ć Driver airbag
86062 Passenger pretensioner ć Central pretensioner ć Driver pretensioner
II Dashboard harness connector
cardiagn.com
Print 603.93.281 Base - May 2004

VAN INTERIOR DOME LAMP CABLES 1/2
Figure 48
cardiagn.com
74012
Base - May 2004 Print 603.93.281

Figure 49
WELDING 1/2
cardiagn.com
Component
Description
code
C12 Cab-hood harness to dome lamp harness connector
C15 Dome lamp connectors to slide door bridle
C16 Dome lamp connectors to electrical lock contacts
37001 Front clearance lamp
39022 Interior door lamp with adjustable spot
39026 Side door lighting dome lamp
42102 Parking brake on indicator switch
53509 Interior lighting switch
Print 603.93.281 Base - May 2004

VAN INTERIOR DOME LAMP CABLES 2/2

Figure 50
cardiagn.com
CHASSIS HARNESS CONNECTOR TO REAR DOME LAMP HARNESS
74013
Base - May 2004 Print 603.93.281

Figure 51
WELDING 2/2
cardiagn.com
74014
Component
Description
code
37002 Rear clearance lamp
39025 Liftgate lighting dome lamp
C11 Chassis harness connector to rear dome lamp harness
Print 603.93.281 Base - May 2004

TRUCK INTERIOR DOME LAMP CABLES

Figure 52
cardiagn.com
74019
Base - May 2004 Print 603.93.281

JUNCTION CONNECTORS
Connection between cab/bonnet cable and injection cable (Unijet)
Figure 53
8587
I F1A
cardiagn.com
I 8588 0000 0077
7740 8159 7740 8159

8159
5577 9990 0000
5577 5000
7740 1311
8150 1310
8150 0077 0077 8150 8847 8150
5577
9990 0000 0000 9990
8589
74269
Cable colour
Ref. Ref. (F1A) Function
code
1 5000 To pin 36 of EDC electronic control unit
2 3 8150 Fuel pump engagement relay
3 4 7740 Relay engagement for engine cooling electromagnetic joint control
4 5 9990 Air conditioning compressor switching off
I 5 6 8159 Fuel oil heating circuit switching on
6 8 0000 Earth
7 1 5577 Fuel oil heating resistance supply
8 16 0077 Fuel oil heating resistance earth
10 8150 Preheat plug centre positive (pin-86)
11 1310 Preheat plug centre control (pin-D1), (EDC pin-B37)
12 1311 Preheat plug centre control (pin-ST), (EDC pin-B42)
13 0000 Preheat plug centre mass (pin-31)
2 8847 Speed adjustment sensor positive
7 - Free
9 - Free
14 - Free
15 - Free
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and air bag cable
Figure 54
8587
cardiagn.com
8590
II
2292 8087 S BR
6711 6722 AR G
0000 6750 AR HN
8591
Cable colour
Ref. Function
code
1 6722-AR Supply (+15)
2 6750-AR Supply (+15)
3 8087-S Supply (+15) for air bag electronic control unit
II 4 2292-BR To diagnostic connector
5 0000-HN Earth
6 6711-G To air bag failure warning light
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and rear differential lock cable

Figure 55
8587
cardiagn.com
III
8592
7777 7777
2222 6660 6660 2222
8879 3400 3400 8879
8593
Cable colour
Ref. Function
code
1 2222 Tachometric signal
2 8879 Supply (+15)
3 7777 Supply (+30)
III 4 - Spare
5 3400 Rear differential lock engagement
6 6660 To rear differential lock on warning light
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and cable for tachometer

Figure 56
8587
cardiagn.com
B
7772 0000
0000
5156
D
5517
8594
0058
5517
5517
5516
2300
2400
8596
8595
Cable colour
Ref. Function
code
1 7772 Supply (+30)
2 - Spare
3 5156 Supply (+15)
40011A 4 - Spare
(white) 5 0000 Earth
6 0000 Earth
7 - Spare
8 - Spare
1 5517 Supply (+15)
2 0058 Earth
40011B 4 5516 To transmitter for tachometer
(yellow) 5 - Spare
6 - Spare
7 - Spare
8 - Spare
1 - Spare
2 - Spare
3 - Spare
40011D 4 2400 To instrument cluster with warning lights
(brown) 5 - Spare
7 2300 To instrument cluster with warning lights
8 - Spare
Base - May 2004 Print 603.93.281

Connection between frame cable and right tail lamp cable
Figure 57
8597
cardiagn.com
72025A
2283 0003
0003 2283 8598
4418 0000 0000 4418

8599
Cable colour
Ref. Function
code
1 2283 Rear fog guard
2 0000 Earth
72025A
3 4418 Rear roof lamp supply
4 0003 Switching on interior lights
Print 603.93.281 Base - May 2004

Connection between frame cable and right tail lamp cable
Figure 58
8597
cardiagn.com
8600
72025B
1125 2227 1125

2227
1172 3335 3335 1172

8601
Cable colour
Ref. Function
code
1 1125 Direction indicator
2 1172 Stop light
72025B
3 3335 Side light
4 2227 Reversing light
Base - May 2004 Print 603.93.281

Connection between frame cable and left tail lamp cable
Figure 59
8597
cardiagn.com
72026A
8602
2283 2283
2227 0000
0000 2227
8603
Cable colour
Ref. Function
code
1 2227 Reversing light
72026A 2 2283 Rear fog guard
3 0000 Earth
Print 603.93.281 Base - May 2004

Connection between frame cable and left tail lamp cable
Figure 60
8597
cardiagn.com
72026B 6804
1177
1177
1120 3334
3334 1120
8605
Cable
Ref. Function
colour code
1 1120 Direction indicator
72026B 2 1177 Stop light
3 3334 Side light
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and roof lamp cable inside cab
Figure 61
8587
72031
cardiagn.com
8608
3339 3339
6662 3330 3330 6662
4418 4418
0000 0000
0000 0003
9074 8904 8904

0205
9074 8903 8903 0204
8609
Cable
Ref. Function
colour code
1 4418 Supply (+30)
2 3330 Left front clearance light
3 3339 Right front clearance light
4 - Spare
5 6662 Handbrake on signal
6 0000 Earth
72031
7 8904 To motor for side door closing control (van)
8 8903 To motor for side door closing control (van)
9 9074-0204 To switch for turning on interior lights (van)
10 9074-0205 To switch for turning on interior lights (van)
11 - Spare
12 0000-0003 Turning on roof lamp
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and 13 pin current socket cable or rear door
opening/closing cable (van)
Figure 62
8587
cardiagn.com
72032A
8612
7777 7777 7777 7777
8901 8881 8881 8901
8902 1386 6120 8902
8593
Cable
Ref. Function
colour code
1 8901 To pin 8 connector A of electronic control unit for central door locking
2 8902 To pin 7 connector A of electronic control unit for central door locking
72032A 3 7777 Supply (+30)
4 7777 Supply (+30)
5 1386-6120 Trailer direction indicator on signal
6 8881 Supply (+15)
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and brake wear/air cleaner clogged cable
Figure 63
8587
cardiagn.com
72036
8598
8016 6663
6663 8016
8016 0000
0000 8016
8601
8599
Cable
Ref. Function
colour code
1 8016 Brake wear signal
2 8016 Brake wear signal
72036
3 0000 Earth
4 6663 Air cleaner clogged signal
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and self-levelling suspension cable

Figure 64
8587
cardiagn.com
72037A 8592
1194 7772 1194

7772
8090 2294 2294 8090
8091 8420 8420 8091
8593
Cable
Ref. Function
colour code
1 8090 Supply (+15)
2 8091 To pin 26 of electronic control unit for vehicle raising/lowering control
3 1194 To 38-pin diagnostic connector (cell 15)
72037A
4 7772 Supply (+30)
5 8420 Suspension levelling control
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and self-levelling suspension cable
Figure 65
8587
cardiagn.com
72037B
8612
6008 1363 1363 6008
5411 5411
8613
Cable
Ref. Function
colour code
1 6008 Self-levelling suspension system failure signal
72037B 2 5411 Tachometric signal
3 1363 Positive with vehicle stop signal switch engaged
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and total power takeoff cable

Figure 66
8587
cardiagn.com
72038A 8592
9135 9136 9136 9135
9133 0057 0057 9133
9134 0056 0056 9134

8593
Cable
Ref. Function
colour code
1 9133 To electronic control unit for switching on total power takeoff (connector P2 cell 3)
72038A
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and total power takeoff cable

Figure 67
8587
cardiagn.com
72038B 8612
9131 9131
0000 0000 8613
Coble
Ref. Function
colour code
1 9131 To switch for total power takeoff engaged signal
72038B 2 0000 Earth
3 - Spare
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and antitheft cable

Figure 68
8587
cardiagn.com
72039A 8608
9070 8879 4442 0200
1545 8914
7741 8911
8912 8912
0000 8913 0000

8913
8916 8915 8915 8916

8609
Cable
Ref. Function
colour code
1 7741-8911 Supply (+30)
2 - Spare
3 8879-4442 Supply (+15)
4 9070-0200 To switch for locking rear door (van)
5 1545-8914 To volumetric sensor
72039A 6 8912 To volumetric sensor
7 8913 To volumetric sensor
10 0000 Earth
11 - Spare
12 - Spare
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and antitheft cable with central door locking
Figure 69
8587
cardiagn.com
72039B 8592
8910 9141
8909 9073 9142 9140
0000 0000
8593
Cable
Ref. Function
colour code
1 8909-9140 Supply (+15)
2 0000 Earth
3 8910-9141 Supply (+30)
72039B
4 - Spare
5 - Spare
6 9073-9142 To self-powered siren for alarm
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and right door cable

Figure 70
8587
cardiagn.com
8614
72040
8859 8002 8862 0000 0026 8809
8857 8830 0000 8806

0000
8858 8861 8861 8808
8906
8906
8905 1111 0000 8905
0000 8615
Cable
Ref. Function
colour code
1 8861 Supply (+15/A)
2 0000 Earth
3 8862-0000 Connection between switches for passenger's door power window
4 8002-0026 Connection between switches for passenger's door power window
5 8830 Heated rear-view mirror
6 - Spare
7 8859-8809 Electrically-operated aimable mirror
72040 10 - Spare
11 1111 To connection between cab/bonnet cable and left door cable
12 0000 Earth
13 - Spare
14 - Spare
15 8905 To door closing control motor
17 - Spare
18 - Spare
19 - Spare
20 - Spare
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and left door cable

Figure 71
8587
cardiagn.com
8614
72041
0000 0000
8859 8002 8862 8862 8002 8809
8857 8830 8861 8861 8830 8857
8858 8829 8829 8858
8906 0026 0026 8906

8905 1111 0000 8905
5532 5532 5532 5532
0000
8615
Cable
Ref. Function
colour code
1 8829 Supply (+15)
2 8861 Supply (+15/A)
3 8862 Connection between switches for passenger's door power window
4 8002 Connection between switches for passenger's door power window
5 8830 Heated rear-view mirror
6 0000 Earth
8 8857 Electrically-operated aimable mirror
9 8858 Electrically-operated aimable mirror
10 0026 Earth
72041
11 1111 To connection between cab/bonnet cable and left door cable
12 0000 Earth
13 5532 To outside temperature sensor
14 5532 To outside temperature sensor
17 - Spare
18 - Spare
19 - Spare
20 - Spare
Print 603.93.281 Base - May 2004

Connection between cab roof lamp and left front clearance light cable
Figure 72
8587
cardiagn.com
72042A
8616
3330 0000 0000 3330
8617
Cable
Ref. Function
colour code
1 0000 Earth
72042A
2 3330 Front clearance light
Base - May 2004 Print 603.93.281

Connection between cab roof lamp and right front clearance light cable
Figure 73
8587
cardiagn.com
72042B
8616
3339 0000 0000 3339
8617
Cable
Ref. Function
colour code
1 0000 Earth
72042B
2 3330 Front clearance light
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and fog lamp cable

Figure 74
8587
cardiagn.com
8618
72043
2228 0000 0000 2228
8619
Cable
Ref. Function
colour code
1 0000 Earth
72043
2 2228 Fog lamps
Base - May 2004 Print 603.93.281

Connection between right tail light cable and rear roof lamp cable
Figure 75
8587
cardiagn.com
8590
72046
1125 0000 0000
0000 0003 0003 0000
1172 4418 4418 1172

8591
Cable
Ref. Function
colour code
1 0003 Switching on roof lamp
2 4418 Supply (+30)
72046 3 0000 Earth
4 1125 Positive with direction indicators/hazard warning lights on
5 1172 Additional stop light
6 0000 Earth
Print 603.93.281 Base - May 2004

Connection between frame cable and side clearance lights cable

Figure 76
8597
cardiagn.com
72047 8602
3334 3334
0000 3335
3335 0000
8603
Cable
Ref. Function
colour code
1 0000 Earth
72047 2 3334 Vehicle right side clearance lights
3 3335 Vehicle left side clearance lights
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and ABS cable

Figure 77
8587
cardiagn.com
72048A 8612
2888 1888 8818 8817
8613
Cable
Ref. Function
colour code
1 2888-8817 To 38-pin diagnostic connector (cell 4)
72048A 2 - Spare
3 1888-8818 To 38-pin diagnostic connector (cell 3)
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and ABS cable

Figure 78
8587
cardiagn.com
72048B 8592
0315 6005 6674 0315
8847 6670 6670 8847
1173 6673 6673 1173
8593
Cable
Ref. Function
colour code
1 8847 Supply (+15)
2 1173 Positive with switch for vehicle stop engaged signal
3 0315 Switching off retarder
72048B
4 6005-6674 ABD device on signal
5 6673 EBD device failure signal
6 6670 ABS device failure signal
Base - May 2004 Print 603.93.281

Connection between cab/bonnet cable and climate control system cable
Figure 79
8587
cardiagn.com
82010A
8592
0000 7551
R M
7711 5532 CN R
4411 5532 C H
Cable
Ref. Function
colour code
1 7551-R Supply (+30)
2 4411-H Positive with side lights on
3 0000-M Earth
82010A
4 7711-R Supply (+15/A)
5 5532-C Outside temperature detection
6 5532-CN Outside temperature detection
Print 603.93.281 Base - May 2004

Figure 80
8587
cardiagn.com
82010B 8612
8163 5532 G L
8613
Cable
Ref. Function
colour code
1 8163-L To set of 3 switches for coolant fluid pressure signal
82010B 2 - Spare
3 5532-G To instrument cluster with warning lights (connector B pin 11)
Base - May 2004 Print 603.93.281


Figure 81
8587
cardiagn.com
8604
82010C
0000
0000
1196 2296
2296 1196
8605
Cable
Ref. Function
colour code
82010C 2 Ċ Spare
Print 603.93.281 Base - May 2004

VENDOR-DERIVED BUS VERSION Figure 82

General Information
Within this handbook, school-buses are included in the Bus
version. If compared to other vehicles, Buses are provided
with different interior lighting harness.
The TGC switch position on dashboard panel is shown in the
Push-button location Figure 82 while the main switch is
located in the engine compartment near the oil filter
(Figure 83). To turn the TGC off, turn the ignition key-switch
to STOP and turn off the general safety switch 52029
Figure 84 ref. 1, on the left of the steering wheel.
A perspective view of the interior lighting harness is provided
in Figure 85.
Figure 84 ref. 2 shows the fan control switch.
73728
TGC CONTROL SWITCH
cardiagn.com
Figure 83
73717
VOLTAGE MAINS REMOTE SWITCH
Figure 84
1 2
73712
1. General safety switch - 2. Fan control switch
Base - May 2004 Print 603.93.281

Perspective view of Vendor-derived Bus version interior lighting harness
Figure 85
cardiagn.com
73716
1. Interior lighting - 2. Driver loudspeaker provisions - 3. Fan
Print 603.93.281 Base - May 2004

Diagnostic connector Figure 86

Near the positive terminal of the battery there is a diagnostic
connector. It is fastened by 2 screws to a special bracket fitted
on the body and access to it is gained by unscrewing the
protective cap; suitably connected to the diagnostic system
(IWT, MODUS), it allows quick identification of the cause of
faults in the various electronic devices.
The diagnosis connector on F1 engine vehicles is located on
the conveyor unit lower party on the passenger side.
The table on the following page shows the correspondence
between the various electronic systems and the connector
pins referring to them.
NOTE The connector shown is seen from the pin side.
cardiagn.com
8620
38-PIN DIAGNOSTIC CONNECTOR
Figure 87
9
3 16
22
29
1 35
4 38
10
17
23 36
30
8621
DENTIFICATION OF THE PINS OF THE 38-PIN

DIAGNOSTIC CONNECTOR
Base - May 2004 Print 603.93.281

System Pin Function
EDC/EGR/Methane 1 L
2 K
ABS/EBD/ABD 3 L
4 K
Air Bag/Retarder 6 K
Tachometer (connector A cell 2 instrument cluster) 8 K
Supply +15/A services 11 Input
Immobilizer/Central door locking/Alarm 12 K
Climate control system 13 L
14 K
Self-levelling suspension 15 L
16 K
cardiagn.com
Engine timing signal (connector B pin 28 EDC control unit) 23 -
Engine timing earth (battery -) 24 Screening
Supply +30 27 Battery +V
Engine rpm 28 RPM
Vehicle speed 29 -
Earth 30 -
- With EDC16: pins 1/23 are not connected.

- Can Line pin 21/22.
The unused pins are not indicated.
Print 603.93.281 Base - May 2004

RELAY AND FUSE HOLDER SUPPORT

Figure 88
cardiagn.com
8631
52
Base - May 2004 Print 603.93.281

Identification of fuses
N
N. F
Functions
1. Additional heater 30
2. Immobilizer/Warming/EDC 5
3. - -
4. Instrument cluster (+30) 5
5. Instrument cluster (+15) 5
6. Stalk unit (rear fog guard, flasher) 5
7. Stalk unit (low beams) 10
8. Stalk unit (high beams) 15
9. Stalk unit (side lights) 15
10. Windscreen wiper 15
11. Stalk unit (direction indicators/hazard warning lights) 15
12. Stalk unit (horns) 15
13. Reversing light 5
14. Side light, clearance, no. plate light 5
15. Side light cluster lighting 5
16. Left low beam headlamp 10
17. Right low beam headlamp 10
cardiagn.com
18. Left high beam headlamp 10
19. Right high beam headlamp/headlamp aming 10
20. Interior lighting/radio/cigar lighter 10
20. Interior lighting/radio 10
21. Electric windscreen defrosting unit 30
21. Cigar lighter 15
22. Heated fuel filter 15
23. EDC electronic control unit 25
24. EDC 10
25. Stop lights 5
26. 13-pin current socket 15
29. 38-pin diagnostic connector 5
30. Fog lamps 10
31. Climate control, additional heater, engine cooling 5
31. Compressor, timer, engine fan 10
32. Climate control 5
33. Additional heater 20
34. Headlamp washer 20
35. Rear differential lock 5
36. ABS, EBD, ABD failure warning light 5
37. ABS 5
39. Heated mirrors 10
39. Heated mirrors, heated rear-screen, heated windscreen 15
40. Power windows 30
40. Power windows (left) 20
10/
41. Heated rear-screen, heated windscreen
20
42. Self-levelling suspensions 5
43. Air bag failure warning light 5
44. Self-levelling suspensions (Wabco) 40
45. Air-bag 5
46. - -
46. Power windows (right) 20
47. Electric fuel pump 10
48. Door locking/alarm 30
49. Door locking/alarm 5
50. Rear differential lock 30
51. Total power takeoff 10
52. Front differential lock (4x4) 30
53. Self-levelling suspensions Techniek) 30
54. Electric hatch (van and 6+1) 15
55. Rototranslating door 15
Print 603.93.281 Base - May 2004

Identification of relays/diode holders

Code Function
25035 Switching on external lights
25003 Switching on fog lamps
25006 Switching on stop lights
25704 Total power takeoff engagement control
25104 Switching off Retarder with ABS on
25209 Loads cut-off during starting
25222 Thermal starter engagement enable
25223 Thermal starter fan control
25307 Climate control compressor engagement
25336 Engine cooling
25337 Climate control compressor disengagement
25340 Compressor on signal
25620 Fuel filter clogged signal
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25705 Diagnostics enable
25810 Heated fuel filter circuit control
25811 Advance variator control (KSB)
25818 Heated windscreen switching on
25837 Electric fuel pump switching on
25858 EDC switching on
25926 Suspension raising enable
25927 Suspension lowering enable
25928 Rear-screen heating switching on
61002A Anti-return from Trinary
61002B Anti-return from TGC (bus)
66010 Timer for headlamp washer
Fuse 39 must be replaced with a 10A fuse if the following optionals are present on the vehicle at the same time:
! - heated wing mirrors with heated driver's seat;
- heated wing mirrors with heated driver's and passenger's seat;
- heated wing mirrors with electric aiming with heated driver's seat;
- heated wing mirrors with electric aiming with heated driver's and passenger's seat.
Fuse 41(39 for F1A) must be replaced with a 15A fuse if the following optionals are present on the vehicle at the
same time:
- heated windscreen with heated rear-screen.
Fuse 55 must be replaced with a 15A fuse if both the seats are heated.
Fuse 70060 (40A) relating to the ABS, device is located in the engine compartment, near the control box.
For the F1A, plug preheat centre 25231is located on the engine compartment to the right of the EDC centre and
is powered by 60A fuse 70064.
The previous indications (fuses/remote control switches) can be changed. Should it occur, make reference to the indications
on the sticker label next to the fuses.
Base - May 2004 Print 603.93.281

OPTICAL INDICATORS Figure 89

A table is shown below with pin out 58918 in 4-connector
version, as well as a 2-connector version one.
1 2 1 2 1 2
D6 B5 * B15 A2 B3 B156
C20 A5 B2 A17 B1 A22
B17 A29 B12 A18 B10 A21
B16 A14 C8 A4 C5 B26
B6 A30 * B4 A3 A1 A23
B8 A32 * B14 A19 C4 B24
B9 A16 A2 A6 A3 A7
B20 A15 C18 B14 C13 B27
C19 B13 A8 A11 C3 B25
C10 B15 D3 B29 B11 B2
A4 A8 B19 A13 C14 B1
A10 A9 D9 B30 C9 B23
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A9 A10 D12 B9
A11 A24 B18 A12
A12 A25 C11 B11
A5 A26 C15 B22 1 2
D8 B3 C12 B21 * B4 A19
D4 B4 D1 B6 * B14 A2
C1 B12 A6 A27 * B15 A3
D11 B10 D10 B8 * Variant for verĆ
B5 A20 D2 B7 sions
i .11/.13/.15.
11/ 13/ 15
B13 A1 D5 B31
C6 B18 C2 B32
C7 B20 A7 A28
C16 B19 B7 A31
C17 B17 D7 B28
74024
058918 PIN OUT OF THE PREVIOUS VERSION
Print 603.93.281 Base - May 2004

Interface bride with the new tool with 32-way connectors

Figure 90
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77025
1 2
Blue Green
0742528t
REAR VIEW OF 32-WAY CONNECTOR UNIT

1. Blue colour seat A" for 32-way female holder connector complete with terminals
2. Blue colour seat B" for 32-way female holder connector complete with terminals
Base - May 2004 Print 603.93.281

INSTRUMENT CLUSTER
Warning lights assembly
Figure 91 58918
1 2 3 4 5 6 7 8 9 10 11 12
21 31
13 14 23 24
15 30 25
20
26
22
19 16 29
18 17 28 27
33
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34
8655
Component
Ref. Description
code
1 58706 Rear fog guard
2 58002 High beam headlamps
3 58732 Side lights
4 58708 Hazard warning lights
5 58707 Tractor direction indicators
6 58709 Trailer direction indicators
7 58700 No battery charge
8 58718 Brake system failure (under TEST)
9 58722 Low engine oil pressure
10 58730 Low engine oil pressure (under TEST)
11 58719 Handbrake on (under TEST)
12 58728 Low power steering fluid level (under TEST)
13 58710 Water in fuel filter (under TEST)
14 58725 Air cleaner clogged (under TEST)
15 58701 EDC failure
16 58702 Engine warming
17 58734 EBD failure
18 58703 ABS failure
19 58713 ECAS failure
20 58735 Rear transversal differential lock
21 58720 Low engine coolant fluid level (under TEST)
22 58704 ABD on
23 58721 High gearbox oil temperature (under TEST)
24 58723 Emergency handle lock (under TEST)
25 58733 EGR failure
26 58717 Immobilizer engaged
27 58731 Seat heating
28 58724 Door open indicator
29 58705 Airbag failure
30 58715 Total power takeoff (PTO) on
31 58714 Emergency handle activated (under TEST)
32 58711 Retarder on
33 44031 Low fuel level (under TEST)
34 47207 High engine coolant fluid temperature (under TEST)
Print 603.93.281 Base - May 2004

Instrument assembly
Figure 92
1 2
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9 8 7 6 5 4
8655
Ref. Description
1 Electronic tachometer
2 Electronic gyrometer
3 Engine coolant fluid temperature gauge with incorporated warning light
4 Instrument lighting adjustment button
5 Trip meter reset button
6 Display for: clock, outside temperature (only with climate control), total odometer (km), trip meter (km)
7 Clock adjustment button (minutes)
8 Clock adjustment button (hours)
9 Fuel level gauge with reserve warning light
Base - May 2004 Print 603.93.281

Rear view
Figure 93
4 1
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3 2
8643
Ref. Description
1 Seat "A" for 12-way, blue, female holder connector complete with terminal
2 Seat "B" for 20-way, blue, female holder connector complete with terminal
3 Seat "C" for 20-way, black, female holder connector complete with terminal
4 Seat "D" for 12-way, black, female holder connector complete with terminal
Print 603.93.281 Base - May 2004

Connector assembly (cable input side view)

Connector A
Figure 94
8643
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2400 5520
5595 6663
2300 5530
2287
2285
4411 1123
1114 1129
A 8644
Cable
Ref. Function
colour code
1 2400 Tachograph failure warning light
2 5595 To cell 8 of diagnostic connector (serial line K)
3 2300 Speed indication from tachograph
4 4411 Side lights on warning light
5 1114 Hazard warning lights on warning light
6 5520 Low engine coolant fluid level warning light
7 6663 Air cleaner clogged warning light
A
8 5530 Water in fuel oil filter warning light
9 2287 Rear fog guard on warning light
10 2285 High beam headlamps on warning light
11 1123 Direction indicators on warning light
12 1129 Direction indicators on warning light
Base - May 2004 Print 603.93.281

Connector B
Figure 95
8643
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5517 0058
5614 5532
5584 5155
0000 2222
2222
8150-5553
0000 5156
6673 6660
6670 6008
6659 6674
8645
B
Cable
Ref. Function
colour code
2 5614 Rev counter signal
3 - -
4 5584 To cell 28 of diagnostic connector (engine rpm repeater)
5 0000 To pin 14 of connector B of electronic control unit for EDC
6 0000 Earth for warming on warning light
7 6673 EBD Failure warning light
8 6670 ABS failure warning light
9 6659 Supply (+15) for ABD, ABS and EBD failure warning lights
10 0058 To electronic tachometer transmitter
B 11 5532 To pin 2 of connector B of air conditioning system electronic control unit
12 - -
13 5155 To pin 4 of connector B of EDC electronic control unit (tachometric signal repeaer)
14 2222 Tachometric signal repeater for rear differential lock
15 2222 Tachometric signal repeater
16 8150 Positive for EDC failure and warming on warning lights (Unijet)
5553 Positive for warming on warning light
17 5156 EDC failure warning light
18 6660 Rear differential lock warning light
19 6008 Self-levelling suspension system failure warning light
20 6674 A.S.R. pilot lamp
Print 603.93.281 Base - May 2004

Connector C
Figure 96
8643
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7778 0000
6722
6711 4411
8879 8888
7772
5556
0000 5555
5552 5557
5506 5528
6770 9075
8646
C
Cable
Ref. Function
colour code
1 - Retarder on warning light (bus)
2 9075 Door open warning light
3 5528 Engine coolant fluid temperature gauge
4 5557 Fuel level gauge
5 5555 Fuel reserve warning light
6 8888 Supply (+50)
7 4411 Positive with exterior light switch on
8 - To pin A1 of radio receiver set
9 0000 Connection to signal earth ms7
10 - Fog lamp pilot lamp
C
11 6770 Sensor for immobilizer on signal
12 5506 Low engine oil level sensor
13 5552 Engine coolant fluid high temperature warning light
14 0000 Earth
15 5556 Low engine oil level sensor
16 7772 Supply (+30)
17 8879 Supply (+15)
18 6711 Air bag failure warning light
19 6722 Supply (+15) for air bag failure signal
20 7778 Supply (+15) for battery charge failure warning light
Base - May 2004 Print 603.93.281

Connector D
Figure 97
8643
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6660
5583
1386 5525
8016 6662
7778 5503
8647
D
Cable
Ref. Function
colour code
1 5503 Low engine oil pressure warning light
2 6662 Handbrake engaged warning light
3 5525 Low power steering fluid level warning light
4 - -
5 - Rotary translating door failure warning lamp (bus)
6 7778 Battery charge failure warning light
D
7 8016 Brake failure warning light
8 1386 Trailer direction indicators on warning light
9 - Handle lock pilot lamp
10 - -
11 5583 EGR failure warning light
12 6660 Total power takeoff (PTO) on warning light
Print 603.93.281 Base - May 2004

SWITCH ASSEMBLY
All the switches and push buttons of this module incorporate a warning led.
Figure 98
CARRIAGE - VAN - MIXED
VENDOR
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PERSONS-VENDOR
COMBI
GOODS-SHIELDED
74271
Base - May 2004 Print 603.93.281

Legend
Vehicles
Position Function CARRIAGE - VAN - MIXED
Standard Optional
1 Emergency lights X
2 Fog lights X
3 Heated rearview mirrors X
4 Rear glass X
5 Rear differential lock X
6 Level compressed air suspension X
7 Lower compressed air suspension X
8 Lift compressed air suspension X
9 Electrical manhole opens X
10 Electrical manhole closes X
11 Heated windshield X
12 Light washer X
13 Cap
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14 Rear door lock X
15 Speed limiter adjustment X
16 Cap
VENDOR PERSONS-VENDOR GOODS-SHIELDED
2 Fog lights X
4 Rear glass X
5 Air heating X
12 Light washer X
13 Rotary travel holder X
14 Rear door lock X
16 Battery sectioner reset X
COMBI
2 Fog lights X
4 Rear glass X
5 Air heating X
12 Light washer X
13 Cap
14 Rear door lock X
16 Cap
Print 603.93.281 Base - May 2004

STALK UNIT
54032
Figure 99
C D
E F A
G
B
WIRING DIAGRAM
8651
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A. Exterior light switch - B. Rear fog guard button - C. Direction indicator switch -
D. High beam headlamp/flasher switch - E. Windscreen wiper switch - F. Windscreen washer pump button -
G. Horn button
Base - May 2004 Print 603.93.281

Figure 100
8640
2201 2201 0000 7728

0000 2284
3333 2200 1123 2283
3333 2200 1129 2283
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8881 8886 1116
8882 8873 9071 7774
8879
P2 7728
P1 8641
TECHNICAL VIEW OF COMPONENT AND CONNECTORS OF CAB/BONNET CABLE TO BE CONNECTED TO

STALK UNIT
Cable
Ref. Function
colour code
1 - -
2 Input from alarm 9071
3 Input from hazard warning lights 7728
4 Supply (+30) for horn button 7774
5 Horns 1116
P1 6 Left-hand direction indicator 1129
((Black)) 7 Right-hand direction indicator 1123
8 Signal earth 0000
9 Positive with fog lights on 2284
10 Supply (+30) for direction indicators and hazard warning lights 7728
11 Rear fog guard and rear fog guard on warning 2283
12 Supply (+15) 2283
1 Windscreen wiper first speed 8881
2 Windscreen wiper second speed 8882
3 Supply (+15/A) for windscreen wiper 8879
4 Windscreen wiper reset input 8873
5 Electric pump for windscreen washer 8886
P2 6 Supply (+30) for side lights switch 3333
((Blue)) 7 Side lights 3333
8 Supply (+15/A) for switching on low beam headlamps 2201
9 Power earth 0000
10 Low beam headlamps 2201
11 Supply (+15/A) for switching on high beam headlamps 2200
12 High beam headlamps 2200
Print 603.93.281 Base - May 2004

Functions
Figure 101
C
E
A B
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7409
EXTERIOR LIGHTING KNURLED RING ROTATION

SECTION F-F
REAR FOG GUARD KNURLED RING ROTATION

SECTION G-G
7433
A.-B. Positions of stalks - C. Horn control - D. Exterior lights knurled ring - E. Rear fog guard knurled ring
Base - May 2004 Print 603.93.281

Technical view Position Electrical function

A Position "0"
A1 Right lane change (unstable)
A2 Right direction
A3 Left lane change (unstable)
A4 Left direction
A5 Light flashing
A6 High beam headlamps
A7 Side light switch position "0"
7410 A8 Side lights
A9 Low beam headlamps plus high beam and fog guard enable
A10 Rear fog guard stable position (on or off)
A11 Rear fog guard unstable position off
Rear fog guard unstable position on only with light switch at position A9
of rear fog guards on
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A12 Horn
B Windscreen wiper reset
B1 Intermittent device
B2 First Speed
B3 Second speed
7411
B4 Second speed unstable
B5 Windscreen washer
Print 603.93.281 Base - May 2004

Cruise Control Figure 102

The cruise control is operated by push-buttons (Figure 102)
installed on the windscreen wiper control lever with following
functions:
- adjust engine idle speed;
- read and adjust drive rpm;
- set and store travel speed.
Cruise control is deactivated by pressing the clutch pedal, the
brake pedal and keeping the accelerator pedal pressed for
over 10 seconds or by turning the switch to OFF".
Cf. the Use and Maintenance Handbook on board the vehicle
for further information on use.
000245t
CRUISE CONTROL
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Figure 103
EEC HOMOLOGATION STAMP AREA
TECHNICAL VIEW OF THE COMPONENT

A. Connector (Cruise control)
Base - May 2004 Print 603.93.281

ELECTRONIC SYSTEMS
Immobilizer
In order to increase protection against attempted theft, the vehicles have been fitted with an electronic engine block system called
"Immobilizer" which is activated automatically removing the ignition key. In fact, the keys are fitted with an electronic
Transponder" that sends a code signal to a special electronic control unit which, only allows the engine to be started if it
recognises the code sent. del motore.
Figure 104
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1
EDC
2
4
000245t
WARNING LIGHT MAIN SYSTEM COMPONENTS

1. Immobilizer electronic control unit - 2. Electronic key containing the transponder - 3. Aerial used for sending/reading
the key code - 4. Code card containing the code for emergency starting
Print 603.93.281 Base - May 2004

System components
Electronic control unit
This is located behind the steering wheel column.
It is able to communicate with "EDC" central unit by a "CAN line".
The main functions of the control unit are:
- recognising insertion and rotation of the key in the ignition switch,
- activating and reading the secret code emitted by the Transponder,
- managing control and processing the codes,
- communicating with the "EDC" control unit,
- memorising any faults,
- system diagnostics.
Figure 105
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8
3 4
1 3
1
B
A 00290t
Pin Function
A1 Aerial
A2 Aerial
A3 Ċ
B1 CAN line L for EDC control unit pin 39 (EDC 16 - pin 61)
B2 Line K for 38-pin diagnostic connector pin 12
B3 Negative for Immobilizer failure warning lamp
B4 CAN H line for EDC control unit pin 8 (EDC 16 - pin 62)
B5 Ċ
B6 Earth
B7 Key-operated positive supply
B8 Ċ
Base - May 2004 Print 603.93.281

Electronic keys Figure 106

An electronic device called Transponder" is fitted in the key
grip which is not supplied by any battery, it is not removable
and contains and transmits the secret code.
Inserting the key, the Transponder" is activated, then, when
it receives the radio waves emitted by the aerial (fitted on the
ignition switch block), it automatically answers transmitting
the secret code.
If the two codes correspond, the control unit enables starting,
otherwise it shuts off the flow of fuel thereby preventing the
engine from starting.
The keys provided are two. Each key contains a

! Transponder" with the corresponding secret code.
It is highly to carry out the correct key teaching
procedure.
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000291t
ELECTRONIC KEYS
Aerial
Figure 107
This is fitted coaxially with the ignition switch and it has the
task of:
- supplying the energy to the Transponder" for sending
the secret code
- receiving the signal from the Transponder and sending it
to the control unit.
It is connected to the control unit on pins A1/A2.
8659
000292t
AERIAL
Print 603.93.281 Base - May 2004

Figure 108 Code card

Card containing the Electronic code and the Mechanical code.
- Electronic code or PIN code
Code absolutely necessary for the starting procedure in
the event of an emergency.
- Mechanical code
Code needed for request to duplicate the mechanical
part of the key.
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CODE CARD
000293t
Warning light
This is located on the instrument cluster and informs the
Figure 109
driver whether the system is working properly or of any
possible faults.
Moving the ignition key to drive the control unit tests the
system turning on the warning light for about 4 seconds".
If it goes out after this time, this means that the key has been
recognised and the system is working, if it does not it indicates
the possible system faults.
000294t
WARNING LIGHT
Base - May 2004 Print 603.93.281

Key teaching procedure Emergency procedure

In the event of loss or replacement of the keys it will be It is absolutely necessary to enter the PIN code" given on
absolutely necessary to follow a precise procedure solely the Code Card, only using the accelerator pedal as
described below:
through the diagnostic tools.
- Move the ignition key to Drive.
- Connect the diagnostic tool.
- After about ~ 2 seconds the EDC warning light starts
Key teaching
to flash quickly
- Engage the first key and turn it to drive.
- Press the accelerator pedal and keep it pressed for
- Wait for the code" warning light on the cluster to go out about ~ 15 seconds.
and turn the key to stop.
- The EDC warning lamp starts flashing slowly.
- Engage the new key and turn it to drive, repeat the
operations described previously. - When the number of flashes corresponds to the first
digit of the PIN code press the accelerator completely
If the code warning light does not go out during the teaching and then release it again. (During this press the EDC
procedure, this means that the operation has not been carried warning light stays off).
out correctly.
- Continue with the reading and corresponding pressing
Possible causes: on the accelerator pedal for the remaining four
numbers of the PIN code".
- The same key has been engaged twice.
- At the end of the sequence if the code entered is
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- The key has not been turned to stop in useful time.
correct and there are no system faults, the EDC
- An attempt has been made to teach more than three warning light stops flashing. The operation has been
keys. concluded correctly.
- Keys already used with another control unit have been - Start the vehicle.
used.
- Aerial reception problems.
NOTE After following this procedure the control unit

memorises the keys and will no longer make this
operation possible without entering the PIN
code.
The keys enabled for starting will never be more
than three.
A previously memorised key but not included in
the last teaching process is no longer able to
start the vehicle.
Print 603.93.281 Base - May 2004

System self-diagnostics
After the initial test, depending on the behaviour of the code" warning light, the system is capable of informing the operator
of possible system faults, as follows:
- Warning light "flashing continuously" with a frequency of "0.3 sec. ON" and 3 sec. OFF" means that there is an error or
that the emergency starting procedure has not been carried out correctly.
- Warning light "flashing continuously" with a frequency of 0.3 sec. ON" and " 0.3 sec. OFF", means that no key teaching
procedure has been carried out.
- Warning light "always on" means that the key teaching procedure has not been carried out correctly.
For preliminary information, it is possible to display any fault codes on the warning light module of the instrument cluster activating
the Blink code.
For complete, more thorough diagnosis it is however indispensable to use the tools available to the service network, such as
MODUS.
Diagnostics through the Blink Code
To activate the Blink code it is necessary to earth line K for at least 2 seconds with the ignition key at drive to display the first
error.
Repeat this operation (line K at earth) to display any other faults.
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The table below shows the various error codes that may appear during diagnostics.
Figure 110
000294t
Number of
Type of fault
blinks
1 Not connected or not configured central unit
2 Central unit not communicating with EDC
Central unit not communicating during installation
3 Central unit not installed
4 -
Short circuit/disturbance on communication line between control unit and "EDC"
5 Key with unknown code
6 Key with code not detected
7 Aerial not connected
8 Internal control unit fault
9 Short circuit on alarm disable line
Ċ Code" warning light short circuit
Ċ Code" warning light open circuit
Base - May 2004 Print 603.93.281

If after accurate diagnosis it is necessary to replace one or more components, proceed as described below
!
PART TO BE PARTS TO BE
OPERATIONS AND NOTES
REPLACED ORDERED
One or two keys • Parts Keys ⇒ Cut the keys according to the mechanical code.
(with one still ⇒ Perform "Key memorising" in Immobilizer diagnostics (*).
available) NB. In this procedure also enter the remaining working keys
Addition of a otherwise the will NO LONGER be enabled for starting.
key
Steering lock • KEYS KIT with: ⇒ Change the steering lock and ratchets.
and/or ratchets 2 cut Parts keysSteering ⇒ Perform "Key
Key memorising
memorising" in Immobilizer diagnostics ((*).
).
ALL the keys lock + Ratchets ⇒ State the new mechanical code on the Code Card.
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Ratchets (excluding • KIT with: ⇒ Change the ratchets.
steering lock) 2 traditional keys + NB. Traditional keys means keys without Transponder.
ratchets
Code card • Code Card ⇒ Complete the "Code Card Duplicate Request Form" printing it
(due to loss) from MODUS and send it as mentioned in the ORDER
MANAGEMENT form of the IVECO SPARES warehouse
concerned.
Aerial • Aerial ⇒ Replace.
ECU Immobilizer • KIT ECU ⇒ Cut the keys according to the mechanical code.
Including: ⇒ Perform "Key memorising" in Immobilizer diagnostics (*).
Immobilizer ECU - NB. At the end of this operation, check that the electronic code
2 keys to be cut shown on the screen corresponds to the one printed on the Code
New Code Card Card, if it is different, put the one on the screen on the Code Card.
⇒ In EDC diagnostics perform "new key recognition".
⇒ Put the old mechanical code on the new Code Card.
⇒ Scrap the old keys as it will be NO LONGER possible to use
them.
⇒ Complete the "New Immobilizer Installation Form" printing it
from MODUS and send it as mentioned in the ORDER
MANAGEMENT form of the IVECO SPARES warehouse
concerned.
EDC control unit • EDC control unit ⇒ The system recognises the new actuator automatically the first
time the ignition key is moved to Drive.
NB. To order the EDC Control Unit complete the specific form
printing it from Modus and sending it to the Market Technical help
Desk.
(*) With release MODUS 2.0 (Windows), 1.6C (DOS) or IWT 1.4, before "Storing new keys", it is necessary to
! disconnect EDC central unit. Once the operation has been completed, clear the fault memory to prevent the error
from staying memorised on the actuator.
⇒ For subsequent releases keep to any new instructions given on the screen.
Print 603.93.281 Base - May 2004

ABS/EBD/ABD skidding (or slipping) between the tyre and the road in the
contact area.
General
The braking of a vehicle in motion and the consequent The figure shows the indicative trend of the longitudinal µl"
deceleration and stopping space mainly depend on the grip and transversal µt" rip coefficients in relation to the
between the tyre surface and the type of road surface. percentage of slipping "S".
With a perfectly efficient braking system, further The diagram reveals that the maximum value of the
improvement of braking can be obtained only acting on the longitudinal grip coefficient is not when the wheel is locked,
tyre friction characteristics or on the quality of the road but for a much lower slipping value.
surface.
Even in these optimum conditions, absolute braking safety Therefore, the road-tyre grip can be exploited to optimise
is not however guaranteed when needing to cope with longitudinal or transversal control of the vehicle. Namely, it
particular critical situations, such as low grip due to the is possible to utilise the grip trying to make the braking
conditions of the wet or icy road surface: this compels the distance as short as possible or to ensure the best possible
driver to moderate the braking action to prevent one or handling.
more wheels from partially locking, with the possibility of
An excellent compromise is obtained using slip rates near
dangerous skidding.
the point S* in which there is a high µl value which ensures
The friction between the tyre and the road surface does not optimum braking and a µt value that offers good lateral
correspond to the friction between rigid bodies but to the roadholding.
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Figure 111
WHEEL
VEHICLE
TRANSVERSAL GRIP
LONGITUDINAL GRIP
STABLE UNSTABLE
AREA AREA
OPTIMUM AREA
TREND OF WHEEL LONGITUDINAL AND TRANSVERSAL GRIP IN RELATION TO SLIPPING
Base - May 2004 Print 603.93.281

In order to better understand the logic of the system and the Experimentation has made it possible to establish that the
parameters that govern it a few basic concepts should be most effective braking condition is obtained for optimum
briefly examined. slipping values contained between about ∼ 5% and 20%.
Due to the effect of the braking action the tyre, that before
was rolling freely, undergoes a deformation, called "braking" The need to contain the slipping values within precise limits
deformation, in its area of contact with the road and slows is imposed by the behaviour of the tyres under the braking
down rotation reducing its peripheral speed, to a higher action, during which the braking friction coefficient comes
extent than the linear speed of the vehicle. into play.
At the limit, with the wheels completely locked under the The higher this coefficient, the more braking is effective.
braking action, and thus with a wheel peripheral speed of
zero, there is the maximum deviation between the wheel If the relation between slipping S and the friction coefficient
rotation speed and the linear speed of the vehicle. U is represented on Cartesian axes µ, we see how there are
Slipping varies its values within the limits set by the two the highest friction coefficient values for slipping values
extreme conditions in which the wheel and vehicle speed between an average of 5% and 20%.
may be in.
As the friction coefficient is directly proportionate with the
When the wheel is free, not braked, thus turning at the same
applicable braking force, the result is that the "ABS" device
speed as the vehicle, the slipping coefficient is 0%.
acts in such a way as to apply the maximum braking force
When the braked wheel is completely locked and the exactly in correspondence with the best friction coefficient,
vehicle continues moving forwards due to inertia, the and this system tends to bring any type of vehicle within this
cardiagn.com
skidding coefficient amounts to 100%. sector.
Figure 112
FRICTION COEFFICIENT
S. Slipping % - A. Dry asphalt - B. Wet asphalt - C. Ice
Print 603.93.281 Base - May 2004

Figure 113
A The locking of one or more wheels, due to excessive pressure
on the brake pedal, (anyway higher than allowed by the grip)
can cause loss of steering control of the vehicle if both front
wheels lock, skidding, resulting in about-facing, if both rear
wheels lock.
The need for abrupt braking on a bend, compels the driver to
immediate action to avoid losing control of the vehicle,
resulting in skidding.
Lastly, the so-called panic braking (caused by a sudden
obstacle), compels the driver to press the brake pedal as
forcibly as possible in the desperate attempt to stop in time..
So what is the solution even for the most expert drivers?
B Being able to avail of a braking system capable of fully

exploiting all the grip available without locking the wheels,
except at a minimum pre-established speed.
The ABS Antibrake Locking System has been developed
exactly to obtain this.
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A device inserted in the braking system, with the task of
preventing wheel locking when the brake operating pressure
is too high in relation to the grip of the tyre on the ground.
Therefore, the purpose of the "ABS" device is to ensure
vehicle stability (under all braking conditions) preventing
locking of the wheels regardless of the conditions of the road
surface, thereby ensuring total use of the grip available.
A Also in the vent of emergency braking, the system makes it
possible to maintain "steerability" of the vehicle, i.e. acting on
the steering to avoid obstacles, without the danger of skidding.
Keeping the rotation and grip of the wheels within the
optimum parameters, the system makes it possible to obtain
those braking distances that only an expert driver would be
able to approach; this way even the less expert driver is able
to act like one of the best.
The diagram opposite shows some examples of braking
without ABS and with ABS.
In order to be able to intervene effectively the system must
not only be precise in response, but also very quick.
This is now possible thanks to electronic information which
warrants reliability, precision and rapidity, with a minimal
number of components and lower system cost.
B
VEHICLE BRAKING TREND

WITHOUT AND WITH ABS
A. Vehicle without ABS - B. Vehicle with ABS
Base - May 2004 Print 603.93.281

In addition to the ABS, the system in question also ABD - Automatic Brake Differential
incorporates the EBD and ABD functions. This device comes into action automatically braking the
EBD - Electronic Brake Force distribution driving wheel that has less grip when moving off or travelling
This device replaces and optimises the function of the and tends to skid transferring the torque through the
present hydraulic braking action proportioning valve, better differential to the wheel with higher grip.
controlling the braking force on the rear wheels. It cuts in up to a speed of about 40 km/h and does not
interfere with the normal braking system.
It is obtained by adding specific software to the ABS and it
acts in a determinate interval before the cutting in of the It cuts in up to a speed of about 40 km/h and does not
ABS. interfere with the normal braking system.
It ensures control on any locking of the rear wheels in The driver is informed when this system is engaged by the
relation to the front ones, optimising the braking force in the flashing of th yellow warning light on the dashboard.
different load, driving and conditions of use of the vehicle.
Figure 114
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ABS EBD
A C B
SYSTEM WARNINGS ON DASHBOARD

A. ABS failure warning light 58703 - B. EBD failure warning light 58734 - C. ABD failure warning light 58704
Print 603.93.281 Base - May 2004

SYSTEM WITH 4 CROSSED CHANNELS (X)

The system shown is used on the following vehicles: 29 L - 35 S
Figure 115
1 2 3 4 5 6 7 8
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13 12 11 10 9
1. Electrohydraulic modulator - 2. Vacuum pump - 3. Vacuum tank - 4. Vacuum servobrake - 5. Hydraulic control sockets
- 6. Parking brake lever - 7. Rear brake caliper - 8. Rear disk brake - 9. Electronic control unit - 10. Sensor -
11. Phonic wheel - 12. Front brake disk - 13. Front brake caliper
Base - May 2004 Print 603.93.281

Location of components
Figure 116
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7 8
4
1
12
11
10
3
9 13 5
1. Eectrohydraulic modulator - 2. Vacuum pump - 3. Vacuum tank - 4. Vacuum servobrake - 5. Hydraulic control sockets
- 7. Rear brake caliper - 8. Rear disk brake - 9. Electronic control unit 88000 - 10. Sensor 88001- 11. Phonic wheel -
12. Front brake disk - 13. Front brake caliper
Print 603.93.281 Base - May 2004

Sensor on phonic wheel The distance between the sensor and the wheel, called gap,
must clearly have a pre-established value so that correct
The sensors supply the electronic control unit all the useful
signals are supplied (0,8 to ÷ 1,6 mm).
information, with the necessary continuity, for it to be able
to control the solenoid valves. The resistance rating of each single sensor detected at the
ends of the connector is between 1÷ 2 kΩ.
The signals are obtained by magnetic flux lines which are
closed through the teeth of an iron toothed wheel facing the The toothed wheel is called phonic wheel because the signal
sensor and turned with the wheel. it generates has the frequency of a sound wave.
The passage from solid to hollow, due to the presence or The frequency of this signal serves to define the wheel
absence of the tooth determines a change of the magnetic rotation speed.
flux which is enough to create an electromotive force
The changes of the frequency, i.e. the rapidity with which the
induced at the terminals of the sensor and thus an alternate
signals follow one another serve to define the acceleration
electric signal, which is sent to the electronic control unit.
and deceleration values.
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Figure 117
SENSOR ON PHONIC WHEEL

A. Phonic wheel
Base - May 2004 Print 603.93.281

Electrohydraulic control unit/modulator MC1 - Diagonal supply LF/RR

The component integrates both the electronic part and the MC2 - Diagonal supply RF/LR
hydraulic modulator for system management.
LF - Left front axle output
It comprises the following:
RR - Right rear axle output
A - Electronic control unit
RF - Right front axle output
B - Electrohydraulic modulator
LR - Left rear axle output
C - Accumulator
It is connected to the electric system through a 31-pin
It is connected to the hydraulic system by the following connector.
connections:
Figure 118
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RR
MCI LR
MC2
LF
RF
C B
CONTROL UNIT/ELECTROHYDRAULIC MODULATOR
Print 603.93.281 Base - May 2004

Electrohydraulic modulator Pressure increase

The figure schematically shows the connection of the Operating the brake pedal, the pressurised oil can reach the
modulator and its internal components. brake calipers as both the drive solenoid valves "6" and the
supply solenoid valve "11" are open.
Figure 119
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1. Vacuum servobrake - 2. Electronic control unit - 3. High pressure accumulator - 4. Recovery pumps - 5. Recovery
pump drive motor - 6. ABD control solenoid valves (setting 90 bar) - 7. One-way safety valves - 8. ABD intake solenoid
valves - 9. ABD one-way valves - 10. Low pressure accumulator - 11. Supply solenoid valves - 12. Discharge solenoid
valves - 13. One-way quick pressure reduction valves - 14. Font axle disk brakes - 15. Rear axle disk brakes
Base - May 2004 Print 603.93.281

Pressure lowering At the same time, supplying the motor "5" that drives the
If the sensors detect the tendency of a wheel or wheels to pumps "4" it will be possible to recover the excess oil volume
lock, they inform the control unit which reduces the braking in the high pressure accumulators "3".
force activating the supply solenoid valves "11" and the
discharge solenoid valves "12".
Figure 120
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SYSTEM OPERATING LAYOUT SHOWING THE PRESSURE MAINTENANCE PHASE
Print 603.93.281 Base - May 2004

Pressure maintenance
Once the optimum braking force has been reached, the
control unit can keep it constant, no longer energising the
discharge solenoid valves "12", the motor "5" and the
associated recovery pumps "4", while the supply solenoid
valves "11" continue being supplied.
Figure 121
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SYSTEM OPERATING LAYOUT SHOWING THE PRESSURE MAINTENANCE PHASE
Base - May 2004 Print 603.93.281

Cutting in of EBD device If both failure warning lights turn on (ABS and EBD) this
If the sensors detect that one or both wheels tend to lock means an EBD system failure.
in relation to the front wheels, they inform the control unit Under these conditions the braking force will not be
which suitably supplies the supply solenoid valves "11" of the distributed between the axles, therefore rear wheel locking
rear axle to optimise the braking force. may occur with the possibility of skidding.
A fault on certain system components causes the ABS
system to be cut off (displayed by turning on the special
warning light), still leaving the EBD system operational.
Figure 122
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FP. Rear axle braking force - FA. Front axle braking force - A. Servobrake distribution curve - B. Ideal distribution -
C. Curve - distribution curve of any porportioning valve - D. EBD system distribution curve
Print 603.93.281 Base - May 2004

Cutting in of ABD device During this phase the maximum pressure is limited by the
If the sensors detect that one or both rear axle wheels tend drive solenoid valves "6" and cannot exceed 90 bar.
to skid, they inform the control unit which supplies the intake
solenoid valves "8" and the drive valves "6". The driver is informed of the cutting in of this system by the
At the same time, supplying the motor "5" which drives the flashing of the corresponding warning light on the
pumps "4" it will be possible to generate the pressure to be dashboard.
sent to the brake calipers concerned.
The braking force generated in this manner is modulated by If the warning light turns on and glows steadily, there is an
solenoid valves "11" and "12". ABD system failure.
Figure 123
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ÓÓÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ ÓÓÓÓÓÓ
ABD DEVICE OPERATING LAYOUT
Base - May 2004 Print 603.93.281

SYSTEM WITH 4 PARALLEL CHANNELS

(11)
The system shown in Figure 124 is used on the following
vehicles: 35 C - 40 C - 45 C - 50 C - 65C.
Figure 124
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1. Electrohydraulic modulator - 2. Vacuum pump - 3. Vacuum tank - 4. Vacuum servobrake - 5. Hydraulic control
sockets - 6. Harking brake lever - 7. Harking drum brake - 8. Hear brake disk - 9. Hear brake caliper - 10. Electronic
control unit - 11. Sensor - 12. Phonic wheel - 13. Front brake disk - 14. Front brake caliper
Print 603.93.281 Base - May 2004

Electrohydraulic control unit/modulator F - Front axle supply

This component integrates both the electronic part and the R - Rear axle supply
electrohydraulic system control modulator.
LF - Left front axle output
It comprises the following:
RF - Right front axle output
A - Electronic control unit
LR - Left rear axle output
B - Electrohydraulic modulator
RR - Right rear axle output
C - Accumulator
It is connected to the electric system through a 31-pin
It is connected to the hydraulic system by the following connector.
connections:
Figure 125
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LR
RF
RR
C B
CONTROL UNIT/ELECTROHYDRAULIC MODULATOR
Base - May 2004 Print 603.93.281

Electrohydraulic modulator Pressure increase

The figure shows the layout of the connection of the Operating the brake pedal, the pressurised oil can reach the
modulator and its internal components. brake calipers as both the drive solenoid valve "7" and the
supply solenoid valves "12" are open.
Figure 126
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1. Vacuum servobrake - 2. Electronic control unit - 3. High pressure accumulators - 4. Recovery pumps -
5. Recover pump drive motor - 6. Accumulator for rear axle system - 7. ABD drive solenoid valve (90 bar setting) -
8. One-way abd valve - 9. Intake abd solenoid valve - 10. ABD one-way valve - 11. Low pressure accumulators -
12. Supply solenoid valves - 13. Discharge solenoid valve - 14. One-way quidk pressure relief valves - 15. Front axle disk
brake - 16. Rear axle disk brakes
Print 603.93.281 Base - May 2004

Pressure reduction At the same time, supplying the motor "5" which drives the
If the sensors detect that a wheel or wheels tend to lock, pumps "4", it will be possible to recover the excess oil in the
they inform the control unit which reduces the braking force high pressure accumulators "3".
activating the supply solenoid valves "12" and the discharge
solenoid valves "13".
Figure 127
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OPERATING LAYOUT OF THE SYSTEM SHOWING THE PRESSURE REDUCTION PHASE
Base - May 2004 Print 603.93.281

Pressure maintenance energising the discharge solenoid valves "13", the motor "5"
and the corresponding recovery pumps "4"; while the supply
Once the optimum braking force has been reached, the
solenoid valves "12" continue being energised.
control unit is able to keep it constant by no longer
Figure 128
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OPERATING LAYOUT OF THE SYSTEM SHOWING THE PRESSURE MAINTENANCE PHASE
Print 603.93.281 Base - May 2004

Cutting in of the EBD device If both failure warning lights turn on (ABS and EBD) this
If the sensors detect that one or both rear wheels tend to means an EBD system failure.
lock in relation to the front wheels, they inform the control Under these conditions the braking force will not be
unit which appropriately supplies the supply solenoid valves distributed between the axles, therefore rear wheel locking
"12" of the rear axle, in order to optimise the braking force. may occur with the possibility of skidding.
A fault on certain system components causes the ABS
system to be cut off (displayed by turning on the special
warning light), still leaving the EBD system operational.
Figure 129
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FP. Rear axle braking force - FA. Front axle braking force - A. Servobrake distribution curve - B. Ideal distribution curve -
C. Any proportioning valve distribution curve - D. EBD system distribution curve
Base - May 2004 Print 603.93.281

Cutting in of the ABD device During this phase the maximum pressure is limited by the
If the sensors detect that one or both rear axle wheels tend drive solenoid valves "6" and cannot exceed 90 bar.
to skid, they inform control unit which supplies the intake The driver is informed of the cutting in of this system by the
solenoid valves "9" drive valves "7". flashing of the corresponding warning light on the
At the same time, supplying the motor "5" which drives the dashboard.
pumps "4" it will be possible to generate the pressure to be If the warning light turns on and glows steadily, there is an
sent to the brake calipers concerned. ABD system failure.
The braking force generated in this manner is modulated by
solenoid valves "12" and "13".
Figure 130
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Ú
Ú
ABD DEVICE OPERATING LAYOUT
Print 603.93.281 Base - May 2004


The following table shows the pin out of the control unit in question.
Figure 131
27 20 19
31 16
26
15 1
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Cable
Pin Function
colour code
1 Right rear sensor Ċ
2 Right rear sensor Ċ
3 Right front sensor (only for 35 C - 40 C - 45 C - 50 C - 65 C vehicles) Ċ
4 Right front sensor Ċ
5 Right front sensor (only for 29 L - 35 S vehicles) Ċ
6 Left front sensor Ċ
7 Left front sensor Ċ
8 Left rear sensor Ċ
9 Left rear sensor Ċ
10 Ċ Ċ
11 Line K to pin 4 38-pin connector for diagnostics 8817
12 Line L to pin 3 38-pin connector for diagnostics 8818
13 Negative for third brake relay 0315
14 Positive from stop light switch 1173
15 Key-operated positive 8847
16 Earth 0000
17 Direct positive 7772
18 Direct positive 7772
19 Earth 0000
20 Negative for ABS failure warning light 6670
21 Negative for EBD failure warning light 6673
22 Ċ Ċ
23 Ċ Ċ
24 Negative for ABD operating warning light 6674
25 Ċ Ċ
26 Ċ Ċ
27 Ċ Ċ
28 Ċ Ċ
29 Ċ Ċ
30 Ċ Ċ
31 Ċ Ċ
Base - May 2004 Print 603.93.281

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.
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NOTE The ABD (Automatic Brake Differential) function is available only in systems of the ABS 5.3 type.
The ESP 8 system, in addition to the ESP 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.
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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.
Application of the ABS 8/ESP8 systems
SYSTEM ABS8 ESP8

X (crossed) II (parallel) X (crossed) II (parallel)
VEHICLES F1A engine with 6 AS 300 VD F1A and F1C engines
automatic gearbox
29L — 35S 35C — 65C 29L — 35S 35C

Four crossed channel system (x)

Electro-hydraulic modulator/control unit
Figure 131/1
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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 131/2
102114
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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 131/3
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102245
Pin (X) Pin (II) Function Cable

1 1 Earth (pump control motor) 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 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 EBD failure warning light 6673
13 13 Decelerator deactivation with ABS system ON 0315
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 for ABS (KL 15) 8847
19 19 Rear right sensor 5573
20 20 Stop signalling switch — brake lights 1173
21 21 - -
22 22 ABS failure warning light 6670
23 23 - -
24 24 - -
25 25 Diagnosis L line 1199
26 26 CAN H line White

ESP 8 control unit PIN OUT (X - crossed channels, II - parallel channels)

Figure 131/4
102246
Pin (X) Pin (II) Function Cable

1 1 Earth (pump control motor) 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 Signal earth 0000
5 5 Front left sensor 5570
6 26 - -
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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 EBD failure warning light 6673
13 13 - -
14 14 CAN L line Green
15 15 Yaw sensor earth 9096
16 16 Yaw sensor signal 9095
17 17 Longitudinal acceleration sensor 9099
18 18 Yaw sensor reference signal 9094
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 0315
23 23 - -
24 24 Diagnosis L line 1199
25 25 - -
26 6 Front left sensor earth 5570
27 27 Rear left sensor earth 5572
28 28 Positive after fuse for ABS (KL 15) 8847
29 29 Rear right sensor 5573
30 30 Stop signalling switch — brake lights 1173
31 31 Exhaust brake actuation enable switch (ASR/ESP passive switch) 8800
32 32 ABS failure warning light 6670
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 1173
42 42 - -
43 43 Reverse gear signal 2227
44/45 44/45 - -
46 46 Speed limiter or ASR failure warning light 6672

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
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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 131/5
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 131/6
101864
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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 131/7
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.
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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 ou 4 capteurs tours roue X X X

3 or 4 wheel revs sensors
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 131/8
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102108
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 131/9
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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 131/10
102116
It measures the vehicle’s acceleration and deceleration changes.
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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 131/11
102111
In a horizontal position, 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. The vehicle is to be taken to a slight slope
and checked if it is kept braked for 2.5 seconds.
Drive back to the service centre, then use a diagnosis instrument to verify that the anomaly is no longer found.

Steering angle sensor
Figure 131/12
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
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taken. The hydraulic unit controls brake pressure as quickly as possible, separately for every single wheel.
Steering angle sensor calibration
Figure 131/13
102110
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 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 131/14
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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.

6AS 300 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 (1a).
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.
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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, such as:
- EDC
- ABS8/ESP8
- IMMOBILIZER
- PTO (POWER TAKE-OFF, if available).

Electronic control
Figure 131/15
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101868
1. Buzzer - 2. Tachograph - 3. Display - 4. IMMOBILIZER control unit - 5. ABS8/ESP8 control unit - 6. EDC control unit -
7. Gear shift lever - 8. PTO icon - 9. PTO - 10. Gearbox - 11. Gearbox control unit - 12. Reversing light actuation -
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 131/16
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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 131/17
101870
Position of the electronic control unit

Connector control unit PIN-OUT — gearbox side (A)
Figure 131/18
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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 4)
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 131/19
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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 H VDB line (female junction)
18 CAN H VDB line (female junction)
28 CAN L VDB line (male junction)
29 CAN L VDB line (female junction)
33 Free
37 Free
38 Free
39 KL 30
40 CAN L --- ZF LINE
41 CAN H --- ZF LINE
43 KL 15
44 On-board panel signal (doors open)
45 On-board panel signal (emergency brake)
46 PTO state signal
47 PTO ON signal
49 Power supply from gearbox electronic control unit
51 Speed signal from on-board panel
52 Diagnosis K line

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 131/20
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90139
Position of actuator
Figure 131/21
101872
1. Gear engaging electric motor - 2. Gear selection electric motor

Figure 131/22
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101873
Wiring diagram
Pin Function
1 Electric motor negative
2 Earth
3 Sensor voltage signal (5 V)
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 131/23
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90137
Figure 131/24
90138
1. Actuating cylinder - 2. Electric motor - 3. Vehicle electric wiring junction block

Figure 131/25
101873
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Wiring diagram
Pin Function
1 Earth
2 Incremental sensor speed signal
3 Electric motor positive
4 Incremental sensor direction signal
5 Sensor voltage signal (5 V)
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.)

Display
Figure 131/26
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101875
The display, located on the board, makes it possible to show all the information required for correct use of the system, such as,
for instance:
- mode (manual or automatic) and, in both cases, the gear engaged;
- the reverse gear/neutral position (R/N);
- faults/misuse with acoustic signal (e.g. clutch overheating);
- the fault code (troubleshooting) shown on page 47 can be displayed only by means of the diagnosis instrument;
- vehicle state condition: gear engaged.
Pin Function Figure 131/27

1 Backlighting ON/OFF control
2
3 Analog backlighting control
4 -
5 CAN H
6 Earth
7 CAN L
8 +12 V
90263

Gear selector
Figure 131/28
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101876
The gear selector is an electronic component located in the cabin next to the driver.
It is interfaced with the gearbox control unit, by means of the CAN communication line, in order to inform of the driver’s intention
of selecting and engaging the gears.
Pin Function Figure 131/29

1 KL 15
2 KL 30
3 CAN L
4 CAN H
5 -
6 -
90262
1. Gear selector connector

Accelerator pedal Figure 131/30

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
6AS 300 VD 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 131/31
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101878
Figure 131/32
101879

PTO
One single button is used to actuate and deactivate the power take-off (PTO).
Operation under NON-STATIONARY conditions
- The PTO can be engaged only when the gear shift is in neutral and the engine is ON;
- then, the first gear can be engaged, and the vehicle can be started;
- after setting off, the gear cannot be changed any more when the vehicle is running;
- the PTO can be disengaged both with the gears running and the neutral ON.
Operation under STATIONARY conditions

- The PTO can be engaged only when the gear shift is in neutral and the engine is ON.
PTO diagram
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Figure 131/33
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 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 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.
- After such time, if the button is kept depressed for more than 30 seconds, a quick flash will be displayed, and
PTO disengagement and lock will be commanded until the vehicle is switched on again.
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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.
- After such time, if the button is kept depressed for more than 30 seconds, a quick flash will be displayed, and
PTO disengagement and lock will be commanded until the vehicle is switched on again.

Remote-control switch and fuse assembly
Figure 131/34
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90264
The system’s power supply is ensured by a set of fuses located in the cabin (see figure) in the marked positions.
64 - control unit power supply
65 - automatic transmission services
66 - start prevent
There are three more 25 A fuses (electric motor power supply) that are connected with control unit pins 4, 5, and 6. In the event
that one or two of these fuses blow, the gearbox functions are not affected. If the third fuse is broken, the gearbox is not able
to operate (i.e. both the clutch motion and the gear selection/engagement will be disabled).
Accelerator pedal sensor

The accelerator pedal position is provided to the gearbox control unit, through a suitable communication line, by the EDC
electronic control unit which is informed about the position by the load transmitter fitted directly to the accelerator pedal.
Engine revs sensor

The sensor is mounted just next to the engine flywheel.
The engine running speed values are sent to the EDC electronic control unit which conveys them to the gearbox control unit
by means of a special communication line.
Vehicle speed sensor

This sensor sends the pulses to the tachometer/electronic tachograph.
The signal is duplicated by the ABS/ESP sensors available on the wheels.

DIAGNOSIS INSTRUMENTS
DISPLAY
First-level diagnosis that provides coded displaying of the errors found in the control unit memory. The information is shown
on the display only by means of diagnosis instruments.
MODUS
Computer-assisted diagnosis station used for diagnosis of braking systems, pneumatic suspensions, engines and
electronically-controlled systems.
The 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 the Electronic Systems fitted to IVECO vehicles. 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.
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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 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).

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
- Gear shift programming
- Clutch engagement/release control
- Control unit programming and configuring
Figure 131/35
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102266
A. IT 2000 - B. E.A.SY. - C. MODUS

TROUBLESHOOTING
DTC DEC DTC HEX Description
10 A ELECTRONIC CONTROL UNIT / TOO LOW TEMPERATURE
11 B ELECTRONIC CONTROL UNIT / TOO HIGH TEMPERATURE
12 C VEHICLE CAN LINE / FAULT
13 D ZF CAN LINE / FAULT
30 1E VEHICLE CAN LINE / DELAY IN RECEIVING THE EEC1 CAN MESSAGE
31 1F VEHICLE CAN LINE / DELAY IN RECEIVING THE EEC2 CAN MESSAGE
32 20 VEHICLE CAN LINE / DELAY IN RECEIVING THE CCVS CAN MESSAGE
33 21 VEHICLE CAN LINE / DELAY IN RECEIVING THE EEC3 CAN MESSAGE
34 22 VEHICLE CAN LINE / DELAY IN RECEIVING THE EBC1 CAN MESSAGE
35 23 VEHICLE CAN LINE / DELAY IN RECEIVING THE ENGCONFMPM CAN MESSAGE
36 24 VEHICLE CAN LINE / DELAY IN RECEIVING THE HRW CAN MESSAGE
37 25 ZF CAN LINE / DELAY IN RECEIVING THE SL_2_TCU CAN MESSAGE
38 26 VEHICLE CAN LINE / DELAY IN RECEIVING THE VDC1 CAN MESSAGE
39 27 VEHICLE CAN LINE / DELAY IN RECEIVING THE VDC2 CAN MESSAGE
50 32 VEHICLE CAN LINE / ERROR ON ENGINE REVS SIGNAL - EEC1 CAN MESSAGE
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52 34 VEHICLE CAN LINE / ERROR ON SIGNAL FOR REQUESTED ENGINE TORQUE - EEC1 CAN
MESSAGE
54 36 VEHICLE CAN LINE / ERROR ON ACCELERATOR PEDAL POSITION SIGNAL - EEC2 CAN
MESSAGE
56 38 VEHICLE CAN LINE / ERROR ON SIGNAL FROM BRAKE PEDAL - CCVS CAN MESSAGE
57 39 VEHICLE CAN LINE / ERROR ON ENGINE TORQUE AND BRAKING TORQUE
CONFIGURATION SIGNAL - EEC1 CAN MESSAGE
58 3A VEHICLE CAN LINE / ERROR ON ACTUAL ENGINE TORQUE SIGNAL - EEC1 CAN
MESSAGE
60 3C VEHICLE CAN LINE / ERROR ON ABSORBED ENGINE TORQUE SIGNAL - EEC2 CAN
MESSAGE
62 3E VEHICLE CAN LINE / ERROR ON REFERENCE ENGINE TORQUE SIGNAL -
ENG_CONF_MPM CAN MESSAGE
66 42 VEHICLE CAN LINE / ERROR ON REAR LEFT WHEEL SPEED SIGNAL - HRW CAN MESSAGE
67 43 VEHICLE CAN LINE / ERROR ON REAR RIGHT WHEEL SPEED SIGNAL - HRW CAN
MESSAGE
77 4D VEHICLE CAN LINE / ERROR ON VEHICLE SPEED SIGNAL - CCVS CAN MESSAGE
100 64 SPEED ACTUATOR - SELECT / SHORT-CIRCUIT TO EARTH ON CONTROL MOTOR
OUTPUT
101 65 SPEED ACTUATOR - SELECT / SHORT-CIRCUIT TO POSITIVE ON CONTROL MOTOR
OUTPUT
102 66 SPEED ACTUATOR - SELECT / INTERRUPTION ON CONTROL MOTOR OUTPUT
103 67 SPEED ACTUATOR - SELECT / SENSOR SUPPLY VOLTAGE - TOO HIGH
104 68 SPEED ACTUATOR - SELECT / SENSOR SUPPLY VOLTAGE - TOO LOW
105 69 SPEED ACTUATOR - SELECT / SENSOR SHORT-CIRCUIT TO EARTH
106 6A SPEED ACTUATOR - SELECT / SENSOR SHORT-CIRCUIT TO POSITIVE OR INTERRUPTION
107 6B SPEED ACTUATOR - SELECT / NON-PLAUSIBLE MOTOR CONTROL SIGNAL
120 78 SPEED ACTUATOR - SELECT / TOO HIGH CURRENT
121 79 SPEED ACTUATOR - SELECT / TOO HIGH TEMPERATURE


130 82 SPEED ACTUATOR - SELECT / MECHANIC FAULT
131 83 SPEED ACTUATOR - SELECT / MECHANIC FAULT
132 84 SPEED ACTUATOR - SELECT / POSITION CONTROL ERROR
180 B4 SPEED ACTUATOR - SELECT / REFERENCE EOL PARAMETER ERROR (LACKING
MEASUREMENT VALUES)
181 B5 SPEED ACTUATOR - SELECT / REFERENCE EOL PARAMETER ERROR
(OUT-OF-TOLERANCE MEASUREMENT VALUES)
200 C8 SPEED ACTUATOR - SHIFT / SHORT-CIRCUIT TO EARTH ON CONTROL MOTOR
OUTPUT
201 C9 SPEED ACTUATOR - SHIFT / SHIFT / SHORT-CIRCUIT TO POSITIVE ON CONTROL
MOTOR OUTPUT
202 CA SPEED ACTUATOR - SHIFT / INTERRUPTION ON CONTROL MOTOR OUTPUT
205 CD SPEED ACTUATOR - SHIFT / SENSOR SHORT-CIRCUIT TO EARTH
206 CE SPEED ACTUATOR - SHIFT / SENSOR SHORT-CIRCUIT TO POSITIVE OR INTERRUPTION
207 CF SPEED ACTUATOR - SHIFT / NON-PLAUSIBLE MOTOR CONTROL SIGNAL
220 DC SPEED ACTUATOR - SHIFT / TOO HIGH CURRENT
221 DD SPEED ACTUATOR - SHIFT / TOO HIGH TEMPERATURE
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230 E6 SPEED ACTUATOR - SHIFT / MECHANIC FAULT
231 E7 SPEED ACTUATOR - SHIFT / MECHANIC FAULT
232 E8 SPEED ACTUATOR - SHIFT / POSITION CONTROL ERROR
252 FC SPEED ACTUATOR - SHIFT / ENGAGING ERROR - 1st SPEED
253 FD SPEED ACTUATOR - SHIFT / ENGAGING ERROR - 2nd SPEED
254 FE SPEED ACTUATOR - SHIFT / ENGAGING ERROR - 3rd SPEED
255 FF SPEED ACTUATOR - SHIFT / ENGAGING ERROR - 4th SPEED
256 100 SPEED ACTUATOR - SHIFT / ENGAGING ERROR - 5th SPEED
257 101 SPEED ACTUATOR - SHIFT / ENGAGING ERROR - 6th SPEED
258 102 SPEED ACTUATOR - SHIFT / ENGAGING ERROR - REVERSE GEAR
259 103 SPEED ACTUATOR - SHIFT / TEACHING REQUEST GEARBOX BOUNDARY OVERRIDE
260 104 SPEED ACTUATOR - SHIFT / TEACHING REQUEST GEARBOX NEUTRAL POSITION
FAILURE
280 118 SPEED ACTUATOR - SHIFT / REFERENCE EOL PARAMETER ERROR (LACKING
MEASUREMENT VALUES)
281 119 SPEED ACTUATOR - SHIFT / REFERENCE EOL PARAMETER ERROR (OUT-OF-TOLERANCE
MEASUREMENT VALUES
282 11A SPEED ACTUATOR - SHIFT / SYSTEM GEOMETRY ERROR (ASYMMETRY)
283 11B SPEED ACTUATOR - SHIFT / MECHANIC FAULT
300 12C CLUTCH ACTUATOR / SHORT-CIRCUIT TO EARTH ON CONTROL MOTOR OUTPUT
301 12D CLUTCH ACTUATOR / SHORT-CIRCUIT TO POSITIVE ON CONTROL MOTOR OUTPUT
302 12E CLUTCH ACTUATOR / INTERRUPTION ON CONTROL MOTOR OUTPUT
303 12F CLUTCH ACTUATOR / SENSOR SUPPLY VOLTAGE - TOO LOW
320 140 CLUTCH ACTUATOR / TOO HIGH CURRENT
321 141 CLUTCH ACTUATOR / TOO HIGH TEMPERATURE
330 14A CLUTCH ACTUATOR / MECHANIC FAULT ON CONTROL MOTOR
331 14B CLUTCH ACTUATOR / MECHANIC FAULT - LOCK AT END OF STROKE
350 15E CLUTCH ACTUATOR / POSITION CONTROL ERROR
351 15F CLUTCH ACTUATOR / NON-PLAUSIBLE POSITION SIGNAL AT THE END OF STROKE
352 160 CLUTCH ACTUATOR / NON-PLAUSIBLE POSITION SIGNAL
354 162 CLUTCH ACTUATOR / MULTIPLE INPUT SPEED PLAUSIBILITY ERROR
355 163 CLUTCH ACTUATOR / MULTIPLE CLUTCH TORQUE PLAUSIBILITY ERROR


356 164 CLUTCH ACTUATOR / NO ENGINE REACTION UPON TORQUE REDUCTION REQUEST
380 17C CLUTCH ACTUATOR / TOO SLOW OR JAMMED CLUTCH MOTION WHEN PERFORMING
ACTIVE DIAGNOSIS
381 17D CLUTCH ACTUATOR / OUT-OF-RANGE CLUTCH MOTION WHEN PERFORMING ACTIVE
DIAGNOSIS
382 17E CLUTCH ACTUATOR / CLUTCH MOTION BEYOND PERMITTED LIMITS
383 17F ELECTRONIC CONTROL UNIT / DATA MEMORY (EEPROM) ACCESS ERROR WHEN
PERFORMING ACTIVE DIAGNOSIS
384 180 CLUTCH ACTUATOR / ERROR DURING CLUTCH CLOSING
385 181 CLUTCH ACTUATOR / ERROR DURING CLUTCH OPENING
386 182 ELECTRONIC CONTROL UNIT / DATA MEMORY (EEPROM) ACCESS ERROR WHEN
PERFORMING ACTIVE DIAGNOSIS (TOUCH-POINT)
400 190 DIGITAL OUTPUTS / SHORT-CIRCUIT TO POSITIVE ON ENGINE STARTING ENABLE
OUTPUT
401 191 DIGITAL OUTPUTS / SHORT-CIRCUIT TO POSITIVE ON REVERSING LIGHT IGNITION
OUTPUT
402 192 DIGITAL OUTPUTS / SHORT-CIRCUIT TO POSITIVE ON PTO ACTUATION ENABLE
OUTPUT
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403 193 SUPPLY VOLTAGE / SUPPLY VOLTAGE INSIDE THE ECU - TOO HIGH
404 194 SUPPLY VOLTAGE / SUPPLY VOLTAGE INSIDE THE ECU - TOO LOW
405 195 SUPPLY VOLTAGE / ECU SUPPLY VOLTAGE +30 HS - TOO HIGH
406 196 SUPPLY VOLTAGE / ECU SUPPLY VOLTAGE +30 HS - TOO LOW
407 197 SUPPLY VOLTAGE / KEY-CONTROLLED SUPPLY VOLTAGE +15 - TOO HIGH
408 198 SUPPLY VOLTAGE / KEY-CONTROLLED SUPPLY VOLTAGE +15 - TOO LOW
409 199 SUPPLY VOLTAGE / SUPPLY VOLTAGE INSIDE THE ECU - TOO HIGH
410 19A SUPPLY VOLTAGE / SUPPLY VOLTAGE INSIDE THE ECU - TOO LOW
411 19B SUPPLY VOLTAGE / ECU SUPPLY VOLTAGE +30 - TOO LOW
412 19C SUPPLY VOLTAGE / ECU SUPPLY VOLTAGE +30 - TOO LOW
413 19D GEARBOX OUTPUT REVS SENSOR / SHORT-CIRCUIT TO EARTH
414 19E GEARBOX OUTPUT REVS SENSOR / NON-PLAUSIBLE SIGNAL
415 19F GEARBOX OUTPUT REVS SENSOR / WRONG SIGNAL
434 1B2 SUPPLY VOLTAGE / ECU SUPPLY VOLTAGE (+30) DIFFERENT FROM KEY-CONTROLLED
VOLTAGE (+15)
435 1B3 GEARBOX OUTPUT REVS SENSOR / NON-PLAUSIBLE SIGNAL
436 1B4 SPEED ACTUATOR - SELECT / NON-PLAUSIBLE SIGNAL FROM THE SENSOR
437 1B5 SPEED ACTUATOR — SHIFT / NON-PLAUSIBLE SIGNAL FROM THE SENSOR
438 1B6 DIGITAL OUTPUTS / SHORT-CIRCUIT TO EARTH ON ENGINE START-PREVENT SIGNAL
439 1B7 DIGITAL OUTPUTS / TOO LOW VOLTAGE ON START-PREVENT SIGNAL
440 1B8 GEAR SELECTOR LEVER / MINOR ANOMALY
441 1B9 GEAR SELECTOR LEVER / SERIOUS ANOMALY - LACKING SIGNAL
442 1BA GEAR SELECTOR LEVER / GEARBOX LEVER POSITION NOT DEFINED
443 1BB DIGITAL OUTPUTS / SHORT-CIRCUIT TO EARTH ON REVERSING LIGHT IGNITION
SIGNAL


444 1BC DIGITAL OUTPUTS / SHORT-CIRCUIT TO EARTH ON PTO ACTUATION SIGNAL
450 1C2 ELECTRONIC CONTROL UNIT / GENERIC DATA MEMORY (EEPROM) ACCESS ERROR
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ELECTRONIC INJECTION SYSTEM

Common rail
General In the common rail a special pump continuously keeps the
In order to reduce the emission of particulate, particularly fuel at high pressure, regardless of the stroke and of the
high injection pressures are required. cylinder that is to receive injection, and accumulates it in a
common duct for all the injectors.
The system on the new Daily makes it possible to inject the
fuel at pressures reaching 1350 bar, while the pressure Therefore, fuel already at the injection pressure is always
obtained with electronic system management optimises the present at the inlet of the injectors.
work of the engine limiting emissions and consumption. When the solenoid valve of an injector is energised by the
In other diesel systems the high pressure is generated only electronic control unit, injection takes place in the
at the moment of injection for each single cylinder (injection corresponding cylinder.
pump or injector-pump).
Figure 132
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14 13 12 11
1
2
3
4
6 7 8 9 10
High pressure
Low pressure
Thermostarter supply
FUEL FEED AND RECIRCULATION DIAGRAM

1. Heat starter plug - 2. Heat starter electro valve - 3. Electrical injector - 4. Rail hydraulic accumulator - 5. 3rd pump
cutout electro valve - 6. High-pressure pump - 7. Fuel filter - 8. Electrically driver pump - 9. Prefilter - 10. Reservoir -
11. Pressure regulator valve - 12. Connection - 13. Pressure limiter valve - 14. Flow limiter
Print 603.93.281 Base - May 2004

Figure 133
In reality the system is much more complex, as the various
control and adjustment components have to be integrated.
The MS6.3 electronic control centre monitors the entire 9
system: it receives data from sensors and activates the
actuators as required based on input signal processing.
8
10
7
6 11
5
HYDRAULIC LAYOUT
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5. Pre-filter - 6. Electric pump - 7. Filter with
overpressure valve - 8. Pressure regulator - 9. Pressure
limiter - 10. Fuel outlets unit - 11. Thermal starter
Figure 134
B
C
OPERATING LAYOUT D
1. 3rd impeller cut-off device - 2. Flywheel rpm sensor - 3. High pressure pump - 4. Pressure regulator - 5. Other actuators
(thermal starter, heated filter, fan control, ac control) - 6. Electronic control unit with built-in atmospheric pressure sensor -
7. Other sensors (accelerator, brake, clutch, vehicle speed, water temperature, air temperature) - 8. From rail pressure
sensor - 9. Fuel tank - 10. Pre-filter - 11. Electric pump - 12. Fuel filter - 13. Filter overpressure valve - 14. Outlets unit
with calibrated hole - 15. Rail pressure limiter - 16. Air flow meter - 17. Common rail - 18. Injectors - 19. Timing sensor on
camshaft - A. To thermal starter - B. Electric circuit - C. Low pressure fuel - D. High pressure fuel
Base - May 2004 Print 603.93.281

Common rail (F1A) Preheat plugs are provided for cold starts.
It differs from the Common rail system on previous engines
in that injected fuel pressure is 1600 instead of 1350 bars.
Figure 135
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0003343t
1. High pressure pump - 2. Piping - 3. Pressure regulator - 4. Water in filter sensor - 5. Fuel filter with water separator -
6. Fule filter clogging sensor - 7. Fuel semperature sensor - 8. Fuel pressure line to filter - 9. Fuel return line to tank -
10. Fuel return line to filter - 11. High pressure piping to common rail - 12. Low pressure return line from rail - 13. Over
pressure valve - 14. Common rail - 15. Fuel pressure sensor - 16. High pressure line between rail and electro injectors -
17. Electro injectors - 18. Return line from electro injectors
Print 603.93.281 Base - May 2004

Hydraulic system (Common Rail - F1A)

The hydraulic system consists of a low and high-pressure circuit, the former consisting of the following piping:
- connecting high-pressure output to the Rail;
- Common Rail;
- connecting the Rail and supplying electro injectors.
The low-pressure circuit consists of the following piping:
- fuel aspiration from tank to prefilter;
- supplying the pump and prefilter;
- supplying the high-pressure pump via the fuel filter.
The Rail exhaust circuit and the electro injectors complete the supply circuit.
The following are mandatory for safety reasons because of high-pressure levels inside this hydraulic system:
- avoid improper connection of high pressure piping junctions;
- avoid connecting high pressure piping with the engine running (useless and hazardous attempts at purging must be avoided!)
Low-pressure circuit integrity is essential to proper system operation, so mishandling and modifications must be avoided, with
immediate action required in case of leaks.
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Figure 136
0003340t
1. High pressure pump - 2. High pressure line - 3. Electro injector recriculation line - 4. Electro injectors - 5. Common
rail - 6. Over pressure valve - 7. Bypass valve - 8. Filter - 9. Priming pump - 10. Tank - 11. Mechanical supply pump -
12. High pressure pump limiter valve - 13. Pressure regulator
Base - May 2004 Print 603.93.281

Figure 137 SYSTEM COMPONENTS

Camshaft pulley and timing sensor
Motor 8040
5 teeth (4 + 1 for timing detection) are machined on the
pulley opposite an inductive sensor equal to the one on the
flywheel.
5 holes (4 + 1 timing recognition hole) are provided on the
F1A engine pulley.
The sensor is of the inductive type and is used by the
electronic control unit to detect the engine stroke during
synchronisation (when starting).
When assembling the sensor:
ensure the dimension illustrated working on the slots of the
bracket and measuring with a thickness gauge
- make sure that the sensor is perpendicular in relation to
the wheel tightening the nuts.
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Figure 138
Motor F1A
0003320t
TIMING RECOGNITION HOLES
0003321t
TECHNICAL VIEWS OF PULLEY AND SENSOR

1. Camshaft pulley - 2. Sensor 1. Camshaft pulley - 2. Sensor
Print 603.93.281 Base - May 2004

Flywheel and rpm sensor Figure 140

The flywheel has a set of 58 holes (60 - 2), as illustrated, for
generating the signal for the inductive sensor.
It is the same as the one on the camshaft and is positioned on
the crankcase and detects the passage of the 58 holes on the
flywheel.
The change in the signal caused by the lack of 2 holes
(synchronism gap) which takes place at each rotation of the
crankshaft is the reference signal that allows the control unit
to recognise the advance in relation to the TDC of piston pair
1-4.
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.
When assembling the sensor:
- ensure the dimension illustrated working on the slots of
the bracket and measuring with a thickness gauge. HOLES FOR GENERATING SIGNALS ON THE
- make sure that the sensor is perpendicular in relation to FLYWHEEL
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the wheel tightening the nuts.
The F1A engine crankshaft sensor features a slatted sound Figure 141
wheel on the crankshaft front.
This features 58 (60-2) teeth and the sensor detects their
passage.
1
Figure 139
TECHNICAL VIEW OF FLYWHEEL AND SENSOR

1. Flywheel - 2. Sensor
Figure 142
0003319t
TECHNICAL VIEW OF THE SOUND WHEEL AND

SENSOR
RPM SENSOR ON CRANKCASE
1. Sound wheel ć 2. Crankshaft sensor
Base - May 2004 Print 603.93.281

Figure 143 Flywheel and camshaft sensor specifications

These are inductive sensors.
The flywheel sensor (48035) is connected at pins 29 and 37
of connector A of the control unit.
It is also used to control the electronic rev counter on the
instrument cluster.
The timing sensor (48042) is connected at pins 4 and 31 of
connector A of the control unit.
The resistance at 20 °C is approx. ~ 860 Ohm.
SENSOR AND CONNECTION CABLE
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Figure 144
SENSOR CONNECTOR AND WIRING DIRAGRAM
Print 603.93.281 Base - May 2004

Pre-filter The pipes are fitted with quick couplings.

This is a simple transparent filter like the one in petrol supply It is connected to pins 7 and 8 of connector A of the control
systems. unit.
Replace it only when a sight check reveals traces of impurity. Specifications
Electric pump Delivery pressure: 2,5 bar
Flow rate: > 155 litres/h
Rotary volumetric pump with integrated by pass (Figure 145) Supply: 13,5 V - < 5 A
located outside the fuel tank. Coil resistance at 20 °C: 28.5 Ohm
It is on the left-hand side of the frame in an accessible area.
There is no need to bleed the fuel supply system.
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Figure 145
TECHNICAL VIEW AND CROSS SECTION OF ELECTRIC FUEL PUMP
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Fuel filter
Cartridge degree of filtering: 5 micron
Differential operating pressure (obstruction indicator): 0.6 bar
The fuel temperature sent by the sensor to the electronic injection control unit allows very accurate calculation of the flow rate
of the fuel to be injected in the cylinders.
It is located in a fairly accessible position in the left front part of the engine compartment.
1. Actuated by ECU via relay with fuel temperature below 3°C.
2. Filtering element
3. Shows presence of water through a warning lamp on instrument panel.
4. Differential pressure sensor calibrated at 0,6 bar : any clogging is shown by warning lamp
5. It is a NTC sensor connected to EDC for fuel temperature reading enabling electronic control to calculate the amount of
diesel oil to be injected into the cylinders.
6. Installed on filter support for excess fuel return to tank.
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Figure 146 Figure 147
Engine 8040 Engine F1A
6 4
5 2
1 3
4
1 2 4
3
3
73731 003312t
FUEL FILTER
1. Heater - 2. Filtering element - 3. Condensation indicator 1. Clogged filter sensor - 2. Fuel temperature sensor -
- 4. Obstruction indicator - 5. Fuel temperature sensor - 3. Water sensor - 4. Heater
6. Discharge
Print 603.93.281 Base - May 2004

High pressure pump The pump is lubricated and cooled by the fuel itself.
This pump has three radial pistons (total displacement 0,7 The 3rd impeller cut-off solenoid valve (78015) serves to
cc) controlled by the timing gear belt, with no need for increase the part of fuel oil that lubricates the radialjet pump,
calibration. it is used above 4200 rpm (when power is no longer needed)
and keeps the intake valve open also when the cylinder is
Each impeller unit comprises:
compressing. It sends one third of the capacity of the high
- a piston (5) operated by a cam (2) integral with the pressure pump back to low pressure.
pump shaft (6)
The on-off time is considerably lower than conventional
- a plate inlet valve (3) injection pumps.
- a ball delivery valve (4) The control solenoid valve is connected to pins 20 and 21
The delivery pressure to the rail is modulated between 250
and 1350 bar by the electronic control unit, acting on the
pressure regulator solenoid valve.
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Figure 148
3 4 6 1
8
1
6 9 5
7 2 2
TECHNICAL VIEW AND CROSS SECTION OF HIGH PRESSURE PUMP

1. Cylinder - 2. Cam - 3. Plate inlet valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft - 7. Low pressure fuel inlet -
8. High pressure fuel delivery - 9. Fuel backflow
Base - May 2004 Print 603.93.281

High-pressure pump (F1A engine) The amount of fuel to be sent to the pump is set by pressure
regulator (7).
This pump is similar to the 8140 engine one.
The pressure regulator stops fuel inflow to the pump based
It differs in Rail line pressure, modulated at between 250 and
on PWM input from the centre.
1600 bars by the electronic centre by acting on the pressure
regulator electro valve and is not provided with a 3rd pump During pump compression, fuel reaches a pressure level
cutout electro valve (78015). sufficient to open the pressure valve to common rail (2), and
supplies it via output (1).
Pump (3) is oriented on the pump shaft cam.
During aspiration the pump is powered via supply conduit
(5).
Figure 149
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13
12
1 11
7 10
2
7
72595
5 6
72597
1. Output for rail pressure Ć 2. Rail pressure valve Ć 3. Pump Ć 4. Pump shaft Ć 5. Pump supply conduit Ć 6. Pressure
regulator supply conduit Ć 7. Pressure regulator Ć 8. High pressure pump Ć 9. Fuel input connection from filter - 10. Fuel
output connection to filter support - 11. Fuel input connection from centre heat exchanger - 12. Fuel output connection
from mechanical pump to filter - 13. Supply mehanical pump
Print 603.93.281 Base - May 2004

Pressure regulator When, after processing the various engine operating

parameters, the electronic control unit determines the need
This is located on the high pressure pump and modulates the
for a different injection pressure, it modulates a command
fuel pressure to the rail (and thus to the injectors) on the
signal in PWM to the regulator solenoid valve which
basis of the commands received from the electronic control
discharges the excess pressure in the pump backflow duct.
unit.
The modulated pressure is checked through the pressure
It mainly comprises:
sensor on the rail by the control unit, which, if necessary,
- a ball shutter (1) suitably modifies the intensity of the command signal to
reach the required result.
- a valve (3) control pin (2)
The control solenoid valve (78013) is connected to pins 9
- a preloading spring (4)
and 20 of connector A of the control unit.
- a coil (5)
When the solenoid is not energised, the delivery pressure
depends only on the spring preload.
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Figure 150
3 2 5 4
1 6
PRESSURE REGULATOR CROSS SECTION

1. Ball shutter - 2. Ppin - 3. Valve - 4. Preloading spring - 5. Coil - 6. Body - 7. Anchor
Base - May 2004 Print 603.93.281

Pressure regulator (F1A) When solenoid (1) is not activated, the magnetic core is
moved to its rest position by preload spring (6).
Similar to the one installed on the 8140 engine and mounted
on the CP3 pump low-pressure circuit. In these conditions, cylinder (3) is in a position to offer
maximum fuel passage cross-section.
When the engine control centre pilots the pressure
regulator via the PWM signal, solenoid (1) is activated, which Control electro valve 78013 is connected to centre
in its turn generates movement of magnetic core (2). connector A pins 9 and 20.
Core movement causes cylinder (3) axial displacement by
fuel delivery partialization.
Figure 151
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5
003386t
4
1 1
2 2
3
5
3 6
4
6
75574 75575
1. Solenoid Ć 2. Magnetic core Ć 3. Cylinder Ć 4. Fuel input Ć 5. Fuel output Ć 6. Preloiad spring Ć 7. Connector
Print 603.93.281 Base - May 2004

Rail (pressure accumulator) Screwed onto the rail there is a fuel pressure sensor. The
signal sent by this sensor to the electronic control unit is
The volume of the rail is small in size (29 cc) to allow quick
feedback information on the basis of which correct actuation
pressurising when starting, at idle speed and in the event of
of the rail pressure is checked.
high loads.
It has however sufficient volume to minimise the plenum
effect caused by opening and closing of the injectors and
operation of the high pressure pump.
Common Rail for engines with serial numbers over 3089322

Temporary solution with simulated flow limiters and over pressure valve connected to the fuel discharge unit.
Figure 152
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2
3
1
5 4
1. Common Rail - 2. Simulated flow limiter - 3. Simulated over pressure valve seat - 4. Pressure sensor -
5. Fuel input from high-pressure pump
Common Rail for engines produced since end-October 2000

Final Common Rail solution without flow limiters and over pressure valve. The new Common Rail features different pressure
sensor layout and discharge unit connection predisposition.
Figure 153
2
4
5
1
1. Common Rail - 2. To electrical injectors - 3. Pressure sensor - 4. Fuel discharge unit attachment -
5. Fuel input from high-pressure pump
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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.
The fuel sensor and overpressure valve are positioned on
Its some 22-cm3 volume dampens fuel pressure oscillations the hydraulic accumulator.
due to:
Figure 154
3
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1 5
75576
1. Common rail - 2. To electro injectors - 3. Fuel pressure sensor - 4. Overpressure valve -

5. Fuel input from high pressure pump
Figure 155
Over pressure valve
The over pressure valve protects system components in
the event that fuel pressure exceeds rated 1750 bars.
A The piston's conical end normally keeps discharge to
tank open.
B In the event of fuel pressure being over 1750 bars in
the rail, the piston is relocated and excess pressure is
discharged into the tank.
70500
70502
IVER PRESSURE VALVE

1. Body - 2. Piston - 3. Stop - 4. Spring - 5. Direct
discharge to tank - 6. Seat on the rail
Print 603.93.281 Base - May 2004

Figure 156 Flow limiters

These are located on the rail fuel outlet and their function is
to protect the engine or vehicle in the event of internal leaks
(for example, atomiser blocked open) and external leaks
(example: high pressure pipe damaged).
Under these circumstances they also allow, within certain
limits, the system to work through the components that are
still intact.
The passage of fuel from the rail to the injectors takes place
through the holes machined on the small diameter of the
piston.
Under normal conditions, the fuel pressure is exerted on both
sides of the piston, held n the open position by the spring.
In the event of a heavy loss of pressure downstream of the
limiter, the inlet pressure becomes preponderant and moves
the piston from the opposite side, obstructing the fuel outlet.
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Pressure limiter
The pressure limiter (1500 bar) screwed in the rail, serves to
protect the system components in the event of a failure to the
pressure regulator on the pump.
If the pressure of the fuel in the rail exceeds 1500 bar the
piston is raised and the excess pressure is eliminated.
TECHNICAL VIEW OF COMPONENT AND LIMITER

CONNECTOR
Fuel pressure sensor
Figure 157
This is fitted at the centre of the rail and measures the existing
VOLTAGE fuel pressure in order to determine the injection pressure.
The injection pressure value is used as feedback for closed
4.8V loop pressure control and to determine the duration of the
electric command for injection.
4.5V
It is connected to pins 6, 13 and 33 of connector A of the
control unit.
It is supplied at 5 Volt.
0.5V
0.2V Minimum
0 bar PRESSURE 1500 bar
PRESSURE LIMITER OPERATING GRAPH
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Injectors Figure 158

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.
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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
- A12 / A40 cylinder 1 injector
- A23 / A42 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
Print 603.93.281 Base - May 2004

Figure 159 Fuel outlets unit

All the outlets, overpressure and backflows of the various
hydraulic components converge in this unit.
3 Part of them is made available to the thermal starter, while the
2 rest returns to the fuel tank.
4
In the unit there is a 2,3 mm diameter drain hole.
This hole regulates the whole outlet system to maintain a
5 constant counter pressure of 0,5 bar, which is indispensable
for correctly supplying the thermal starter and it ensures flow
rates which prevent overheating of the fuel.
The calibrated hole is made in a union similar to

! the other unions. In the event of work on the
FUEL OUTLET UNIT system, take care not to fit another different
1. Fuel outlet to tank - 2. Return from injectors - union in its place as this would cause serious
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3. Delivery to thermal starter - 4. Leading from high operating failures.
pressure pump - 5. Arrival from filter
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Air flow meter Figure 161

This component incorporates a temperature sensor and a
pressure sensor.
It is fitted on the engine intake manifold (Figure 162) 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 A19 ECU - earth -
Pin 2 sensor - Pin A2 ECU - temperature signal
Pin 3 sensor - Pin A3 ECU - 5V - supply
Pin 4 sensor - Pin A34 ECU - 0 ÷ 5V
pressure signal -
Course of sensor in relation to the temperature:
Temperature Resistance
- 40 °C 48.50 kOhm 8660
AIR FLOW METER
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- 20 °C 15.67 kOhm
0 °C 5.86 kOhm Figure 162
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.
003323t
1. Air flow meter location
Figure 160
Figure 163
VOLTAGE
4.65V
19
34
0.4V
0.2 bar ABSOLUTE PRESSURE 2.5 bar
AIR FLOW METER OPERATING GRAPH AIR FLOW METER CONNECTION
Print 603.93.281 Base - May 2004

Figure 164 Air delivery gauge

Used in the EGR version to replace the one mounted on the
engine aspiration manifold.
The gauge is of the heated film type and is located o their
aspiration conduit between the turbine and the air filter.
The gauge contains the aspired air temperature sensor.
It is connected to the centre on pins A5 / A17 / A18 / A26
/ A28.
Pin 1 sensor - Pin A5 ECU - temperature signal
Pin 2 sensor - Pin A17 ECU - 5V power supply
Pin 3 sensor - Pin A18 ECU - mass
Pin 4 sensor - Pin A26 ECU - reference voltage
Pin 5 sensor - Pin A28 ECU - pressure signal
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003333t
1. Connector - 2. Gauge body - 3. Air input grid
The operating principle is based on a heated membrane

Figure 165 inserted in a measurement canal through which air to the
engine flows.
The hot film membrane is kept at a constant temperature
some 120 °C above incoming air level by the heating resistor.
The air mass traversing the measurement canal tends to
subtract heat from the membrane so current must cross the
resistor to maintain constant film temperature.
Current absorbed is proportional to the air mass flowing to
the engine and is measured with a Wheatstone bridge and the
signal is forwarded to the electronic centre.
003334t
TECHNICAL VIEW OF GAUGE CONNECTOR
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Figure 166 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.
It is connected to pins 1 and 30 of connector A of the control
unit.
Course of the sensor in relation to the temperature:
- 40°C 48.30 kOhm
- 20°C 15.46 kOhm
COURSE OF SENSOR RESISTANCE IN RELATION TO
Ą Ą0°C 5.89 kOhm
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TEMPERATURE
Ą 20°C 2.50 kOhm
Figure 167 Ą 40°C 1.17 kOhm
Ą 60°C 0.59 kOhm
Ą 80°C 0.32 kOhm
100°C 0.19 kOhm
120°C 0.11 kOhm
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.
unit.
It is exactly the same as the engine coolant temperature
sensor.
TECHNICAL VIEW OF ENGINE COOLANT
TEMPERATURE SENSOR
NTC
003324t
LOCATION OF F1A ENGINE COOLANT

TEMPERATURE SENSOR
WIRING DIAGRAM 1. EDC - 2. Signal instrument panel signal
Print 603.93.281 Base - May 2004

Figure 170
The accelerator pedal position sensor is of the potentiometric
type with incorporated N.O. minimum switch.
It gives the electronic control unit a value proportionate with
the operating angle of the pedal itself determining fuel
delivery.
It is supplied at 5 Volt.
The potentiometer resistance is approx. ~ 1 kOhm.
It is connected at pins 2, 13, 27, 29 and 35 of connector B of
the control unit.
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LOCATION OF SENSOR ON ACCELERATOR PEDAL
Figure 171
SENSOR WIRING DIAGRAM
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Figure 172 Brake pedal switches

Two switches are located on the brake pedal; N.C. 53565 si
connected directly to electronic centre pin B31 and 53501 is
connected to the centre via remote switch 25006 for stop
light actuation and to generate a redundant signal on the
centre increasing system reliability degree.
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003326t
1. Brake pedal switches
Figure 173
Clutch pedal switch
An N.C. switch connected to electronic centre pin B38 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
Print 603.93.281 Base - May 2004

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 174
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003328t
ELECTROMAGNETIC JUNCTION TECHNICAL VIEW0 (F1A)

1. Coil
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Preheat plug electronic centre Figure 175

(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 B42)
DI - EDC electronic centre (pin B37)
30 - Battery positive (+30)
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G1 - Preheat plugs
G2 - Preheat plugs
G3 - Preheat plugs
003332t
G4 - Preheat plugs
PREHEAT CENTRE
Figure 176
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 177
75579
PREHEAT PLUS
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EDC MS6.3 / 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:
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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%.
With heavy acceleration, on the basis of the signals received
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 (E.G.R. if present)
Depending on the engine load and the signal from the
accelerator pedal sensor, the control unit limits the amount
of air taken in, actuating partial suction of the exhaust gases.
Base - May 2004 Print 603.93.281

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 (F1 Engine)
- 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
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- overheating
Checking activation of air-conditioning system
- turbine over-revving.
The control unit operates the air-conditioning compressor:
The delivery can be modified in the case of:
- 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.
Print 603.93.281 Base - May 2004

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 (.15 - .17) 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.
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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
delivery, in relation to the engine load (accelerator position, is 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.
- in phases of acceleration;
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).
Base - May 2004 Print 603.93.281

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.
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.
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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
If there is no signal from the camshaft sensor, the control unit
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
control unit continues with the sequence on which it has
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
sequence and to start up the engine.
Print 603.93.281 Base - May 2004

Bosch MS6.3 control unit

Figure 178 85150
B A
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7420
PERSPECTIVE VIEW
A. Housing for injection cable connector - B. Seat for cabin-bonnet cable (UNIJET motor drive)
Figure 179
7406
LOCATION ON THE VEHICLE
Base - May 2004 Print 603.93.281

Control unit connection to the injection cable on engine side (housing A)

Figure 180
7421
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VIEW OF BOSCH 43-WAY CONNECTOR FROM CABLE INPUT SIDE
Cable
Pin Function
colour code
1 To engine coolant temperature sensor 5154
2 To turbo-blower air pressure and temperature sensor for EDC (without EGR) 5151
4 To engine rpm sensor on camshaft (cams) White
5 To temperature sensor and ambient air pressure for EDC (with EGR) 5151
6 Fuel pressure adjustment sensor earth 0000
7 Control to relay for switching on fuel pump 8150
8 Common EDC centre mass ć Centre monitored remote control switches - EGR electro valve 0000
9 To solenoid valve for pressure adjustment 9925
10 To solenoid valve for electronic injection (injector 2 - cylinder 3) Ċ
11 Spare Ċ
13 To solenoid valve for pressure adjustment 5590
14 Spare Ċ
15 Sensor (fuel temperature) for switching on fuel warming 5592
16 Spare Ċ
17 To ambient air temperature and pressure sensor for EDC (with EGR) 8150
19 Air temperature and pressure sensor earth (without EGR) 0165
20 Earth shared by control unit and radialjet and pressure solenoid valves (no radialjet for F1A) 0000
21 To solenoid valve for radialjet pump control (not for F1A) 9917
22 Spare Ċ
25 To solenoid valve controlling anti-pollution system (EGR.) (.13 - F1A) 5577
27 To speed limiter adjustment sensor 8847
29 To sensor for engine rpm White
30 Earth shared by control unit and temperature sensors 0150
31 To engine rpm sensor on camshaft (cams) Black
32 Control to relay for heated fuel oil filter 8159
33 To sensor for fuel pressure adjustment 5591
35 Control to relay for engaging conditioner compressor 9990
36 To solenoid valve actuator for VGT (.15) or to WASTE GATE solenoid valve (.13) 5000
37 To engine rpm sensor (.13 - .15 - F1A) Black
38 Spare -
39 Control to relay for engine cooling joint 7740
Print 603.93.281 Base - May 2004

Control unit connection to cab-bonnet cable (housing B)

Figure 181
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7422
VIEW OF BOSCH 43-WAY CONNECTOR FROM CABLE INPUT SIDE
Cable
Pin Function
colour code
1 To cruise Control 8156
2 To load sensor on accelerator for EDC 5157
3 Spare Ċ
4 To instrument panel module A1 rpm indicator repeater 5155
5 Spare Ċ
6 Compressor engaged signal to EDC 8162
7 To diagnostic socket 2299
8 To alarm control unit Green
9 EDC control unit supply 8150
11 Control to relay for connection with fuel tank for thermal starter (not for F1A) 0000
12 To earth signal (battery negative) 0000
14 Instrument panel module A20 rpm indicator repeater mass 0000
15 Spare Ċ
16 To instrument panel module A17 rpm signal 5614
17 Spare Ċ
18 Spare Ċ
20 To key-operated fuse 2 8051
21 To instrument panel module Al A30 engine preheat warning leds 0000
23 To instrument panel module Al EDC A29 defect warning leds 5156
25 To Cruise Control 8155
26 Supply with stop lights on 8153
30 Spare Ċ
31 Supply when brake pedal is pressed 8158
34 Spare Ċ
36 Spare Ċ
37 F1A preheat centre control 1310
38 To clutch pressed signal relay for EDC 0160
39 To alarm control unit White
40 Control to relay for EDC engagement 8150
42 Heater starter insertion remote control switch control/F1A preheat centre control 0000 / 1311
Base - May 2004 Print 603.93.281

EDC system components
Component
Ref. Description
code
1 58918 Instrument panel tachometer
2 58918 Instrument panel rev counter
3 42374 Clutch pedal switch
4 53565 Brake pedal switch
5 85152 Idling switch and accelerator pedal position sensor
6 47106 Fuel temperature sensor (F1A engine)
7 47106 Fuel temperature sensor
Fuel filter clogging sensor (8140 engine)
8 85157 Fuel pressure sensor (F1A engine)
9 85157 Fuel pressure sensor (8140 engine)
10 47035 Coolant temperature sensor
11 85156 Air delivery sensor
cardiagn.com
12 48042 Distribution sensor
13 48035 Crankshaft sensor (F1A engine)
14 48035 Flywheel sensor (8140 engine)
15 78247 Electro injectors
16 19005 Hot starter
78000 Hot starter electro valve (8140 engine)
17 25231 Plug preheat centre (F1A engine)
18 19010 Preheat plug (F1A engine)
19 85151 Fuel electro pump
20 78015 3rd pump cutout electro valve (8140 engine)
21 78013 Pressure regulator (8140 engine)
22 78013 Pressure regulator (8140 engine)
23 12012 AC compressor
24 78209 EGR modulating electro valve
25 85159 Air delivery sensor
26 58701 EDC warning light
27 58702 Preheat warning light
28 54032 Cruise Control/PTO controls
29 85130 Start key with Immobilizer
30 72027 Diagnosis connection
31 78248 VGT control electro valve (for 8140.43N engine)
32 85022 Fan electromagnetic connection
(*) On version without EGR
(**) On version with EGR
J Only on 8140 engines
F Only on F1A engines
Print 603.93.281 Base - May 2004

Figure 182
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77024
Base - May 2004 Print 603.93.281

Blink Code (up to chassis no. 5383302/ D187233) The order in which the errors are shown is the one in which
they occurred.
With the ignition switch off, press the diagnostic button.
To remove the error list from the memory, proceed as
Two series of blinks of the EDC warning light, at intervals
follows:
with a brief pause, will indicate the code of the first error
memorised. - With the ignition key off, press the diagnostic button
Press the button again to move to the next error. - keeping the button pressed, switch the ignition on
Each time the last error is reached, the first one will be - keep the button pressed for 5 seconds
repeated.
- release the button
The list of the errors contains all the errors memorised and
- Switch the ignition off.
not only the active ones.
The error codes are given in the following table.
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Common Rail 8140.43B - 8140.43S - 8140.43N - EDC MS6.3
(Software version 5.5)
Warning light Reduction level

Blink-Code Warning light
EDC (*)
VEHICLE
1.1 on Vehicle speed
1.3 off Cruise Control
1.4 flashing Accelerator pedal X
1.5 off Clutch switch
1.6 on Brake switch
1.7 off Brake/accelerator plausibility Idling setting
1.8 off Diagnostic warning light / Main EDC warning
1.9 off Conditioner control relay
ENGINE 1
2.1 flashing H2O temperature sensor X
2.2 off Air temperature sensor
2.3 on Fuel oil temperature sensor
2.4 flashing Boosting pressure sensor X
2.5 off Atmospheric pressure sensor
2.7 flashing Fuel pump
2.8 off Fuel filter heater control relay
2.9 on Fan control relay
ENGINE 2
3.1 flashing Cylinder 1 balancing
3.5 off Battery voltage
3.6 off Thermal starter warning light
3.7 off Thermal starter
3.8 off Thermal starter solenod valve
3.9 off Preheat monitoring
TURBINE
4.4 flashing VGT monitoring
4.5 on VGT electro valve
Print 603.93.281 Base - May 2004

Warning light Reduction level

Blink-Code Warning light
EDC (*)
INJECTORS
5.1 flashing Cylinder injector 1
5.7 on Bearing 1 (cylinders 1-4)
5.8 on Bearing 2 (cylinders 2-3)
ENGINE RPM
6.1 flashing Engine rpm sensor X
6.2 flashing Camshaft revolution sensor X
6.4 flashing Over-revving
INTERFACE
7.1 off PWM signal
7.2 off CAN bus inactive
7.3 off CAN bus control
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7.4 off CAN message control
FUEL PRESSURE/EGR
8.1 flashing Fuel pressure control X or
Engine cutout
8.2 flashing Fuel pressure sensor X
8.3 flashing Pressure regulator
8.4 off 3rd impeller cut-off solenoid valve
8.5 on EGR control
8.6 on EGR valve
8.7 on Debit meter X
8.8 off EGR atmospheric pressure sensor
CENTER
9.1 flashing Control unit error X or
Engine cutout
9.2 on Control unit EEPROM fault
9.3 flashing Immobiliser - EDC communication
9.4 on Main relay
9.5 off After run Test
9.6 flashing Engine stop test (ECU)
Engine stop test (ECU)
9.7 flashing Sensor supply X or
Engine cutout
9.8 flashing Control unit error Start impossible
9.9 flashing ECU operating system Engine cutout
F1A Common Rail

Differs for the following codes:
3.6 off Preheat warning light

3.7 off Preheat plug centre
3.8 off Preheat plug centre
3.9 off Preheat monitoring
8.4 off (Not used)
Base - May 2004 Print 603.93.281

EDC16
The EDC.16 control unit offers a few innovations compared to the control unit used with system EDC MS6.3.
- latest-generation hardware and software;
- possibility of processing a greater number of signals (both input and output);
- preset for the control of new additional functions and devices, which will be adopted later for technological improvement
of the product range or compliance with forthcoming anti-pollution rules.
The variants compared with the MS6.3 system are as follows:
- new sensor on the accelerator pedal;
- new sensor on the distributing shaft (phase);
- engine cable;
- bonnet/cab cable;
- new connectors for control unit connection.
The EDC.16 system replaces the MS6.3 system on engines F1A (.10 - .12). It is present on F1C engines.
Diagnosis is only performed by using the diagnostic instruments available. No Blink Code is provided.
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The other features are the same as the 6.3 system.
Print 603.93.281 Base - May 2004

Bosch EDC16 control unit

Figure 183
K A
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85711
PERSPECTIVE VIEW
A. Engine side injection cable connector - K. Bonnet/cab cable connector
Figure 184
7373
LOCATION ON THE VEHICLE
Base - May 2004 Print 603.93.281

Control unit connection to the injection cable on engine side (housing A)

Figure 185
85708
85710
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Cable
Pin Function
colour code
1 0000 Cylinder injector 3
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
19 0000 Pressure regulator negative
20 7158 Distributing shaft sensor positive
21 − Drive shaft sensor braided wire
23 0165∗ Boosting air pressure and temperature sensor negative
27 white Drive shaft sensor
28 5591 Rail sensor power supply
29 8152 Air flow meter power supply (available with EGR)
37 5151 Air flow meter air temperature signal (available with EGR)
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
Print 603.93.281 Base - May 2004

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
(*) Available when the EGR is not provided
- Pins not highlighted are not used
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Base - May 2004 Print 603.93.281

Control unit connection to cab-bonnet cable (housing K)
Figure 186
85708
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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)
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 2299 K line
28 8051 +15
30 0159 Accelerator pedal sensor negative (pin 3)
31 5157 Accelerator pedal sensor signal (pin 6)
38 8155 Cruise Control (resume)
42 - Speed limiter button
45 5158 Accelerator pedal sensor power supply (pin 2)
46 5158 Accelerator pedal sensor power supply (pin 1)
48 5614 Engine speed sensor (revs counter)
52 1310 To preheating spark plug actuation remote-control switch pin D1
54 8162 Signal from air-conditioning ON compressor remote-control switch
56 8157 Cruise Control (set +)
57 - Auxiliary speed limiter (where available)
58 - Signal from clutch switch
61 - CAN L line
62 - CAN H line
68 8150 Fuel filter heating remote-control switch positive
Print 603.93.281 Base - May 2004

Cable
Pin Function
colour code
Positive to the remote-control switch for engine water recirculation shut-off solenoid valve
70 9990
control with auxiliary heater ON
71 5156 EDC warning light negative
72 8150 Main relay (negative)
75 5155 Vehicle speed signal (tachometer)
77 8154 Cruise Control (off)
78 8156 Cruise Control (set -)
80 8158 Brake pedal signal
90 7740 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
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Base - May 2004 Print 603.93.281

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
signals (V) are detected by the control unit that processes 5 V voltage supplied by the control unit itself.
them according to stored threshold values and manages the
cardiagn.com
Figure 187
EDC MS6.3 EDC 16
85714
Print 603.93.281 Base - May 2004

Figure 188 Camshaft sensor (F1A)

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).
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0003320t
The resulting signal is supplied to the processor that controls
the injection system.
1. Phase identification holes
Figure 189
0003321t
1. Distributing shaft pulley - 2. Sensor
Figure 190
2
1 3
85712 85713
PERSPECTIVE VIEW
1. Power supply positive - 2. Signal output - 3. Earth
Base - May 2004 Print 603.93.281

Injection cable F1A (.10 - .12)

Figure 191
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85723
Print 603.93.281 Base - May 2004

Injection cable F1A (.14)

Figure 191/1
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101882


19010 Preheat plug
25231 Plug insert centre
70064 1-way fuse holder
85150 EDC center
85156 EDC blower air pressure sensor
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Joint connector
Connection between cab/bonnet cable and injection cable (Unijet)
Print 603.93.281
Figure 192
8587
I 8588
7740 8159 7740

8159
5577 5577 5000
I F1A
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8150 0077 0077 8150 0000 0077
9990 0000 0000 9990
8159
8589
I F1A (EDC16)
9990 0000
7740 1311
8150 1311 8150

1131
5577
5577 8150 1310
8847 8150
5577
8150 0077 0077 8150

74269
1310 0000 0000 1310
Ref. (F1A Cable colour

Ref. Ref. (F1A) Function
EDC16) code
1 5000 To pin 36 of EDC electronic control unit
2 3 8150 Fuel pump engagement relay
3 4 7740 Relay engagement for engine cooling electromagnetic joint control
4 5 9990 Air conditioning compressor switching off
I 5 6 8159 Fuel oil heating circuit switching on
6 8 0000 Earth
7 1 1 5577 Fuel oil heating resistance supply
8 16 8 0077 Fuel oil heating resistance earth
10 2 8150 Preheat plug centre positive (pin-86)
11 4 1310 Preheat plug centre control (pin-D1), (EDC pin-B37)
12 5 1311 Preheat plug centre control (pin-ST), (EDC pin-B42)
13 6 0000 Preheat plug centre mass (pin-31)
2 8847 Speed adjustment sensor positive
7 - Free
9 - Free
14 - Free
15 - Free
3 8150 Positive after key for air flow meter
Base - May 2004 Print 603.93.281

Diagnostic connector Figure 194

Near the positive terminal of the battery there is a diagnostic
connector. It is fastened by 2 screws to a special bracket fitted
on the body and access to it is gained by unscrewing the
protective cap; suitably connected to the diagnostic system
(IWT, MODUS), it allows quick identification of the cause of
faults in the various electronic devices.
The table on the following page shows the correspondence
between the various electronic systems and the connector
pins referring to them.
NOTE The connector shown is seen from the pin side.
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The diagnosis connector on F1A engine vehicles is located on
the conveyor unit lower party on the passenger side.
85620
38-PIN DIAGNOSTIC CONNECTOR
9
3 16
22
29
1 35
4 38
10
17
23 36
30
8621
38-POLE DIAGNOSIS TAKEOFF DENTIFICATION OF THE PINS OF THE 38-PIN

DIAGNOSTIC CONNECTOR
Print 603.93.281 Base - May 2004
Diagnostic connector pin description table
System Pin Function
EDC/EGR/Methane 1∗ L
2 K
ABS/EBD/ABD 3 L
4 K
Air Bag/Retarder 6 K
Tachometer (connector A cell 2 instrument cluster) 8 K
Supply +15/A services 11 Input
Immobilizer/Central door locking/Alarm 12 K
Climate control system 13 L
14 K
Self-levelling suspension 15 L
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16 K
Engine timing signal (connector B pin 28 EDC control unit) 23∗ -
Engine timing earth (battery -) 24 Screening
Supply +30 27 Battery +V
Engine rpm 28 RPM
Vehicle speed 29 -
Earth 30 -
(*) In vehicles equipped with F1 engine and EDC 16 electronic control unit, diagnosis connector pins 1 and 23 are free.
Pin 21/22 CAN line
Base - May 2004 Print 603.93.281

High-pressure pump (F1A engine) The amount of fuel to be sent to the pump is set by pressure
regulator (7).
This pump is similar to the 8140 engine one.
The pressure regulator stops fuel inflow to the pump based
It differs in Rail line pressure, modulated at between 250 and
on PWM input from the centre.
1600 bars by the electronic centre by acting on the pressure
regulator electro valve and is not provided with a 3rd pump During pump compression, fuel reaches a pressure level
cutout electro valve (78015). sufficient to open the pressure valve to common rail (2), and
Pump (3) is oriented on the pump shaft cam.
(5).
Figure 196
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9
1
7
85846
2
7
3
5 6
72597
1. Rail delivery output - 2. Rail delivery valve - 3. Pplunger - 4. Pump shaft - 5. Plunger supply duct - 6. Pressure regulator
supply duct - 7. Pressure regulator - 8. High-pressure pump - 9. Mechanic feed pump - A. To the tank - B. Return from
hydraulic accumulator (rail) - C. Fuel filter return - D. Delivery to hydraulic accumulator (rail) - E. From the tank
- F. Return from injectors.
Print 603.93.281 Base - May 2004

F1C ENGINE
Figure 197
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*** *
**
87246
1. Injectors - 2. Common-Rail pressure sensor - 3. Pre-heating glow plugs - 4. Air temperature sensor - 5. Pre-heated
diesel oil filter - 6. Diesel oil temperature sensor - 7. High pressure sensor - 8. Pre-heating glow plugs central unit -
9. Sectioning by cab cable - 10. Pre-heating central unit positive - 11. Fuse - 12. Central unit - 13. Engine r.p.m. sensor -
14. Water temperature sensor for EDC - 15. Camshaft r.p.m. sensor - *. Water temperature transmitter for thermometer -
**. Oil filter clogged sensor - ***. Engine oil level sensor
Base - May 2004 Print 603.93.281

Injection cable F1C (.14 - .17)

Figure 198
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with .17 (VGT)
*
90164
Print 603.93.281 Base - May 2004

Connection between cab/bonnet cable and injection cable
Figure 199
8587
cardiagn.com
I 8588
8159
8159
5577 5577 5000
8150 0077 0077 8150
9990 0000 0000 9990
8589
Cable colour
Ref. Function
code
1 5577 Heated diesel oil filter positive
2 8150 Pre-heating central unit (pin 86)
3 - -
4 1310 Pre-heating central unit (pin-D1)
I 5 1311 Pre-heating central unit (pin-ST)
6 0000 Pre-heating central unit earth (pin-31)
7 - -
8 0077 Heated diesel oil filter earth
Base - May 2004 Print 603.93.281

R.p.m. / timing sensors
Figure 200
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88056
1. R.p.m. sensor - 2. Phonic wheel on drive shaft - 3. Timing sensor - 4. Phonic wheel on camshaft
Print 603.93.281 Base - May 2004

Timing sensor (stroke)
Figure 201
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88264
88267
1. Phonic wheel on camshaft - 2. Identification slots - 3. Sensor
Base - May 2004 Print 603.93.281

RPM sensor Figure 203

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
cardiagn.com
Figure 204
Figure 202
87793
1. Phonic wheel
0003319t
TECHNICAL VIEW OF THE SOUND WHEEL AND

SENSOR
1. Sound wheel - 2. Sensor
Print 603.93.281 Base - May 2004

Figure 205 RPM sensor

These are inductive sensors.
The flywheel sensor (48035) is connected at pins 27 and 12
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 206 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.
cardiagn.com
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 207
2
3 1
85712
TIMING SENSOR
1. Earth - 2. Signal output - 3. Power supply positive
Base - May 2004 Print 603.93.281

High-pressure pump The amount of fuel to be sent to the pump is set by pressure
regulator (7).
Pressure delivered to the rail is modulated between 250 and
1600 bars by the electronic central unit by operating on the The pressure regulator stops fuel inflow to the pump based
solenoid valve of pressure regulator. on PWM input from the centre.
Pump (3) is oriented on the pump shaft cam. During pump compression, fuel reaches a pressure level
sufficient to open the pressure valve to common rail (2), and
(5).
Figure 208
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B–B
88072
1. Output for rail pressure - 2. Rail pressure valve - 3. Pump - 4. Pump shaft - 5. Pump supply conduit - 6. Pressure
regulator supply conduit - 7. Pressure regulator - 8. High pressure pump - 9. Fuel input connection from filter - 10. Fuel
output connection to filter support - 11. Fuel input connection from centre heat exchanger - 12. Fuel output connection
from mechanical pump to filter - 13. Supply mehanical pump
Print 603.93.281 Base - May 2004

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 209
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5
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
Base - May 2004 Print 603.93.281

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 210
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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 211
VOLTAGE
4.8V
4.5V
0.5V
0.2V Minimum
0 bar PRESSURE 1500 bar
PRESSURE LIMITER OPERATING GRAPH
Print 603.93.281 Base - May 2004

Figure 212 Air delivery gauge with EGR

Used in the EGR version to replace the one mounted on the
engine aspiration manifold.
The gauge is of the heated film type and is located o their
aspiration conduit between the turbine and the air filter.
The gauge contains the aspired air temperature sensor.
It is connected to the central unit on connector "A".
Pin 1 sensor - Pin A37 - temperature signal
Pin 2 sensor - Power supply (+15)
Pin 3 sensor - Pin A44 - mass
Pin 4 sensor - Pin A29 - reference voltage
Pin 5 sensor - Pin A42 - pressure signal
* If present
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003333t
GAUGE
1. Connector - 2. Gauge body - 3. Air input grid
The operating principle is based on a heated membrane

inserted in a measurement canal through which air to the
Figure 213 engine flows.
The hot film membrane is kept at a constant temperature
some 120 °C above incoming air level by the heating resistor.
The air mass traversing the measurement canal tends to
subtract heat from the membrane so current must cross the
resistor to maintain constant film temperature.
Current absorbed is proportional to the air mass flowing to
the engine and is measured with a Wheatstone bridge and the
signal is forwarded to the electronic centre.
003334t
TECHNICAL VIEW OF GAUGE CONNECTOR
Base - May 2004 Print 603.93.281

Air temperature/pressure sensor Figure 214

(without EGR)
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
8660
AIR FLOW METER
cardiagn.com
- 40 °C 48.50 kOhm
- 20 °C 15.67 kOhm
0 °C 5.86 kOhm Figure 215
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 216
VOLTAGE
4.65V
0.4V
0.2 bar ABSOLUTE PRESSURE 2.5 bar
AIR FLOW METER OPERATING GRAPH
Print 603.93.281 Base - May 2004

Figure 217 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.
unit.
Course of the sensor in relation to the temperature:
- 40°C 48.30 kOhm
COURSE OF SENSOR RESISTANCE IN RELATION TO - 20°C 15.46 kOhm
TEMPERATURE
Ą Ą0°C 5.89 kOhm
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Ą 20°C 2.50 kOhm
Ą 40°C 1.17 kOhm
Figure 218
Ą 60°C 0.59 kOhm
Ą 80°C 0.32 kOhm
100°C 0.19 kOhm
120°C 0.11 kOhm
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.
unit.
It is exactly the same as the engine coolant temperature
sensor.
TECHNICAL VIEW OF ENGINE COOLANT
TEMPERATURE SENSOR
Figure 220
Figure 219
NTC
003324t
LOCATION OF ENGINE COOLANT TEMPERATURE

SENSOR
WIRING DIAGRAM 1. EDC signal - 2. Signal instrument panel
Base - May 2004 Print 603.93.281

Fuel filter
Cartridge degree of filtering: 5 micron
Differential operating pressure (obstruction indicator): 0.6 bar
The fuel temperature sent by the sensor to the electronic injection control unit allows very accurate calculation of the flow rate
of the fuel to be injected in the cylinders.
It is located in a fairly accessible position in the left front part of the engine compartment.
1. Actuated by ECU via relay with fuel temperature below 3°C.
2. Filtering element
3. Shows presence of water through a warning lamp on instrument panel.
4. Differential pressure sensor calibrated at 0,6 bar : any clogging is shown by warning lamp
5. It is a NTC sensor connected to EDC for fuel temperature reading enabling electronic control to calculate the amount of
diesel oil to be injected into the cylinders.
6. Installed on filter support for excess fuel return to tank.
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Figure 221
1 3
2 4
003312t
1. Clogged filter sensor Ć 2. Fuel temperature sensor Ć 3. Water sensor Ć 4. Heater
Print 603.93.281 Base - May 2004

Figure 222 Brake pedal switches

On brake pedal there are two switches; an N.C. (53565) is
directly connected to the central unit at pins K17-K80. It
provides signals (voltages) in order to warn the central unit
about occurred braking.
Second switch 53501 N.A. provides a voltage for turning on
stop lights.
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003326t
1. Brake pedal switches
Figure 223 Clutch pedal switch

An N.C. switch connected to electronic centre pin K58 is
mounted on the clutch pedal (42374).
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
Base - May 2004 Print 603.93.281

Injectors Figure 224

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.
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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
Print 603.93.281 Base - May 2004

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 225
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88064
ELECTROMAGNETIC JUNCTION TECHNICAL VIEW

1. Coil - 2. Connector
Base - May 2004 Print 603.93.281

CLIMATE CONTROL - manually:

fan speed
General compressor on/off
The function of the system is to automatically or manually outside air inlet/re-circulation
control the temperature required in the cab. MAX DEF function (defrosting);
According to the set required temperature the system - totally manually (through bowden cables):
controls: distribution of air flows to the air vents.
- automatically:
air vent temperature
fan speed (continuous changing)
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Figure 226
000250t
AIR FLOW DISTRIBUTION INSIDE THE CAB
Print 603.93.281 Base - May 2004

Operating logic The control unit carries out and sets certain functions to
obtain adaptation of the temperature of the cab to the one
A special electronic control unit controls automatic system
required depending on the requests received and the
operation checking the various parameters in order to
temperature conditions detected.
provide the comfort required in the cab.
Figure 227
1 2 3 4
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11 12 5
TEMP – kml
6
3 9
16
22
29
1 35
4 38
10
17 36
23
30
10
6A
7
000251t
9 8
CLIMATE CONTROL ELECTRONIC CONTROL UNIT CONNECTIONS

1. Controls on dashboard: inside temperature sensor, re-circulation switch, "eco" switch, fan control potentiometer -
2. Outside temperature sensor - 3. Evaporator sensor - 4. Blown air sensor - 5. Digital display - 6. Fan electronic control
module - 6A. Fan - 7. Compressor - 8. Gear motor for re-circulation function - 9. Air mixing gear motor -
10. Diagnostic connector - 11. EDC-EGR control unit - 12. Climate control electronic control unit
Base - May 2004 Print 603.93.281

Air distribution knob Figure 228

A. Face area vents
B. Face and floor area vents
C. Floor area vents
D. Floor and windscreen area vents
E. Windscreen area vents
C
B D
A E
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000252t
DETAIL OF AIR DISTRIBUTION KNOB
Figure 229
1 2 3
4
000241t
VENTILATION AND HEATING CONTROLS ASSEMBLY

1. Temperature adjustment knob - 2. Fan speed control knob - 3. Air distribution knob - 4. Outside air inlet or re-circulation
Print 603.93.281 Base - May 2004

Figure 230 Air distribution knob with climate control system
A. Face area vents

B. Face and floor area vents
C C. Floor area vents
D. Floor and windscreen area vents
E. Windscreen area vents
F. Max def" function
B
D
A E
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F
000254t
DETAIL OF AIR DISTRIBUTION KNOB
Figure 231
1 2 3
6 5 4
00025et
CLIMATE CONTROL SYSTEM CONTROLS ASSEMBLY

1. Knob for setting required temperature - 2. Fan speed control knob - 3. Air distribution knob - 4. Eco" function switch -
5. inside temperature sensor - 6. Re-circulation knob
Base - May 2004 Print 603.93.281

Setting the required temperature Figure 232

To set the required temperature, turn the corresponding
knob (Figure 232) to the 18 °C - 30 °C range.
This knob is connected to a potentiometer which detects the
different angular positions and transmits a signal to the
There are fifteen different positions (one per degree
centigrade) with two extremes LO" and HI" which
correspond respectively to the coldest and warmest
positions.
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000255t
KNOB FOR SETTING REQUIRED TEMPERATURE
Setting the fan speed

Figure 233
To set the required fan speed, turn the corresponding knob
(Figure 233) to the 0 to 4 range.
This knob is connected to a potentiometer which detects the
different angular positions and transmits a signal to the
There are six different positions, four of which are set
manually (1, 2, 3, and 4), one for no air flow (0) and an
automatic one controlled by the electronic control unit
where the system itself selects the most suitable air flow to
reach and/or maintain the required temperature (AUTO).
000256t
KNOB FOR SETTING FAN SPEED
Print 603.93.281 Base - May 2004

Auto" function In the MAX DEF" mode this function is cut off regardless
With the ventilation control knob in the AUTO" position, of the position of the switch.
the control unit will be able to control:
MAX DEF" function
- The air temperature at the vents. The engagement of this function is completely manual and
- Fan speed. is obtained turning the air distribution clockwise as far as the
MAX DEF" position.
Function 0" (OFF)
The control unit will be informed of this request by the
With the ventilation control knob in the 0" position, the closing of a special N.O. microswitch in the rear part of the
control unit acts as follows: knob.
- No air flow (fan off). The engagement of this function involves:
- Mixing stopped in the previous position. - Maximum air flow, regardless of the position of the
- Re-circulation on. knob.
- Compressor off. - Air distribution towards the windscreen through
bowden cables.
- MAX DEF" function cut off if in progress.
- Mixing with the highest heat available (memorising the
ECO" function last position of the motor before leaving the adjustment
The engagement of this function is completely manual and state).
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is obtained through the special switch which makes it - Outside air inlet, regardless of the position of the
possible to disengage the compressor electromagnetic re-circulation button.
clutch.
- Compressor on, regardless of the position of the ECO
Compressor control is however linked to other parameters, button.
namely:
Switching this function off the gear motor moves back to the
- Outside temperature ( > 5 °C ON" ) position memorised previously if the temperature
- Evaporator temperature ( > 4 °C ON", < 3.5 °C adjustment knob is not at LO" or HI".
OFF" ) If this function is already selected when the ignition key is
- Coolant fluid system pressure (min. 3.5 bar, max. 28 bar) turned on, no position will be memorised, and switching it
off, the adjustment procedure will be started with the mixing
- EDC or EGR control unit (in versions where applicable). gear motor in the HI" condition.
Re-circulation" function
The engagement of this function is completely manual and
is obtained through the special switch which makes it
possible to shut off the outside air inlet.
Base - May 2004 Print 603.93.281


This automatically controls the system monitoring the thermodynamic parameters in order to provide the suitable climate
(temperature and humidity) required by the driver.
It is located on the lower part of the passenger's side duct unit.
Figure 234
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A B
000257t
Connector Pin Function

1 Signal from treated air temperature sensor
2 Signal from required temperature potentiometer
3 Signal from ventilation control potentiometer
4 Earth
5 Positive from ECO" switch
6 Positive from microswitch for MAX DEF" function
A
7 Signal earth
8 Supply (+15/A)
9 5 V supply for ventilation, temperature and air mixing potentiometers
10 Line L for 38-pin diagnostic connector pin 13
11 Line K for 38-pin diagnostic connector pin 14
12 Positive from switch for re-circulation
1 Positive (0 to 8 V) for fan electronic control module (0 to 6 V)
2 Serial line for digital display (instrument cluster pin B 11")
3 Signal from evaporator temperature sensor
4 Reference voltage from air mixing motor (0 to 5 V)
6 Signal from outside temperature sensor
7 Signal from inside temperature sensor
8 Negative for fan electronic control module
B
10 Supply (0 to 12 V) for re-circulation gear motor (+12 V for switching on re-circulation)
11 Supply (0 to 12 V) for re-circulation gear motor (+12 V for switching on re-circulation)
12 Key-operated positive supply
13 Positive for compressor control relay
14 Supply (0 to 12V) for air mixing gear motor (+12V with HI" function)
15 Supply (0 to 12V) for air mixing gear motor (+12V with LO" function)
16 Reference voltage from electronic fan control module (0 to 12 V)
Print 603.93.281 Base - May 2004

Figure 235 Outside air temperature sensor

This is an NTC sensor on the left wing mirror (Figure 235) for
both types of drive.
The resistance at 25 °C is 10 kOhm.
Operating range between - 30 °C and + 50 °C.
It is connected to pin 6 connector B of the control unit.
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8665
OUTSIDE TEMPERATURE SENSOR
Base - May 2004 Print 603.93.281

Inside temperature sensor

This is an NTC sensor located on the climate control module (Figure 237) between the two Re-circulation" and ECO"
switches.
It is ventilated and contains a motor/fan so that the temperature reading is not affected by stagnating air inside the dashboard
which is not realistic.
The resistance is 2.2 kOhm at 25 °C
Operating range between + 5 °C and + 45 °C
The motor A, fan B and sensor C are a single part and are connected to the wiring by a single connector at pin 12.
Figure 236
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A B C
000260t
Pin Function
1 Positive for motor
2 Negative for motor
3 Signal earth
4 Sensor signal for control unit (pin 7 connector B)
5 Positive from microswitch for MAX DEF" function to control unit (pin 6 connector A)
6 Ċ
7 Positive from ECO" switch to control unit (pin 5 connector A)
8 Earth
9 +15/A supply
10 +15/A supply
11 Negative for lighting pictograms
12 Positive from re-circulation switch to control unit (pin 12 connector A)
Print 603.93.281 Base - May 2004

Figure 237 Blown air temperature sensor

This is an NTC sensor positioned inside the distributor unit
upstream of the air distribution ports to the various vents.
The resistance at 25 °C is 10 kOhm.
Operating range between 0 °C and - 80 °C
It is connected to pin 1 connector A of the control unit.
Evaporator temperature sensor

This is an NTC sensor positioned inside the distributor unit
and it is fitted directly on the evaporator. It causes switching
on (>4 °C) and switching off (>3.5Ă°C) of the compressor
electromagnetic clutch. The resistance at 25 °C is 10 kOhm.
Operating range between 0 °C and +25 °C.
Required temperature potentiometer

This is a potentiometer connected to the required
temperature setting knob on the climate control panel.
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It detects the various angular positions (Figure 238) and
transmits a signal to the electronic control unit for a total of
fifteen different positions (one per degree centigrade) two of
which are the extremes HI" and LO" which correspond
respectively to a request for the coldest and warmest
positions.
000255t
It is supplied by the control unit at 5V.
Resistances R1 to R16 are approx. 700 Ohm.
Resistance R17 is approx. 1.1 Mohm
The total resistance R is approx. 11 kOhm.
It is connected to pin 2 and 9 connector A of the control unit.
REQUIRED TEMPERATURE SETTING KNOB
Figure 238
A B C
000265t
POTENTIOMETER POSITION DETECTION LAYOUT
A. Signal earth (ms7) - B. Signal to control unit pin 2 connector A - C. positive from control unit pin 9 connector A
Base - May 2004 Print 603.93.281

Ventilation control potentiometer Figure 239

This is a potentiometer connected to the ventilation control
knob positioned on the climate control panel.
It detects the various angular positions (Figure 240) and
transmits a signal to the electronic control unit for a total of
six different positions, four of which are manual flows (1, 2, 3,
and 4), one no air flow and one automatic (AUTO).
It is supplied by the control unit at 5 V.
The resistance R1 to R7 are approx. 1.5 kOhm.
Resistance R8 is approx. 1.1 Mohm.
The total resistance R is approx. 10.5 kOhm.
It is connected to pins 3 and 9 connector A of the control unit.
000256t
VENTILATION CONTROL KNOB
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Figure 240
A B C
000266t
POTENTIOMETER POSITION DETECTION LAYOUT

A. Signal earth (ms7) - B. signal to control unit pin 3
connector A - C. Positive from control unit pin 9
connector A
Print 603.93.281 Base - May 2004

Figure 241 Electronic fan control module

This is an electronic circuit inside the distributor unit near the
fan (Figure 241) and it adjusts the fan speed.
It is driven by the control unit with a voltage of between o and
5 Volt.
It drives the fans with a voltage of 0 to 12 Volt.
It is connected to pins 1 and 16 connector B of the control
unit.
The graph (Figure 243) represents the air flow rate in relation
to the control voltage from the control unit.
LOCATION OF FAN ELECTRONIC CONTROL

MODULE
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Figure 242
A
B
000268t
ELECTRONIC FAN CONTROL MODULE

CONNECTIONS
A. Electronic fan control module - B. Electronic climate
control unit - C. Fan motor
Figure 243
000269t
GRAPH OF AIR FLOW RATE IN RELATION TO

VOLTAGE
Base - May 2004 Print 603.93.281

Air mixing gear motor

The gear motor formed of a motor and potentiometer is positioned inside the distributor unit and acts on the port that sends
or does not send the flow of incoming air onto the heater radiator to be able to adjust the required temperature.
The potentiometer detects the actual position of the mixing port and informs the control unit of its position. The control unit
reaches the two extreme positions, which correspond to the request for the coldest position LO" and the warmest position
HI" inverting the polarity on pins 14 and 15 of connector B of the control unit.
+ 15 / - 14 for LO" function
- 15 / + 14 for HI" function.
Motor
This is supplied by the control unit at 12 V. It is connected to the control unit on pins 14 and 15 of connector B of the control
unit. Loadless absorption is ≤ 60 mA, in D.C. it is ≤ 380 mA.
Potentiometer
It is supplied by the control unit at 5 V. The resistance is 4.7 kOhm. It is connected to the control unit on pins 7 and 9 connector
A and on pin 4 connector B of the control unit.
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Figure 244
8669
Pin Cable colour Function

1 White-Blue Positive (5 V) for potentiometer from pin 9 connector A of the control unit
2 Grey-Black Reference voltage (0 to 5 V) from pin 4 connector B of the control unit
3 Black Signal earth
4 Yellow-Green Supply (0 to 12 V) for motor from pin 15 connector B of the control unit
5 - -
6 Blue-Red Supply (0 to 12 V) for motor from pin 14 connector B of the control unit
Print 603.93.281 Base - May 2004

Re-circulation gear motor

The gear motor is located on the front part of the distributor unit and acts on the air inlet port.
The control unit opens or closes this port to control air inlet from outside or re-circulation inverting the polarity on pins 10 and
11 of connector B of the control unit.
+ 11 / - 10 to switch on re-circulation
- 10 / + 11 for outside air inlet.
There are no intermediate positions. It is supplied by the control unit at 12 V. It is connected to the control unit on pins 10 and
11 connector B of the control unit. Loadless absorption is ≤ 60 mA, in D.C. it is ≤ 380 mA.
Figure 245
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1 3
8668

1 Blue-Red Supply (0/12 V) from pin 11 connector B of the control unit
3 Brown Supply (0/12 V) from pin 10 connector B of the control unit
Base - May 2004 Print 603.93.281

Compressor Figure 246

This is fitted on the left-hand side of the engine and it is a
NIPPONDENSO SCROLL 08.
The fluid used is Freon R 134A".
The quantity of fluid is 720 grams.
The type of oil used is solely ND Oil 08.
The quantity of oil is 80 grams.
000274t
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COMPRESSOR
Figure 247
Safety pressure switches
These are fitted directly on the dryer filter (Figure 248).
The minimum A" and maximum B" pressure switches make
it possible to keep the pressure constant in the system
between a minimum of 2 bar and a maximum of 27 bar, while A B
the average set at 19 bar is used to switch on the condenser
fan.
C
1 3 4 2
8666
PRESSURE SWITCH UNIT WIRING DIAGRAM

A. Mnimum = 2 bar - B. Maximum = 27 bar -
C. Average = 19 bar
Figure 248
8666a
PRESSURE SWITCH UNIT ON DRYER FILTER
Print 603.93.281 Base - May 2004

Figure 249 SYSTEM SELF-DIAGNOSTICS

Through suitable control logic the control unit is able to
memorise and display a series of faults (present and/or
A B C intermittent) that may occur to the system.
In the event of these faults the control unit still continues
controlling the system replacing the abnormal values detected
with suitable recovery" values which ensure minimal
operation of the system.
As a fault arises, the control unit shows the wording Error
Cli" on the display on the instrument cluster.
- For preliminary information it is possible to show any
faults on the display on the instrument cluster following
000276t a precise procedure.
- For complete more thorough diagnostics it is however
CLIMATE CONTROLS ASSEMBLY necessary to use the diagnostic tools available to the
A. Required temperature setting knob service network such as MODUS.
B. Speed control knob
C. Air distribution knob Diagnostics through blink code
To find out which is the component concerned, proceed as
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Figure 250
follows:
Move the temperature setting knob to the HI" position (Ref.
30 / 15 A Figure 249).
Move the fan control knob to the 0" position (Ref. B
Figure 249).
Move the air distribution knob to the MAX DEF" position
(Ref. C Figure 249)
Engage the ignition switch (Figure 250) at the services
position (+15).
Within 10 seconds, operate the fan control knob (Figure 250)
with the following sequence:
0" ⇒ AUTO" ⇒ 0" ⇒ AUTO" ⇒ 0".
At this point the display on the instrument cluster
(Figure 251) displays the error code. If more than one error
is present, they are displayed every 3 seconds.
000278t
IGNITION SWITCH AND FAN SPEED CONTROL

KNOB SETTING
Figure 251
Error
Cli ⇒ 54
000279t
DISPLAY ON INSTRUMENT CLUSTER
Base - May 2004 Print 603.93.281

Blink codes
The table below shows the different error codes that may appear on the display on the instrument cluster instead of CLI" during
diagnostics.
Figure 252
Error
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Cli ⇒ 54
000279t
Codice Description
14 Short circuit or open circuit of blown air temperature sensor
32 Short circuit towards earth of outside temperature sensor
34 Short circuit or open circuit of outside air temperature sensor
42 Short circuit towards earth of inside temperature sensor
44 Short circuit or open circuit of inside air temperature sensor
52 Short circuit towards earth of evaporator temperature sensor
54 Short circuit or open circuit of evaporator temperature sensor
65 Air mixing gear motor failure
82 Short circuit towards earth of required temperature potentiometer
84 Short circuit or open circuit of required temperature potentiometer
92 Short circuit towards earth of ventilation control potentiometer
94 Short circuit or open circuit of ventilation control potentiometer
B2 Short circuit towards earth of air mixing potentiometer signal
B4 Short circuit or open circuit of air mixing potentiometer signal
D5 Fan electronic control module failure
E2 Short circuit towards earth of pin 9 of connector A of control unit for supplying potentiometers
E3 Short circuit towards positive of pin 9 of connector A of control unit for supplying potentiometers
F6 Supply voltage over maximum limit
F7 Supply voltage below minimum limit
Print 603.93.281 Base - May 2004

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.
The system components are connected to one another and with the rest of the electric system through a special harness, that
can be easily recognised as it has a yellow sheath which is connected to the cab/bonnet cable by a 6-cell connector.
Figure 253
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A B
C 9
3 16 22 E
29
1 35
4 38
10
17 23 36
30
8546
8621
F G H
000287t
AIR BAG SYSTEM COMPONENTS

A. Driver's air bag module - B. Passenger's air bag module - C. 38-pin diagnostic connector - D. Electronic control unit -
E. Air bag failure warning light on instrument cluster - F. Driver's reel with pretentioner - G. Centre reel with pretensioner
- H. Passenger's side reel with pretensioner.
Base - May 2004 Print 603.93.281

Operation deployed bags and the inside of the vehicle may be covered
The air bag system consists of a cushion which inflates with dust: this may irritate the skin and eyes. In the case of
instantly contained in a special recess in the centre of the exposure, wash with neutral soap and water.
steering wheel for the driver and in the dashboard for the two
passengers.
In the event of a head-on crash a deceleration sensor inside
the air bag control unit activates the pretensioners and the NOTE Turning the ignition switch to MAR, the air bag failure
instantaneous inflating device of the cushion or cushions warning light turns on for four seconds as system
which act as protective barrier between the body of the self-diagnostics takes place.
occupants and the vehicle structure. Immediately afterwards
the driver's air bag and, if requested, the passenger's air bag
deflate.
Deployment of the air bag system produces heat and a small Each time the system is activated, the control unit keeps the
amount of powder. This powder is not harmful and does not failure warning light on the instrument cluster on and it will
cause fire. In addition the surface of the be necessary to change the whole system (control unit, belts
and pretensioners, bags and harness).
The system does not require any maintenance or checks.
Figure 254
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A B C D E F
L K J I H G 8556
LOCATION OF AIR BAG SYSTEM COMPONENTS AND CABLE
A. 38-pin connector for diagnostics - B. Air bag failure warning light - C. Cock spring - D. Driver's air bag module -
E. Connection between cab/bonnet cable and air bag cable - F. Passenger's air bag module - G. Passenger's reel with
pretensioner - H. Centre reel with pretensioner - I. Air bag earth - J. electronic control unit - K. driver's reel with
pretensioner - L. relay/fuse holder support
Print 603.93.281 Base - May 2004

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
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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.
Base - May 2004 Print 603.93.281

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
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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.

!
Print 603.93.281 Base - May 2004

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,
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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.
Base - May 2004 Print 603.93.281

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
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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.
Print 603.93.281 Base - May 2004

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
safety device is disabled and this could cause unforeseen
components) should be installed. As mentioned previously,
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
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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.
Base - May 2004 Print 603.93.281

Figure 255 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.
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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
Print 603.93.281 Base - May 2004

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
deployed the vehicle can be scrapped - by squashing
It is advisable to deploy the explosive charges on the vehicle
directly connecting the electric connector of the single or crushing - and/or recycled depending on the cases.
module to the remote deployment system.
Figure 256
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
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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.
Base - May 2004 Print 603.93.281

Figure 257 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
8547
the direction in which the deceleration sensor reads
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BATTERY CABLE INSULATION the values for defining the crash condition and thus
triggering the air bag.
Figure 258
The electronic control unit should always be replaced after a

crash that causes deployment of the complete system (air bag
and pretensioners).
To remove the control unit:
- follow the rules of safety
- disconnect the battery cables (firstly the negative one
then the positive) and isolate them taping the terminals
- wait at least ten minutes before proceeding
- remove the cover under which the control unit is to be
found
8548
- using a small screwdriver on the catch of the connector
REMOVING THE CONNECTOR FROM THE that locks the connector fastening lever, turn the latter
CONTROL UNIT outwards
Figure 259 - disconnect the connector from the control unit
- slacken the three screws fastening the control unit to the
floor.
8549
REMOVING THE CONTROL UNIT
Print 603.93.281 Base - May 2004

One-connector electronic control unit pin-out
Figure 260
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000283t
Pin Function Pin Function
1 Positive for driver's pretensioner 26 Driver's pretensioner short circuit

2 Negative for driver's pretensioner 27 Driver's pretensioner short circuit
3 Positive for passenger's pretensioner 28 Passenger's pretensioner short circuit
4 Negative for passenger's pretensioner 29 Passenger's pretensioner short circuit
5 Key-operated positive supply 30 Ċ
6 Earth 31 Earth short circuit
7 Ċ 32 Short circuit
8 Ċ 33 Ċ
9 Line k for diagnostics 34 Ċ
10 Positive for driver's bag 35 Driver's bag short circuit
11 Negative for driver's bag 36 Driver's bag short circuit
12 Ċ 37 Ċ
13 Positive for passenger's bag 38 Passenger's bag short circuit
14 Negative for passenger's bag 39 Passenger's bag short circuit
15 Ċ 40 Failure warning light
16 Positive for centre pretensioner 41 Centre pretensioner short circuit
17 Negative for centre pretensioner 42 Centre pretensioner short circuit
18 Ċ 43 Ċ
19 Ċ 44 Ċ
20 Ċ 45 Ċ
21 Ċ 46 Ċ
22 Ċ 47 Ċ
23 Ċ 48 Ċ
24 Earth for diagnostics 49 Ċ
25 Ċ 50 Ċ
Base - May 2004 Print 603.93.281

The figure shows the components of the AIRBAG system with two-connector control unit. This type of control unit shall be
fitted on the vehicles in the future to replace the one-connector control unit.
Figure 261
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A B
C 9
3 16 22 E
29
1 35
4 38
10 73790
17 23 36
30
8621
F G H
000287t
AIR BAG SYSTEM COMPONENTS

A. Driver's air bag module - B. Passenger's air bag module - C. 38-pin diagnostic connector - D. Electronic control unit -
E. Air bag failure warning light on instrument cluster - F. Driver's reel with pretentioner - G. Centre reel with pretensioner
- H. Passenger's side reel with pretensioner
Print 603.93.281 Base - May 2004

The two-connector control unit operates within a temperature range of -40 a +85°C with a maximum inclination angle
tolerance at installation of ±4°. The control unit weight is 200g max and features software version 4.4 and hardware version 11.0.
The following figure represents a perspective view of the electronic control unit with two connectors (A and B).
Figure 262
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A
B
73792
PERSPECTIVE VIEW OF THE ELECTRONIC CONTROL UNIT WITH TWO CONNECTORS

A. Black - B. Grey
Base - May 2004 Print 603.93.281

ECU pin-out to the two connectors
Figure 263
A B
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73791
GREY CONNECTOR (A) BLACK CONNECTOR (B)

Pin Function Pin Function
1 Ground 1 -
2 +15 power supply 2 -
3 K-line for diagnosis 3 -
4 - 4 -
5 - 5 -
6 - 6 -
7 - 7 -
8 - 8 -
9 - 9 -
10 Warning lamp 10 -
11 - 11 -
12 - 12 -
13 - 13 Driver side pre-tensioner positive
14 - 14 Driver side pre-tensioner negative
15 - 15 Front passenger seat pre-tensioner negative
16 - 16 Front passenger seat pre-tensioner positive
17 - 17 -
18 - 18 -
19 - 19 -
20 - 20 -
21 Driver front AIR-BAG positive 21 Front center pre-tensioner positive
22 Driver front AIR-BAG negative 22 Front center pre-tensioner negative
23 Passenger front AIR-BAG negative 23 -
24 Passenger front AIR-BAG positive 24 -
Print 603.93.281 Base - May 2004

Figure 264 Drivers air bag module

The module is at the centre of the steering wheel.
It mainly comprises the following:
- a bag inflation device, containing the triggering device and
the explosive charge
- a synthetic fibre bag, folded in a special wrapping
- a plastic cover which at the centre and sides has
pre-established splitting lines which allow the bag out.
- A plate that fastens the module to the steering wheel
with two screws
Inflation of the bag takes place through the pre-established
controlled expansion of the volume of inert harmless gas
(ARGON), contained in a special module, after the heating
caused by a charge of solid propellant.
The rear part of the bag has suitably-sized holes which deflate
8557
the bag immediately after inflation.
AIR BAG MODULE To remove the air bag module, proceed as follows:
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Figure 265 - follow the rules of safety
then the positive) and isolate them taping the terminals;
- wait at least ten minutes before proceeding;
- slacken the two screws in the rear part of the steering
wheel; to gain access to each screw, turn the steering
wheel to be able to always work from the part of the
upper steering column cover;
- lift the module enough to disconnect the connector in its
centre;
- remove the module from the steering wheel.
8558
AIR BAG MODULE FASTENING SCREWS After removal undeployed air bags must be stored
Figure 266 ! in a special, key-lockable cabinet with the plate
rested on the shelf.
8559
AIR BAG MODULE REMOVAL
A. Connector
Base - May 2004 Print 603.93.281

Clock spring Figure 267

The clock spring is a device fitted on the stalk unit ensuring
electrical continuity between the driver's module and the air
bag cable; it is formed of a container from which two cables
lead. One is connected to the air bag cable and one to the
driver's module. The container is composed of two overlaid
plates; the lower one is fastened to the stalk unit by three
screws and the upper one is made integral with the steering
wheel through two appendixes on its upper section.
Inside the two plates, the connection cables are wound in a
coil to be able to allow the cables to follow the movements
of the steering wheel, The clock spring also has a mechanism
that automatically prevents it from turning when it is removed
from the steering wheel; this consists in preventing the upper
plate, no longer restrained, from turning freely causing
unwinding or winding of the cables, with the possibility of
breakage.
When the steering wheel is assembled the device locks 8560
automatically. REMOVING THE STEERING WHEEL FASTENING

NUTS
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To remove the clock spring, proceed as follows:
- remove the driver's air bag module as described on the Figure 268
previous page
- align the wheels and keep them in this position
throughout the whole operation
- slacken the nut fastening the steering wheel to the
steering column
- still with the wheels aligned, mark the position between
the steering wheel hub and the steering column
- remove the steering wheel taking care not to withdraw
the clock spring cable
8561
REFERENCE BETWEEN STEERING WHEEL HUB AND

STEERING COLUMN
Make sure that removing the steering wheel cause Figure 269
! the upper plate of the clock spring to raise. If the
upper plate turns, it must be locked taking it
outwards; a click will be heard during locking.
8562
REMOVING THE STEERING WHEEL
Print 603.93.281 Base - May 2004

Figure 270 - remove the steering column lower half cover slackening
the three fastening screws (Figure 270)
- working from inside, remove the upper steering column
half cover slackening the two fastening screws
- cut the strap that fastens the clock spring cable to the
steering column and disconnect the connector of this
cable from the air bag cable
- slacken the three screws fastening the clock spring to the
stalk unit and remove it.
It is necessary to remove the clock spring without

! making it turn, holding the upper plate in place with
a strap or adhesive tape.
8563
REMOVING THE STEERING COLUMN COVER HALVES

To refit the clock spring, proceed as follows:
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- make sure the wheels are aligned
Figure 271 - if replacement of the clock spring is not necessary, refit
it, after removing the adhesive tape or strap put on
previously, without making the upper plate turn, then
tighten the three fastening screws
- in the case of fitting a new clock device, after fastening it
to the stalk unit, tear the plastic tab to lock the upper plate
and check that it does not turn
- connect the air bag cable connector to the clock spring
cable and fasten the latter to the steering column using
a suitable clamp
- assemble the two steering column halves fastening them
on the support plate with their screws
- carefully insert the cable to be connected to the driver's
air bag module through the slot provided on the steering
wheel hub
8564 - assemble the steering wheel making the reference marks
made previously coincide.
REMOVING THE CLOCK SPRING
- Tighten the steering wheel fastening nut to the specified
torque.
Figure 272
Do not re-use the steering wheel fastening nut

! removed previously, replace it with a new one and
caulk it.
NOTE If the stalk unit is changed it must be replaced by

one inclusive of the clock spring.
8565
CLOCK SPRING
Base - May 2004 Print 603.93.281

Passenger's air bag module Figure 273

This module is fitted on the dashboard and it is fastened on
the body by a special bracket; the operating principle is the
same as for the driver's module, only the size of the bag differs,
as it has to protect two people.
To remove the air bag module, proceed as follows:
- slacken the two screws fastening the dashboard cover
- remove the dashboard cover in such a way as to
overcome the resistance of the snap button in the lower
part of the cover
- disconnect the module cable connector from the air bag
cable 8553
- slacken the four screws two on either side, that fasten the PASSENGER'S AIR BAG MODULE
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module support bracket to the body and remove it.
Figure 274
NOTE If the passenger's air bag is not fitted as it is optional,

a specific resistance is fitted on the connector during
production to simulate the charge
(R = 2.15 Ohm ± 0.35)
8554
REMOVING THE DASHBOARD COVER
Figure 275
8555
REMOVING THE AIR BAG MODULE
Print 603.93.281 Base - May 2004

Figure 276 Pretensioners

The pretensioner is an explosive device activated electrically
with a signal leading from the electronic control unit; it is an
integral part of the seat belt reel and forms a single component
with it which is fastened to the vehicle pillar. It comes into
action in the event of a crash of a certain entity, in order to
take up the unavoidable slack in the seat belts due to the
action of the weight of the body, keeping the body close to
the seat back.
After cutting in the belt remains locked meaning that the
device has been triggered.
Operating principle
The moment in which a determinate deceleration of the
vehicle takes place, the electronic sensor in the control unit
sends a signal which ignites the explosive charge (ref. A) of the
gas generator (detonator).
The combustion of the propellant (ref. B) develops a gas, the
pressure of which generates a force that pushes the rack and
REEL WITH PRETENSIONER pinion piston (ref. C) upwards.
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Figure 277 The upward movement of the piston makes the gears turn
(ref. D) which reverse the direction of rotation of the belt
rewinding it a few centimetres.
D
C
NOTE The belt is unserviceable after every crash and needs

B to be changed.
A
- The charge for the driver's pretensioner is connected to
the control unit on pins 1/2.
- The charge for the passenger's pretensioner is connected
to the control unit on pins 3/4.
TECHNICAL VIEW OF REEL WITH PRETENSIONER
- The charge for the centre pretensioner is connected to
BEFORE DEPLOYMENT
the control unit on pins 16/17.
A. Explosive charge - B. Propellant - C. Rack and pinion
piston - D. Gears
Figure 278
TECHNICAL VIEW OF REEL WITH PRETENSIONER

AFTER DEPLOYMENT
Base - May 2004 Print 603.93.281

Driver's/passenger's pretensioner Figure 279
Do not use percussion screwing machines for the

! following operations on active pretensioners.
To remove the driver's or passenger's reel with pretensioner,

proceed as follows:
- slacken the screw fastening the tool kit under the seat
- slacken the seat fastening screw and remove it
- slacken the two screws fastening the step to the door 8550
pillar base
STEP FASTENING SCREW
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- partially remove the door weatherstrip
- slacken the screw fastening the seat belt Figure 280
- remove the lower pillar trim overcoming the resistance
of the two snap buttons in the upper part of the trim
- disconnect the pretensioner connector from the air bag
cable (ref. A)
- connect the specific resistance on the air bag cable to
simulate the presence of the pretensioner; this is to
prevent the control unit from signalling a failure on the
system that does not exist if the ignition switch is
inadvertently turned to AVV or MAR.
- slacken the reel fastening screw (ref. B) and remove the
reel.
8551
REMOVING THE WEATHERSTRIP AND BELT FROM

THE PILLAR
Figure 281
8552
A
REMOVING THE REEL WITH PRETENSIONER
A. Connector - B. Fastening screw
Print 603.93.281 Base - May 2004

Figure 282 Centre passenger's pretensioner
Do not use percussion screwing machines for the

! following operations on active pretensioners.
The centre passenger's reel with pretensioner has the same

operating principle as the other two reels. To remove it
proceed as follows:
- slacken the screw fastening the tool kit under the seat
8566
- slacken the seven screws fastening the seat
REMOVING THE TOOL KIT - disconnect the pretensioner connector from the air bag
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cable
Figure 283
- remove the seat
- connect the specific resistance on the air bag cable to
simulate the presence of the pretensioner; this is to
prevent the control unit from signalling a failure on the
system that does not exist if the ignition switch is
inadvertently turned to AVV or MAR.
- slacken the three screws fastening the guard on the rear
part of the seat
- remove the guard
- slacken the reel and belt fastening screw, then remove the
reel with pretensioner
8567
REMOVING THE SEAT

8569
8568
REMOVING THE GUARD REMOVING THE REEL WITH PRETENSIONER
Base - May 2004 Print 603.93.281

DOOR-BLOCKER WITH ANTI-THEFT PROTECTION

General information
The anti-theft protection is supplied with the door-blocker and consists of the following:
- a warning siren
- an (ultrasonic) electronic module for volumetric detection, including a LED for signalling that the anti-theft protection is ON
- an electronic central control unit (ECU) for the anti-theft/door-blocker, 433.92 MHz for the European market
- two remote-control keys.
When the anti-theft protection is activated/de-activated by means of the remote-control key, the doors (driver's and passenger's
doors and, for the van version, the side and rear doors) of the vehicle close/open simultaneously.
To complete the system, in addition to the components already mentioned above there are the following:
- switches and motors for closing/opening the doors.
- switch for signalling that the bonnet is being opened.
- switch on a switchboard for locking the rear door.
In addition, the electronic central control unit is connected to the immobiliser control unit, to the direction indicator switch
(indicator flashing lights) and to the 38-pin diagnostics connector (cell 12).
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Figure 286
A B C D E F G
8572
M L K J I H
LOCATION OF COMPONENTS
A. Switch for signalling opening of the bonnet - B. Electronic central control unit (ecu) - C. Motor for closing/opening the
lock on the passenger-side door - D. Electronic module for volumetric detection and led for signalling that the anti-theft
protection is on - E. Motor for closing/opening lock on right-hand side door - F. Switch for signalling opening of rear door -
G. Motor for closing/opening lock on rear door - H. Switch for signalling opening of right-hand side door - I. Switch for
signalling opening of door on driver's side - J. Motor for closing/opening lock of door on driver's side - K. Switch for signalling
opening of door on passenger's side - L. Switch for blocking rear door - M. Self-powered siren
Print 603.93.281 Base - May 2004

System components
Figure 287
Rear door
button
Driver Passenger RH side LH side Rear
Side doors
button
Driver
Passenger
Engine
Bonnet
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50288
Ref. Function
1 Driver door lock/release motor

2 Passenger lock/release motor
3 RH door lock/release motor
4 LH door lock/release motor
5 Rear door lock/release motor
6 Rear door button
7 Side doors button
8 Driver/passenger doors button
9 Engine bonnet button
10 Siren
11 Remote control key
12 Injection system control unit
13 Volumetric detector electronic module
14 Tester connector
15 Direction indicator telltale
16 Electronic control unit
Base - May 2004 Print 603.93.281

Operation
When the push-button on the remote-control key is activated, this is signalled by the LED on the key itself, and a radio-frequency
(RF) signal is sent to the ECU. This signal controls closing of the doors by means of the motors, activates the volumetric sensor
installed in the ceiling-lamp inside the cab and signals that the anti-theft protection has been activated by causing the indicator
flashing lights to flash twice and the "anti-theft activated" LED to flash once. About ten seconds pass between the time when
the signal is sent to the ECU and when the system is actually active. During this period of time, the ECU checks that all the
necessary conditions (state of the doors, inside of the cab) for activating the anti-theft protection are met. Once the 10 seconds
have elapsed the system is active and is constantly checked by the ECU.
If the ECU does not find all the conditions required for correct activation of the system while it carries out the anti-theft activation
procedure (for example, if one of the doors is not closed), the state of the door will not be checked during the system monitoring
that the ECU carries out upon completion of the activation procedure. Once the door has been closed, this too will be checked
by the ECU, starting ten seconds from the time when it was closed.
The conditions in which the anti-theft protection switches on are the following:
- if the driver's/passsenger's doors are opened
- if the rear door is opened
- if the bonnet is opened
- if the side door(s) is(are) opened
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- if the engine is switched on
- if the volumetric detection module is activated.
If any of the above conditions occur, the sound of the self-powered siren and the flashing of the indicator flashing lights for five
minutes will signal that the system has switched on.
In order to be able to open the doors and de-activate/switch off the anti-theft protection, it is necessary to press the push button
on the remote-control key again. The ECU will de-activate the anti-theft protection. The indicator flashing lights will flash once
and the signalling LED of the anti-theft protection will go off to confirm that it has been de-activated.
Print 603.93.281 Base - May 2004

240
Base - May 2004

B
C Figure 288
ELECTRIC/ELECTRONIC SYSTEM
Arrangement of components
G F
50287
A. Engine bonnet switch - B. Volumetric detector electronic module - C. Door lock motor - D. Remote control key - E. Door switch - F. Electronic control unit
- G. Siren
DAILY
Print 603.93.281
cardiagn.com
MAIN COMPONENTS OF THE SYSTEM

Remote-control key
The electronic device controlling the anti-theft protection with the door-blocker can be mounted in the grip of the key or in
any suitable place for the remote-control function.
Features:
- transmission frequency 433.92 MHz
- transmission of combined code (fixed and variable)
- red LED for signalling transmission of the code
- 3V CR 2032 battery
- operation from -30 °C to +60 °C
- retention of the rolling-code" data (variable part of the combined code) in the memory of the microprocessor in the key
during replacement of the battery
- maximum power transmitted: 10 mW.
On pressing the push button in the key, all the doors will be opened or closed and the anti-theft protection will be activated
or de-activated. The red LED on the key will flash to signal transmission of the radio-frequency code to the ECU. If the pushbutton
is activated for a time exceeding 20 minutes, transmission of the code to the ECU will be broken off, in order to prevent the
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battery of the remote-control key from going dead due to accidental activation of the push button.
As already stated, the remote-control key transmits a combined code (fixed and variable). The fixed code that is transmitted
is always the same for each individual key, while the second part changes each time the pushbutton is pressed.
The keys supplied are two. It is important that they should both follow the correct key-learning procedure by means of the IVECO
diagnostic tools with the +15 power supply on. The indicator flashing lights will flash once to signal that the code has been received
by the ECU.
If the remote-control key gets partly or totally damaged, with the +15 power supply on, the immobiliser will send a signal to
the ECU to de-activate it.
If the exchange of data between the transponder and the engine management is successfully completed, the immobiliser will send
a 500 msec ± 10 % message to the ECU. This signal will occur after 500 msec ± 10 % from when the +15 power supply is switched
on. If it is not, that is to say if the immobiliser signal does not fall within the range of values indicated above, the ECU will switch
on the anti-theft protection. The impulses generated by the immobiliser after repeated switching on of the +15 power supply
will be ignored.
Figure 289
50268
Print 603.93.281 Base - May 2004

Remote control key battery

The key supplied as standard contains a 3 volt type CR2032 lithium battery. Battery life is about one year, since Bosch guarantees
it for 50,000 working cycles at a temperature of between -30 °C to + 60 °C.
Batteries from competing brands can be easily found on the market, but the Bosch warranty is not valid unless only PANASONIC
batteries are used.
Replacing the battery
Battery replacement should not take longer than 3 minutes. When fitting the new battery pay attention to battery polarity.
If you fail to comply with the foregoing instructions the ROLLING CODE necessary to transmit the signal from the key to the
control unit will be deleted.
The ROLLING CODE can be reset by following the key synchronisation procedure.
Key synchronisation procedure
- introduce the key into the switch
- turn it to start
- press the remote control button
This procedure makes it possible to reset the ROLLING CODE
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Base - May 2004 Print 603.93.281

Electronic central control unit (ECU)

The central control unit is located underneath the central dashboard. It controls both centralised closing/opening of the doors
and activation/de-activation of the anti-theft protection by means of the signal supplied to it by the remote-control key, with
the consequent switching on of the remote-control switches located inside the actual control unit.
If one of the remote-control switches should be blocked (working contact blocked) during operation, causing continuous
activation of the door-locking motor(s), the control unit will switch on remote-control switches that create bridges on the
remote-control switch in question, in order to avoid serious damage to the motor(s) concerned. Once normal operation of the
faulty remote-control switch is reinstated, then these remote-control switches will switch off.
The central unit is connected to the cable in the cab/bonnet by means of one 12-pin connector and one 28-pin connector. Each
central unit has a pin code, which is programmed at the end of the line test. This pin code will consist of 5 digits, each of which
will be a binary-coded decimal number from 0 to 9.
In addition, the ECU detects faults in the system, signalling the by causing the anti-theft signalling LED at the centre of the ceiling
light to flash. It is possible to identify two types of failure: minor and major. In the first case, with the +15 power supply on, the
LED will remain on without flashing, while in the second case, again with the +15 power supply on, the LED will flash. Major failures
are those concerning the ECU, and are caused by:
- an error in the ROM/RAM check sum
- an error in the EEPROM check sum
- remote-control switch with working contact blocked.
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Print 603.93.281 Base - May 2004

Technical view of the ECU

Figure 290
B A
50285
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Pin out ECU
Connector Pin Function
1 Door-blocker on driver's and passenger's side

2 -
3 +15 power supply
4 -
5 Rear door-blocker from switch on dashboard
A
6 -
7 Side and rear door-blocker
8 Door-unblocker
9 +30 power supply
10 -
11 Earth
12 -
1B4 -
5 Siren
6 Power supply to led for signalling activation of the anti-theft protection
7 Earth
8B11 -
12 Immobiliser disabling
13 -
14 Switching on of LED signalling activation of the anti-theft protection
15 To switches for switching on the inside lights on driver's and passenger's side doors
B
16 To the switches for switching on the inside lights on the right-hand side doors
17 To the switches for switching on the inside lights on the rear door
18-19 -
20 To the switch signalling opening of the bonnet
21 To the 38-pin diagnostics connector (cell 12)
22 To the switch for switching on the inside lights on the left-had side door
23 Signal from electronic volumetric detection module
24 Switching on of indicator flashing lights
25B28 -
Base - May 2004 Print 603.93.281

DAILY
Print 603.93.281
Figure 291
B
Arrangement of the switches
50284
ELECTRIC/ELECTRONIC SYSTEM
A. Volumetric detector electronic module - B. Rear door button - C. Buttons on front doors - D. Engine bonnet button
245
Base - May 2004

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Switches for signalling opening of doors and bonnet

These switches are the same, excluding the one for the bonnet, that controls switching on of the ceiling lights inside the cab and,
for the van version, the loading platform. They send the signal indicating the status of the doors and of the bonnet to the ECU.
Door-blocker/unblocker motors
Each door has its own motor for closing/opening the lock on the door.
Operation of the motor is enabled by switching the remote-control switches on the circuit card of the ECU on/off for a
pre-established period of time, programmable in the EEPROM of the ECY.
These motors can be activated in two different ways:
- by means of the pushbutton on the remote-control key (blocking/unblocking of all the doors)
- - by means of the switch on the switch panel (blocking/unblocking of the rear door only, in the van version).
With the +15 power supply on, operation of the motors by pressing the pushbutton on the remote-control key is not possible.
Activation of the motor of the rear door by means of the switch on the switch panel is possible, on the other hand, regardless
of the presence or otherwise of the +15 power supply.
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Pinout of a door blocker/unblocker motor
Time
Pin Function V
required
Blocking +12V X750 sec.

1
Unblocking 0V X750 sec.
Blocking 0V X750 sec.

2
Unblocking +12V X750 sec.
Base - May 2004 Print 603.93.281

Figure 292
50283
A. Door opening button
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B 50282
B. Engine bonnet switch
50281
C. Door lock/release button
Print 603.93.281 Base - May 2004

Electronic volumetric-detection module

This module carries out volumetric detection inside the cab, by means of the two sensors located on the sides of the ceiling-light
(A) inside the cab, starting from when the anti-theft protection is activated. It sends the data to the ECU. Any changes in the
state inside the cab due, for example, to the windows being smashed or an object being accidentally moved, will be transmitted
to the ECU, which will command the anti-theft protection to switch on.
The module includes a LED for signalling that the anti-theft protection has been switched on. This is also mounted in the
ceiling-light inside the cab (B), and in addition to the state of the anti-theft protection (active, inactive), it also signals that key
learning has been accomplished and any failures in the system.
Pin out
Pin Function
1 Power supply from ECU (connector B pin 6)
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2 +30 power supply
3 Earth
4 Receiving and transmitting of serial data
5 Signal to ECU (connector B pin 23)
6 LED driver
Figure 293
50280
Base - May 2004 Print 603.93.281

Siren
The siren is located inside the engine compartment. It is self-powered by an internal battery that enables it to sound when it
is disconnected from the vehicle, and it must comply with specific requisites, such as supplying a value greater than or equal to
100 dB at a distance of 1 metre from the siren after 5 minutes of operation.
The batteries of the siren are recharged in the following ways:
- trickle-charging
- rapid charging
- charging after disconnecting the siren from the vehicle
Trickle-charging is always activated in order to compensate for the normally occurring loss of charge of the batteries. The
batteries will be charged by supplying a 12 mA current for one minute at intervals of one hour.
Rapid charging takes place for a duration of 14 hours with a current of 12 mA. This method is used when the siren is connected
for the first time, or when it is reconnected to the system following maintenance operations on the vehicle that require the battery
to be disconnected. Once the required time has elapsed, charging stops. This type of charging does not require the +15 power
supply to be on.
With the third type of charging, if the siren of the vehicle is disconnected while it is not sounding, the whole time for which it
remains disconnected will be the same required to recharge the batteries when it is connected to the system again. If, on the
other hand, the siren is disconnected after it has been triggered, when it has to be reconnected to the system the batteries will
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be charged for 45 seconds for each second that the siren remained disconnected. This recharging process is only carried out
with the +15 power supply off. If the batteries are below the minimum charging level, they will be recharged, with the +15 power
supply on, for 14 hours at 12 mA.
Figure 294
Siren pin-out
Pin Function
1 +15 power supply
2 +30 power supply
3 Serial input/output signal
4 Earth
A B
A. Horn
B. Siren
50279
Print 603.93.281 Base - May 2004

Siren modes and states

Delivery mode/state
This mode indicates the state of the siren when it is delivered to IVECO. An acoustic signal emitted by the siren will signal its
activation when it is connected to the system.
Idle mode/state
This state indicates when the siren has been disconnected and its operating state has been blocked, implementing the siren service
mode described below. The siren is blocked in order to retain the charge of the batteries and its microprocessor is de-activated.
An acoustic signal produced by the siren will signal its activation when it is reconnected to the system.
Siren disabled state
The siren always goes into an idle state when it is connected to the vehicle on the IVECO production line. In addition, the siren
also goes into this state when the anti-theft protection is de-activated by the remote-control key.
Enabled state 1
This is the normal state of the siren, and it indicates that the anti-theft protection has not been activated and that the +15 power
supply is off. In this state, the siren can still trigger off an alarm if it is disconnected from the vehicle.
Enabled state 2
In this state, the anti-theft protection is activated. The siren has already received a serial activation command from the ECU. In
this state, if the siren is disconnected or the ECU detects a signal able to switch on the siren, this will be activated.
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Alarm state 1
In this state the siren is on, however the ECU is not activated. The siren was activated because it was disconnected.
Alarm state 2
In this state the siren is on. The ECU is activated. The siren may have been caused to switch on by a signal from the ECU triggering
anti-theft protection or because it was disconnected from the battery of the vehicle.
Base - May 2004 Print 603.93.281

ERROR CODES
Any faults and their causes are detected by the ECU and stored in it. There is a diagnostics system that enables them to be
identified, with the +15 power supply on, by detecting the number of times that the anti-theft signalling LED flashes. Correct
interpretation of the flashing will lead to identification of the number of the error code. In order to do this, it is necessary to know
that:
- the LED on for 1 second is equivalent to ten
- the LED on for 0.5 seconds is equivalent to one unit.
The time that passes between each time that the LED goes on and the next is 0.5 seconds. If two or more error codes should
be detected, the time for which the LED remains off would be 2 seconds.
The error codes are signalled, if the corresponding fault is present, once only and in ascending order. Then, once all the active
faults have been signalled, the LED will extinguish.
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Figure 295
0.5 0.5
1 sec. sec. sec. 2 sec.
Led on
Led off error code 11 error code 12
8597
ERROR CODE SEQUENCE
Print 603.93.281 Base - May 2004

Error code table
Error
Type of improper functioning Fault detection Condition for detecting fault
code
Checksum error in the

Once for each time the +15
11 EEPROM of the ECU remote-control key code in the
power supply is turned on.
EEPROM of the ECU
Checksum error on activation of

RAM/ROM checksum error. the ECU.
12 ECU Remote-control switch with Each time the motor is
working contact blocked operated the working contact
blocks
No remote-control key
13 No key programmed Once every second
programmed in the ECY
No EEPROM PIN code

14 No PIN code programmed Once every second
programmed
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Door-closing output signal Inccorrect door-closing output With remote-control switch on.
15
shorted to earth or battery+ signal Once every second
Low output with remote-control

Output signal inside cab shored to switch on. With remote-control switch on.
16
earth or battery + High output with remote-control Once every second
switch off
Low output with remote-control

Rear door output signal shorted to switch on. With remote-control switch on.
17
earth or battery+. High output with remote-control Once every second
switch off
Left direction indicator output signal Low output with remote-control

18 With remote-control switch on
to earth switch on
Right direction indicator output Low output with remote-control

19 With remote-control switch on
signal to earth switch on
Once every second.

Led output signal shorted to earch
20 Incorrect Led output signal For the 10 seconds required to
or battery+
activate the ECU
No response from ultrasonic No signal from ultrasonic For the 10 seconds required for
21
module module activation
No signal from siren in response to For the 10 seconds required for

22 No response from siren
ECU activation
For the 10 seconds required for

23 Siren batteries dead Serial message from siren
activation
For the 10 seconds required for

24 Siren self-test wrong Serial message from siren
activation
Rolling code transmitted in RF from

Rolling code of remote-control key
25 the remote-control key not On receiving the RF message
out of range
recognised by the EEPROM
Base - May 2004 Print 603.93.281

AIR SUSPENSIONS ECAS

High-flexibility air suspension system with highly efficient vibration damping effect provided with self-adjusting feature that keeps
constant chassis-to-road height, regardless of the load carried by the vehicle. A special push-button allows to change
chassis-to-road surface distance, that is the height of the vehicle cargo compartment floor.
Besides the traditional advantages of any air suspension system, the ECAS system also allows:
- air consumption reduction
- prompt response to adjustment
- simple systems
- high safety
- complete system diagnosis.
The ECAS (Electronically Controlled Air Suspension) system automatically controls the vehicle air suspension system nominal
level.
The features described above are bound to special operating and safety conditions of the associated systems.
The ECAS electronic control unit automatically checks chassis level (height from road surface) by reading the real values supplied
by the sensors and comparing them to the rated values stored in the memory.
With any change of the vehicle trimming, the electronic control unit controls the electropneumatic units to bring the actual level
to the level set or previously memorized by the driver.
cardiagn.com
MODEL MOTOR ECAS VTB
29L .10 .11 .12 .14 X
35S .10 .11 .12 .13 .14 .17 X
35C .10 .11 .12 .13 .14 .17 X
40C .10 .11 .12 .13 X
45C .11 .13 X
50C .11 .13 .14 .17 X
60C .15 X
65C .15 .17 X
Print 603.93.281 Base - May 2004

WABCO electronically controlled air suspensions (ECAS)

The system in figure is installed in the following vehicles:
29L - 35S.
Figure 296
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SYSTEM OPERATING DIAGRAM
Base - May 2004 Print 603.93.281

Pin Description Component code

1 ECAS electronic control unit 86023
2 Chassis manual leveling control push-button 52090
3 Chassis lifting control push-button 53051
4 Chassis lowering control push-button 53052
5 ECAS pilot lamp 58713
6 Stop light switch 53501
7 Tachometer ć tachograph 40001 - 40011
8 RH air spring -
9 RH level sensor 40046
10 Hydraulic brake action compensator -
11 Brake action compensator actuator air cylinder -
12 LH level sensor 40046
13 LH air spring -
14 Electrocompressor unit 78233
15 RH chassis actuator solenoid valve -
cardiagn.com
16 LH chassis actuator solenoid valve -
17 Throttle valve -
18 Dryer filter -
19 Air spring relief solenoid valve -
20 One-way valve -
21 Compressor -
22 One-way valve -
23 Intake filter -
24 Compressor motor -
25 Motor relay -
26 Diagnostic socket 72008
Print 603.93.281 Base - May 2004

Vehicles with braking system without ABS
Figure 297
cardiagn.com
ÓÓÓ
ÓÓ ÓÓ
ÓÓÓ
ÓÓ
ÓÓÓ
ÓÓ
000217t
1. ECAS warning lamp - 2. RH level sensor - 3. RH air spring - 4. Chassis lifting control push-button - 5. Chassis lowering
control push-button - 6. ECAS ECU - 7. Chassis leveling control push-button - 8. Hydraulic brake action compensator -
9. Brake action compensator air cylinder - 10. LH air spring - 11. Air supply unit - 12. LH level sensor -
13. Centralized diagnostic socket
Base - May 2004 Print 603.93.281

Vehicles with ABS system
Figure 298
cardiagn.com
ÓÓÓ
ÓÓ ÓÓÓ
ÓÓÓ
ÓÓÓ
000217t
1. ECAS warning lamp - 2. RH level sensor - 3. RH air spring - 4. Chassis lifting control push-button - 5. Chassis lowering
control push-button - 6. ECAS ECU - 7. Manual chassis leveling control push-button - 8. LH air spring - 9. Air supply unit -
10. LH level sensor - 11. Centralized diagnostic socket.
Print 603.93.281 Base - May 2004

Electronic Control Unit

The electronic control unit controls different chassis positions in accordance with the requests from the driver.
As the ignition key switch is turned to ON position, the electronic central unit runs a system check while the red warning lamp
on the dashboard panel comes on for about 2 seconds.
If any failure is detected, this warning lamp can stay on fixed for serious system failure or flashing for compressor failure due to
overtemperature.
The electronic control unit checks the level sensor at regular intervals in order to keep chassis level constant as required by the
driver, and operates the necessary compensation when a deviation of more than 3 counts is detected.
The compensation shall be operated with the following delay:
~ 1 sec. with vehicle still
~ 30 sec. with vehicle moving
If the level is not restored within a maximum time of 30 seconds from the beginning of the compensation, the control unit
memorizes a plausibility error and the warning lamp comes on fixed.
During braking, the electronic control unit detects the signal from the stop light switch and stops any chassis level automatic
adjustment.
If a difference of more than 4 counts is detected between RH and LH sensors with vehicle still, after a delay of about 8 seconds,
cardiagn.com
the control unit recognizes a step" condition and stores the data in memory, keeping the chassis level as it is.
Besides a blink code" option through the red warning lamp for preliminary diagnosis, the electronic control unit is provided
with an advanced self-diagnosis system capable to detect and memorize any failures, depending on the concurrent conditions,
including intermittent errors occurred in the system during operation and ensure a more appropriate and reliable servicing.
All interventions concerning diagnosis, programming, failures memory deletion, etc. can be performed by using available diagnosis
instrument.
Base - May 2004 Print 603.93.281

Electronic control unit pin out
Figure 299
000095t
Cable
Pin Function
colour code
1 Battery positive supply 7772
2 L" line to pin 15 of the 38-pole diagnostic connector 1194
cardiagn.com
3 - -
4 K" line to pin 16 of the 38-pole diagnostic connector 2294
5 - -
6 - -
7 - -
8 RH level sensor positive 5421
9 Ignition switch positive supply 8090
10 - -
11 (Positive to air reservoir solenoid valve supply) 9445
12 - -
13 Positive to LH chassis control solenoid valve 9425
14 - -
15 Positive to electric compressor control relay 9444
16 Positive from stop light switch 1363
17 - -
18 - -
19 Negative from chassis level push-button 8420
20 - -
21 - -
22 Vehicle speed signal 5411
23 - -
24 - -
25 LH level sensor positive 5422
26 Chassis lift/lower push-button communication line 8091
27 Negative 0000
28 - -
29 Positive to relief solenoid valve 9423
30 - -
31 Positive to RH chassis control solenoid valve 9424
32 - -
33 Negative for failure warning lamp 6008
34 - -
35 - -
Print 603.93.281 Base - May 2004

Level sensor Figure 300

The level sensor consists of a coil fastened to the chassis and
a piston (Figure 300).
The piston is moved inside the coil by the action of a cam and
a lever connected to the axle, this way varying the coil
inductance.
These variations shall be used by the electronic control unit
at the different stages of system operation.
cardiagn.com
000369t
LEVEL SENSOR
Figure 301
Here is shown the nominal characteristic curve of the sensor
as a function of the angle displacement of the lever.
000370t
OPERATING DIAGRAM
Base - May 2004 Print 603.93.281

Figure 302 Pneumatic supply unit

This component produces, dries,supplies or discharges
suspension spring air.
cardiagn.com
000222t
INTERNAL COMPRESSED AIR DIAGRAM
Figure 303
Components of the air supply unit
1. Relief solenoid valve
2 3 2. Electrical motor control relay
3. Intake filter
1 4. RH chassis control solenoid valve
5. LH chassis control solenoid valve
6. Compressor
7. Drier filter
4 8. Compressor electrical motor
5 9. Electrical connector
9
6
7
8
000222t
SUPPLY UNIT
Print 603.93.281 Base - May 2004

Brake action compensator Figure 304

The vehicles not equipped with ABS / EBS / ABD system need
a system providing a better control of the braking action on
the rear wheels. This system includes an dual brake action 2
compensator and a brake action compensator pneumatic
actuator.
Depending on the load applied on the rear axle, as detected
by the pneumatic actuator, the brake action compensator
automatically adjust the braking torque applied to the axle by
the brakes.
The diagram shows the compensation ratio corresponding to
0.15 as a function air spring variations.
cardiagn.com
000372t
BRAKE ACTION COMPENSATOR UNIT

1. Dual brake action compensator
2. Pneumatic actuator for brake action compensator
Figure 305
000371t
OPERATION DIAGRAM
A. Hydraulic output pressure (bars) - B. Hydraulic control
pressure (bars) - C. Pneumatic control pressure (bars) -
D. Characteristic curve with 0.15 ratio (empy) -
E. 1:1 ratio (loaded) - F. Characteristic curve of pneumatic
pressure/load
Base - May 2004 Print 603.93.281

A" Braking action

Figure 306
ÔÔÔÔ ÒÒÒÒ
Ö
ÖÖ Ö Ö ÖÒÒÒÒ
Ö
ÔÔÔÔ
ÖÖ ÒÒÒÒ
Ö Ö ÒÒÒÒ
Ö
ÔÔÔÔ
ÔÔÔÔ
ÔÔÔ
ÔÔÔÔ
ÔÔÔ
ÕÛÕÕ
ÚÚ
Û
ÔÔÔÔ ÕŠŠ
ÒÒ
Õ Ô
ÔÔÔÔ
Û
Õ
ÚÚ
ÛÕŠŠÔ
ÕÕ
Õ
ÔÔÔÔ
ÔÔÔÔ 000219t
cardiagn.com
B" Braking action with empty vehicle
Figure 307
ÔÔÔÔ
ÔÔÔÔ
ÖÒÒÒÒ
Ö Ö ÒÒÒÒ
Ö
Ö Ö Ö Ö
ÔÔÔÔÒÒÒÒ
Ö ÒÒÒÒ
Ö
ÔÔÔ
ÔÔÔ
ÔÔÔÔ
ÔÔÔÔ
Û
Õ
ÚÚÕÕ
ÕŠŠ
ÒÒ
Õ Ô
Û
Õ
ÚÚ
ÔÔÔÔ
ÔÔÔÔ ÕÕ
ÕŠŠ
Õ
ÒÒÔ
ÔÔÔÔ 000220t
C" Braking action with laden vehicle

Figure 308
ÔÔÔ
Ö ÒÒÒÒÒ
ÖÖ ÒÒÒÒ
ÖÖ
ÔÔÔ
Ö
ÖÖ
ÖÖ
ÒÒÒÒÒ
ÖÖ
ÖÖ ÖÖ
ÒÒÒÒ
ÖÖ
ÔÔÔ
ÔÔÔÔÔ
ÔÔÔ
ÔÔÔÔÔ
ÔÔÔ
ÔÔÔÔÔ
Õ
ÚÚ
ÛÛÕ
ÕÕ
ÒÒ
ŠŠ
Õ Ô
ÔÔÔÔÔ
Õ
ÚÚ
Û
ÔÔÔÔÔÛÕ
ÕÕ
ÒÒ
ŠŠ
Õ Ô
ÔÔÔÔÔ 000221t
Print 603.93.281
ÔÔÔÔÔ Base - May 2004
Chassis lifting
This operation is allowed at a speed below 15 Km/h; as soon as this speed is exceeded, automatic chassis leveling is actuated.
Proceed as follow to lift the chassis:
- Press chassis lifting push-button and keep it pressed to enable the relay to close the switch and receive a 5A supply. Now,
the control unit commands the relay to start the compressor (6) electrical motor (2). Air is then aspirated through the filter
(3), compressed and delivered into the system via the one-way valve and the drying filter (7).
Simultaneously, the control unit starts solenoid valves 4" and 5" so that the compressed air is supplied to the suspension
air springs to lift the chassis.
During the entire operation, the red warning lamp on the dashboard panel shall flash to inform the driver that the chassis is off
trim.
The warning lamp shall keep flashing until the chassis is off normal trim.
Chassis lowering is stopped as the push-button is released while the chassis level reached is maintained.
The maximum height is set by level sensors according to the calibration data memorized in the electronic control unit.
Maximum lifting actuation time is 2 minutes to prevent preheats that could damage the electro compressor.
cardiagn.com
Figure 309
000224t
SYSTEM OPERATION DIAGRAM

1. Exhaust solenoid valve - 2. Electrical motor control relay - 3. Intake filter - 4. RH chassis control solenoid valve -
5. LH chassis control solenoid valve - 6. Compressor - 7. Dryer filter - 8. Compressor control electrical motor -
9. Electrical connector
Base - May 2004 Print 603.93.281

Chassis lowering
This operation is allowed at a speed below 15 Km/h; as soon as this speed is exceeded, automatic chassis leveling is actuated.
Proceed as follow to lower the chassis:
- Press the lowering push-button and keep it pressed to enable the relay to send a signal to the control unit to energize solenoid
valves (4) and (5) and the exhaust valve (1).
The compressed air contained in the suspension air springs can flow back through the dryier filter 7" for cleaning and, as
imposed by the closed one-way valve, flow to the relief solenoid valve to be released in the atmosphere through the intake
filter.
During the entire operation, the red warning lamp on the dashboard panel shall flash to inform the driver that the chassis is off
trim.
The warning lamp shall keep flashing until the chassis is off normal trim.
Chassis lowering is stopped as the push-button is released while the chassis level reached is maintained.
The maximum height is set by level sensors according to the calibration data memorized in the electronic control unit.
Figure 310
cardiagn.com
000223t

5. LH chassis control solenoid valve - 6. Compressor - 7. Dryer filter - 8. Compressor control electrical motor -
9. Electrical connector
Print 603.93.281 Base - May 2004

Chassis leveling
Chassis leveling can be achieved with vehicle moving at a speed below 15 Km/h by pressing the leveling push-button.
This way, the control unit shall start the lifting or lowering action until the normal height is reached and maintained in accordance
with the signals received from the level sensors and the calibration data stored in the control unit memory.
On achievement of the normal trim, the warning lamp on the dashboard panel shall stop flashing.
The same leveling shall be obtained automatically as the vehicle exceed the speed of 15 Km/h.
Figure 311
cardiagn.com
000363t

5. LH chassis control solenoid valve - 6. Compressor - 7. Dryer filter - 8. Compressor control electrical motor - 9. Electrical
connector
Base - May 2004 Print 603.93.281

VB TECHNIEK PNEUMATIC SUSPENSIONS

The system illustrated is used in the following vehicles:
65C - 60C - 50C
Figure 312
cardiagn.com
004282t
OPERATION DIAGRAMS
Print 603.93.281 Base - May 2004

Pin Description
1 Electronic control unit
2 Manual mode actuation button
3 Lowering button
4 Lifting button
5 VBT signalling warning light
6 Tachograph
7 Electric motor control relays
8 Discharge solenoid valve (for washing)
9 Choking valve
10 Unidirectional discharge valve
11 Unidirection feed valve
12 Drier filter
13 Right-hand air spring
14 Pneumatic discharge valve
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15 Compressor
16 Compressor actuation electric motor
17 Filter
18 Braking connector
19 Exhaust silencer
20 Exhaust solenoid valve
21 Left-hand air spring
22 Level sensor
Base - May 2004 Print 603.93.281

Vehicles with braking system without ABS
Figure 313
cardiagn.com
85725
1. VBT warning lamp - 2. Suspension control unit (ECU, pneumatic supply unit) - 3. Chassis lifting switch - 4. Chassis
lowering push-button - 5. Manual control button - 6. RH air spring - 7. Level sensor - 8. Pneumatic brake action
compensator - 9. Brake action compensator - 10. LH air spring
Print 603.93.281 Base - May 2004

Vehicles with ABS system
Figure 314
cardiagn.com
85724
1. VBT waring lamp - 2. Suspension control unit (ECU, pneumatic supply unit) - 3. Chassis lifting switch - 4. Chassis lowering
push-button - 5. Manual control button - 6. RH air spring - 7. Level sensor - 8. LH air spring
Base - May 2004 Print 603.93.281

SYSTEM COMPONENTS
Electronic Control Unit (35C - 40C - 45C)
The electronic control unit controls different chassis positions in accordance with the driver's requests.
As the ignition key switch is turned to ON position, the electronic central unit runs a system check while the red warning lamp
on the dashboard panel comes on for about 5 seconds.
If no failures are detected, this warning lamp shall turn off, otherwise an automatic blink code shall be started with the following
meaning:
Slow blinking - Electric compressor overload due to prolonged manual actuation.
Fast blinking - Electric compressor overload
Fixed on - Level sensor cable
Off - Supply failure
Dimmed light - Wrong button operation (simultaneous action) or button connecting cabling failure.
The control unit is fitted with a warning led 1" connected to the warning lamp on the dashboard panel, and a set of five
connectors 2" of which only 1, 3 and 5 are used.
Figure 315
cardiagn.com
000373t
Connector Pin Function Cable colour

1 Signal from level sensor White
2 Signal from level sensor Brown
3 Positive from level sensor Yellow
1
4 Negative from level sensor Green
5 - -
6 - -
1 Signal from lifting switch Grey
2 Negative for trim variators Green
3 Signal from lowering switch Brown
3
4 Negative for failure warning light Yellow
5 Key-controlled positive Pink
6 Signal from handbrake switch White
1 Electric compressor control remote-control switch positive White
2 Discharge solenoid valve control positive Yellow
3 Positive from battery Red
5
4 Negative from battery Black
5 - -
6 - -
Print 603.93.281 Base - May 2004

Electronic control unit (60C - 65C - 50C)
Figure 316
cardiagn.com
004283t

1 Pink +15
2 Yellow Warning light bulb
3 Green Button negative
4 White Signal from handbrake
5 Brown Lowering button
6 Grey Lifting button
7 - Free
8 - Free
9 - Free
10 - Free
11 - Free
12 Black Tachograph
13 White Signal from level sensor for lifting
14 Brown Signal from level sensor for lowering
15 Yellow Positive for level sensor
16 Green Negative for level sensor
17 Green Earth
18 Pink +30
19 Brown Discharge solenoid valve control
20 Grey Compressor relay 2 control
21 Yellow Discharge solenoid valve control
22 White Compressor relay 2 control
Base - May 2004 Print 603.93.281

Figure 317 Level sensor

In accordance to the chassis height from floor, the level sensor
shown sends the signals to start chassis leveling to the ECU.
It is connected to the control unit by means of four cables:
- White: Lifting signal
- Brown: Lowering signal
- Yellow: Positive
- Green: Negative
000374t
cardiagn.com
LEVEL SENSOR
Figure 318 Pneumatic supply unit

The function of this component is that of distributing or
discharging suspension spring air.
Shows the connection of its internal components of the
supply unit..
Components of the pneumatic supply unit
1 - Air spring relief solenoid valve
2 - Dryer filter
3 - Compressor
4 - Supply filter
5 - Electrical motor
6 - Relief pneumatic valve
7 - Muffler
000375t
PNEUMATIC SUPPLY UNIT
Print 603.93.281 Base - May 2004

Brake action compensator Figure 319

Those vehicles not equipped with ABS / EBS / ABD require
the installation of a system providing better braking action on
the rear wheels This system includes an dual brake action
compensator and a brake action compensator pneumatic
actuator.
Depending on the load applied on the rear axle, as detected
by the pneumatic actuator, the brake action compensator
automatically adjust the braking torque applied to the axle by
the brakes.
The correction ratio is calibrated at 0.25.
cardiagn.com
000376t
BRAKE ACTION COMPENSATION UNIT

1. Brake action compensator - 2. Pneumatic actuator for
brake action compensator
Base - May 2004 Print 603.93.281

ROTATING SLIDING DOOR

Description
The rotating sliding door consists of:
- Complete panel and door compartment frame
This aluminum extruded profile guarantees a rigid bearing structure to support all system components such as:
- access step;
- moving hinge;
- seals;
- two locks;
- the electronic center;
- door panel front lock pins;
- extension arm;
- compressed air sensitive edge (bus version only);
- motor unit.
cardiagn.com
Figure 320
73726
Print 603.93.281 Base - May 2004

SYSTEM COMPONENTS
Electronic center
The electronic center is located under the access step.
In addition to the motor reduction gear control, it also features a series of vehicle and door system communication inputs and
outputs. A tachometer signal reading system for the following purposes is provided to prevent the door from being opened with
the vehicle moving:
- to prevent the door from opening when the vehicle travels at over 5 Km/h;
- to generate a buzzer when the vehicle is moving and the door is open;
- for the absence of a tachometer signal involving the possibility of the door opening (after push button actuation) with the
vehicle moving.
Electrical features
Power 12V dc
Standćby absorption 20 ÷ 30 mA
Operating absorption 3.5 ÷ 5 mA
Operating temperature -30°C ÷ +60°C
cardiagn.com
Figure 321
73741
ECU LOCATION
Base - May 2004 Print 603.93.281

Electronic center pin-out

Pin Description
1A Free
2A Free
3A Tachometer signal
4A Open open/close push button
5A Centralized opening remote control input
6A Centralized opening remote control input
7A Free
8A Positive from battery
1B Free
2B Free
3B Positive input from key switch
4B Door open warning output
5B External emergency lock closed warning output
6B Door defect warning output
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7B Free
8B Negative from battery
1C Free
2C Free
3C Free
4C Free
5C Free
6C Free
7C Ceiling light control output
8C Free
Figure 322
73740
ECU LOCATION
Print 603.93.281 Base - May 2004

Optical and sound warnings Figure 323

Component location on instrument panel:
1. Door open warning light.
2. Emergency handle lock
(yellow warning light).
3. Emergency handle lock activated
(bus yellow warning light).
4. Door open/close control push button.
cardiagn.com
72609
COMPONENT LOCATION ON INSTRUMENT PANEL
Figure 324
Sound device
This electronic center piloted device warns users of special
operating conditions, such as the vehicle moving with the
door open, for instance. 1
73739
BUZZER
Base - May 2004 Print 603.93.281

Description and operation

The open/close control is only activated with the vehicle moving, via the instrument panel push button.
If the vehicle is provided with a centralized closing system, door opening can be activated even with the vehicle stationary. In
this case, opening and closing must be limited to prevent discharging the vehicle battery.
Opening with the instrument panel push button

The operator controls automatic door opening by actuating the instrument panel push button.
Pressing the push button sends an electrical impulse required for mechanical electro magnetic induced lock release.
At release end, the lock on travel end warning loses the signal and starts the motor reduction gear that makes the door panel
rotate open and given visual warning of door open, with a warning light on the instrument panel.
Opening end is with the Complete Opening micro switch.
During door opening, a cam located on the lower part of the hinge and solidal with motor reduction gear rotation lowers the
access step to its use position.
Closing with the instrument panel push button

The operator controls automatic door closing by actuating the instrument panel push button.
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Pressing the push button sends an electrical impulse to the motor reduction gear that completes its closing travel.
During closing a double obstacle detection system operating on motor ammeter measurement and adjustable via a timer on the
center is activated, another one is located on the compressed air sensitive edge of the two door compartment uprights.
Near door close a position reading sent to the tachometer on the door control motor disenables the ammeter controlled
sensitive edge to enable otherwise impossible door closing.
The compressed air sensitive edge is activated until receipt of door closed micro switch signal, which activates a signal switching
all center functions off.
When closing, the door enables rotation of the mobile step to its rest position with a return spring.
If the vehicle moves with the door open, its closing can be controlled with the push button even at speeds over 5 Km/h, in which
case the buzzer remains active (inclusive of the door open warning light) until complete door closing.
Opening/closing with the remote control

The open/close control extends to all vehicle doors including the rotating sliding one.
Movement inversion
After door open/close push button actuation, in whatever position it may be, actuating the push button generates its controlled
movement inversion.
Obstacle detection system

The system features motor ammeter control capable of detecting peaks of voltage and of the compressed air sensitive edge
located on the front and back of the door compartment, for obstacle detection.
If an obstacle counters door panel movement during closing, over 150N force of compressed air transducer activation opens it.
If an obstacle counters door panel movement during opening, over 150N force of compressed air transducer activation closes it.
Since the door is equipped with the anti-squash function, reading the nearly closed door status signal generated by the motor
encoder automatically cats out this function to enable complete door closing.
Print 603.93.281 Base - May 2004

Emergency operation Figure 325

The door can be opened in case of system failure or power
down by using the emergency lever from the inside of the lock
close to the door panel from the outside.
In case of emergency operation, automatic door opening or
closing is disenabled until the system is restarted manually.
The outside emergency lock is provided with a key that can
be used to secure the vehicle (Figure 325).
An internal buzzer is actuated if the starter switch is actuated
in the service position with external opening emergency
locked with the key.
Diagnosis
The system reports a failure when the failure warning light 73720
goes on.
EXTERNAL EMERGENCY OPENING
This failure can be due to the following causes:
- Closing does not occur a maximum of ~20 sec after Figure 326
cardiagn.com
actuation
- Possible causes:
Door open micro switch warning failed.
Electrical cabling cut.
- Over voltage when opening or closing
- Possible causes:
Motor short circuit
- Door opening/closing travel abnormal.
- Possible causes:
Motor encoder signals not recognized.
- Door does not open.
- Possible causes:
Tachometer signal detective or down.
73718
STEP LIGHT
Figure 327
73718
1. Light - 2. Emergency openings
Base - May 2004 Print 603.93.281

Description of opening
Opening
Press open/close push

button
No Speed control (B7)

≤ 5 Km/h
Yes
Center actuation
cardiagn.com
Electromagnet excitation
(∆T = ^0.5 s)
Electromagnet de-excitation
No Lock micro switch actuation

(opens on contact)
Yes
Engine start in opening
Position and speed control with engine encoder

Constant speed start and travel
No Micro switch complete

opening" position engaged
Yes
Position and speed control

with engine encoder
Print 603.93.281 Base - May 2004

Description of closing cycle
Closing
Press open/close push

button
Reposition
on opening
No Micro switch complete
opening position engaged?
Yes
Engine start in closing
cardiagn.com
Position and speed control with engine encoder
Ramp start
Constant speed travel to next stage
Encoder reading of door

nearly closed
Deceleration
Complete closing
No
Micro switch engaged on lock
Yes
Engine cut out
Center cut out
Base - May 2004 Print 603.93.281

Operating diagram
REMOTE
CONTROL
CLOSES
MECHANICAL OPERATOR door LOCKED

KEY OPENS REMOTE
CONTROL
ROTO door CLOSED OPENS
OPERATOR door UNLOCKED OPERATOR door UNLOCKED

EMERGENCY REMOTE
HANDLE. CONTROL
ROTO door CLOSED CLOSES ROTO door CLOSED
cardiagn.com
INSTRUMENT INSTRUMENT
PANEL PUSH REMOTE PANEL PUSH
BUTTON CONTROL BUTTON
OPENS OPENS OPERATOR door LOCKED CLOSES
ROTO door OPEN
OPERATOR door UNLOCKED OPERATOR door UNLOCKED

ROTO door OPEN ROTO door CLOSED
REMOTE
CONTROL
OPENS
INSTRUMENT
PANEL PUSH MECHANICAL REMOTE
BUTTON OPERATOR door UNLOCKED KEY CONTROL
CLOSES CLOSES
ROTO door OPEN
OPERATOR door LOCKED

REMOTE
CONTROL
CLOSES ROTO door CLOSED
N.B.: As a consequence of use by

IVECO of passive type door locks,
disconnected operation may occur
between operator and rotating sliding
door opening and closing.
Print 603.93.281 Base - May 2004

Figure 328 ELECTRONIC TACHOGRAPH

Removing the lower dashboard cover
- Remove the snap-fitted panel (Ref. A) to gain access to
the panel fastening screws (Ref. B).
- Slacken the 4 fastening screws, two on either side, of the
lower panel (Ref. A).
Electronic tachograph control unit housing

assembly
Fasten the control unit to the support, insert the 3
connectors, eliminating the bridges between the connectors
(white, yellow and brown) and apply the seals (ref. A).
B
A 8670
LOWER DASHBOARD SNAP-FITTED PANEL
cardiagn.com
Figure 329
A
8781
LOWER PANEL FASTENING SCREWS
A 8782
8783
LOWER PANEL FASTENING SCREWS CONNECTIONS AND TACHOGRAPH CONTROL

UNIT SUPPORT
Base - May 2004 Print 603.93.281

Assembling the tachograph control unit Figure 333

support on the dashboard
Use the six screws to fasten the tachograph control unit
support to the dashboard.
8784
TACHOGRAPH CONTROL UNIT

Figure 334
cardiagn.com
8785
TACHOGRAPH CONTROL UNIT FASTENING TO

DASHBOARD
Figure 332
8786
TACHOGRAPH CONTROL UNIT SUPPORT FASTENING SCREWS
Print 603.93.281 Base - May 2004

Figure 335 Removing the instrument cluster module

To replace the module, proceed as follows:
1. Remove the upper trim working on the three screws
shown by the arrows.
2. Lift and remove the trim taking care not to damage the
velcro stoppers.
8787
UPPER TRIM FASTENING SCREW
cardiagn.com
8788 8790
UPPER TRIM FASTENING SCREW TRIM REMOVAL
8789
8791
UPPER TRIM FASTENING SCREW
INSTRUMENT CLUSTER
Base - May 2004 Print 603.93.281

Work on the 4 screws, 2 on either side, to remove the cluster Figure 341
module with tachometer.
Disconnect the electrical connections and replace with the
module for tachograph sealing the electrical connections
concerning the wiring for tachograph.
Fasten the instrument cluster to the dashboard and refit the
upper and lower trim.
8792
INSTRUMENT CLUSTER FASTENING
cardiagn.com
Figure 342
8793
Figure 340
REMOVING THE INSTRUMENT CLUSTER
Figure 343
8795 8794
CONNECTIONS CONCERNING WIRING FOR

COMPLETE INSTRUMENT CLUSTER TACHOGRAPH
Print 603.93.281 Base - May 2004
Figure 344 Operations on gearbox

1. Replace the sensor on the gearbox with a suitable one for
tachograph.
2. Seal with lead the electrical connection to the sensor and
to the gearbox body.
If necessary, drill (4 mm) the ribbing on the gearbox (see
arrow) for passing the wire.
8796
SENSOR REPLACEMENT ON GEARBOX
cardiagn.com
Figure 345
8797
CONNECTION OF SENSOR TO WIRING

Figure 346
8798
SENSOR TECHNICAL VIEW
Base - May 2004 Print 603.93.281

Operation in bonnet Figure 347

1. Disconnect the terminals of the power cables from the
battery terminals.
2. Remove the battery from the engine compartment, after
removing the fastening bracket.
3. Seal the connector between the frame and cab/bonnet
cables with sealing wire.
cardiagn.com
8799
CONNECTOR BETWEEN CAB/BONNET AND FRAME

CABLES
Figure 348
4. Refit the battery, re-connect the terminals to the battery

terminals, ensuring correct polarity and calibrate the
tachograph using the special VDO tool.
5. In the front part, seal the tachograph control unit with the
special red plug as shown.
6. Apply the labels; on the driver's door and on the tilting
plate of the tachograph control unit.
10.04.98 13 : 00
100436.8km
8800
FRONT VIEW OF TACHOGRAPH CONTROL UNIT
Print 603.93.281 Base - May 2004

cardiagn.com
Base - May 2004 Print 603.93.281

Circuit charts
Page
CIRCUIT CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . 295
NOTES AND SPECIFICATIONS . . . . . . . . . . . . . . 295
CHART 1A: START . . . . . . . . . . . . . . . . . . . . . . 296
CHART 1B: START (.10 - .12) . . . . . . . . . . . . . 297
CHART 2A: PREHEATING (.9) . . . . . . . . . . . . . 298
CHART 2B: PREHEATING (.11) . . . . . . . . . . . . 299
CHART 2C: PREHEATING (.13 - .15) . . . . . . . 300
CHART 2D: PREHEATING (.10 - .12) . . . . . . . 301
cardiagn.com
CHART 2E: PRE-HEATING (.10 - .12 - .14 -
.17 - EDC16) . . . . . . . . . . . . . . . . . 302
CHART 3: RECHARGE . . . . . . . . . . . . . . . . . . 303
CHART 4: INSTRUMENTS . . . . . . . . . . . . . . . 304
CHART 5: TACHOMETER . . . . . . . . . . . . . . . 305
CHART 6A: RPM COUNTER (.9) . . . . . . . . . . . 306
CHART 6B: RPM COUNTER (.11) . . . . . . . . . . 307
CHART 6C: RPM COUNTER (.10 - .12 - .13 -

.15) . . . . . . . . . . . . . . . . . . . . . . . . . 308
CHART 6D: RPM COUNTER (.10 - .12 - .14 -

.17 - EDC16) . . . . . . . . . . . . . . . . . 309
CHART 7A: OPTICAL INDICATORS (.9 - .11) 310
CHART 7B: OPTICAL INDICATORS . . . . . . . . 311
CHART 8: OUTSIDE LIGHTING (CAB

INSTRUMENTS) . . . . . . . . . . . . . . 312
CHART 9A: OUTSIDE LIGHTING (POSITION

LIGHTS) . . . . . . . . . . . . . . . . . . . . . 313
CHART 9B: OUTSIDE LIGHTING (CAB POSITION

LIGHTS VAN) . . . . . . . . . . . . . . . . 314
CHART 10: FLOOD AND DIPPED LIGHTS . . 315
CHART 11A: BACK AND FRONT FOG LIGHTS 316
CHART 11B: BACK AND FRONT FOG LIGHTS

(VAN) . . . . . . . . . . . . . . . . . . . . . . 317
Print 603.93.281 Base - May 2004

Page Page
CHART 12: FRONT LIGHT SETTING . . . . . . . 318 CHART 23B: ENGINE COOLING (.11) . . . . . . . 341
CHART 13A: DIRECTION AND EMERGENCY CHART 23C: ENGINE COOLING (.13-.15) . . . 342
LIGHTS . . . . . . . . . . . . . . . . . . . . . 319
CHART 23D: ENGINE COOLING (.10 - .12) . . 343
CHART 13B: DIRECTION AND EMERGENCY
LIGHTS (VAN) . . . . . . . . . . . . . . . 320 CHART 23E: ENGINE COOLING (.10 - .12 - .14 -
.17 - EDC16) . . . . . . . . . . . . . . . . . 344
CHART 14A: STOP LIGHTS . . . . . . . . . . . . . . . . 321
CHART 24A: EGR/EXHAUST GAS ELECTRONIC
CHART 14B: STOP LIGHTS (VAN) . . . . . . . . . . 322 CONTROL SYSTEM (.9) . . . . . . . . 345
CHART 15A: BACKUP LIGHTS . . . . . . . . . . . . . 323 CHART 24B: EGR/EXHAUST GAS ELECTRONIC
CONTROL SYSTEM FOR EDC (.13) 346
CHART 15B: BACKUP LIGHTS (VAN) . . . . . . . . 324
CHART 24C: EGR/EXHAUST GAS ELECTRONIC
CHART 16: HORN . . . . . . . . . . . . . . . . . . . . . . 325 CONTROL SYSTEM FOR EDC
(.10 - .12) . . . . . . . . . . . . . . . . . . . 347
CHART 17: WINDSCREEN AND FRONT LIGHT
cardiagn.com
WASHER . . . . . . . . . . . . . . . . . . . . 326 CHART 24D: EGR EXHAUST GAS ELECTRONIC
CONTROL SYSTEM FOR EDC
(.10 - .12 - .14 - .17 - EDC16) . . 348
CHART 18A: WINDSCREEN DEFROSTER . . . . 327
CHART 25A: SPARK LEAD VARIATOR (.9) . . . . 349
CHART 18B: WINDSCREEN DEFROSTER
(.10 - .12) . . . . . . . . . . . . . . . . . . . 328
CHART 25B: SPARK LEAD VARIATOR (.11) . . . 350
CHART 19: RADIO SET . . . . . . . . . . . . . . . . . . 329
CHART 26A: E.D.C. (.13) . . . . . . . . . . . . . . . . . . 351
CHART 20A: INTERNAL LIGHTING AND
CIGARETTE LIGHTER . . . . . . . . . 330 CHART 26B: E.D.C. WITH VGT (.15) . . . . . . . . . 352
CHART 20B: INTERNAL LIGHTING (VAN) . . . 331 CHART 26C: E.D.C. WITH WASTE GATE (.13) 353
CHART 20C: INTERNAL LIGHTING 6+1 VEHICLE 332 CHART 26D: E.D.C. WITHOUT EGR (.10 - .12) 354
CHART 20D: INTERNAL LIGHTING AND CHART 26E: E.D.C WITHOUT EGR (.10 - .12 -
CIGARETTE LIGHTER (F1A) . . . . 333 .14 - .17 - EDC16) . . . . . . . . . . . . 355
CHART 21A: IMMOBILIZER (.9) . . . . . . . . . . . . . 334 CHART 27A: HEATED FUEL FILTER (.9 - .11) /
OPT 2287 . . . . . . . . . . . . . . . . . . . 356
CHART 21B: IMMOBILIZER (.11) . . . . . . . . . . . . 335
CHART 27B: HEATED FUEL FILTER (.13 - .15) . 357
CHART 21C: IMMOBILIZER (.10 - .12 - .13 - .15) 336
CHART 27C: HEATED FUEL FILTER (.10 - .12) . 358
CHART 21D: IMMOBILIZER (.10-.12-.14 - .17
EDC16) . . . . . . . . . . . . . . . . . . . . . 337 CHART 27D: HEATED FUEL FILTER (.10 - .12 -
.14 - .17 - EDC16) . . . . . . . . . . . . 359
CHART 22A: DIAGNOSIS CONNECTION
(.9 - .11) . . . . . . . . . . . . . . . . . . . . 338 CHART 28A: POWER WINDOW OPERATOR AND
PASSENGER SIDE / OPT 693 . . . . 360
CHART 22B: DIAGNOSIS CONNECTION
(.10-.12-.13-.15-.14-.17) . . . . . . . 339 CHART 28B: POWER WINDOW OPERATOR SIDE /
OPT 4028 . . . . . . . . . . . . . . . . . . . 361
CHART 23A: ENGINE COOLING (.9) . . . . . . . . 340
CHART 28C: POWER WINDOW OPERATOR AND
PASSENGER SIDE (.10 - .12) . . . . 362
Base - May 2004 Print 603.93.281

Page Page
Print 603.93.281/A
CHART 29: HEATED REARVIEW MIRRORS / CHART 39B: REAR DIFFERENTIAL LOCK /
OPT 697 . . . . . . . . . . . . . . . . . . . . 363 OPT 131 . . . . . . . . . . . . . . . . . . . . 383
CHART 30: REARVIEW MIRROR ADJUSTMENT / CHART 40: 13-POLE POWER CONNECTION /
OPT 2714 . . . . . . . . . . . . . . . . . . . 364 OPT 6520 . . . . . . . . . . . . . . . . . . . 384
CHART 31: HEATED WINDSCREEN / OPT 685 365 CHART 41A: TOTAL PTO (.9 - .11) . . . . . . . . . . 385
CHART 32: HEATED REAR WINDOW / CHART 41B: TOTAL PTO (.10 - .12 - .13 - .15) 386
OPT 6815 . . . . . . . . . . . . . . . . . . . 366
CHART 41C: TOTAL PTO (EDC 16) . . . . . . . . . 387
CHART 33: ABS/EBD/ABD / OPT 2091 . . . . . . 367
CHART 42A: HEATED OPERATOR SEAT BUS
CHART 34A: E.C.A.S. WITHOUT RESERVE AIR VERSION / OPT 6628 . . . . . . . . . . 388
RESERVOIR (.9-.10-.11-.12-.13-.14-
.17) . . . . . . . . . . . . . . . . . . . . . . . . . 368 CHART 42B: HEATED SEATS / OPT 6644 . . . . 389
CHART 34B: E.C.A.S. WITH RESERVE AIR RESERVOIR CHART 43: DAY LIGHTS FOR NORTHERN
(.9-.10-.11-.12-.13-.14-.17) . . . . . . . 369 EUROPE VEHICLES / OPT 2536 . 390
cardiagn.com
CHART 34C: VB TECHNIEK (35C - 40C - 45C) 370 CHART 44: DOOR LOCK / OPT 6536 . . . . . . 391
CHART 34D: VB TECHNIEK (60C - 65C - 50C) 371 CHART 45A: TELMA SCUDATI RETARDER (.9 - .11) /
OPT 235 . . . . . . . . . . . . . . . . . . . . 392
CHART 35A: AUTOMATIC CONDITIONER (.9) /
OPT 6650 . . . . . . . . . . . . . . . . . . . 372 CHART 45B: TELMA RETARDER (.10 - .12 - .13 - .15) /
OPT 235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
CHART 35B: AUTOMATIC CONDITIONER (.11) /
OPT 6650 . . . . . . . . . . . . . . . . . . . 373 CHART 46: ELECTRICAL BATTERY SECTIONER /
OPT 2532 . . . . . . . . . . . . . . . . . . . 394
CHART 35C: AUTOMATIC CONDITIONER
(.13-.15) / OPT 6650 . . . . . . . . . . . 374 CHART 47A: CRUISE CONTROL . . . . . . . . . . . 395
CHART 35D: AUTOMATIC CONDITIONER CHART 47B: CRUISE CONTROL (EDC 16) . . . 396
(.9 - .10 - .11 - .12 - .13 - .14 -
.15 - .17) / OPT 6650 . . . . . . . . . . 375 CHART 48: ENGINE WATER HEATER /
OPT 6654 . . . . . . . . . . . . . . . . . . . 397
CHART 35E: AUTOMATIC CONDITIONER
(.10 - .12) / OPT 6650 . . . . . . . . . . 376 CHART 49: ELECTRICAL CONTROL SLIDING
SIDE DOOR . . . . . . . . . . . . . . . . . 398
CHART 35F: AUTOMATIC AIR CONDITIONING
(.10 - .12 - .14 - .17 - EDC16) . . . . 377 CHART 50: ROTATING SLIDING DOOR . . . 399
CHART 36: ELECTRONIC TACHOGRAPH / CHART 51: ELECTRICAL PIT ON PAVILION /
OPT 5130 - 5131 . . . . . . . . . . . . . 378 OPT 640 . . . . . . . . . . . . . . . . . . . . 400
CHART 37A: AIR BAG AND PRE-TENSIONERS / CHART 52: SCUDATI CENTRAL EMERGENCY
OPT 4495 - 4496 . . . . . . . . . . . . . 379 CONTROL / OPT 2546 . . . . . . . . 401
CHART 37B: AIR BAG AND PRETENSIONERS 380 CHART 53: SYSTEM FOR NORTH AFRICA
VEHICLES . . . . . . . . . . . . . . . . . . . 402
CHART 38: DOOR LOCK WITH ANTI-THEFT /
OPT 6890 . . . . . . . . . . . . . . . . . . . 381 CHART 54: SYSTEM FOR BUS VEHICLES WITH
2-TONE HORN . . . . . . . . . . . . . . 403
CHART 39A: FRONT DIFFERENTIAL LOCK /
OPT 131 . . . . . . . . . . . . . . . . . . . . 382 CHART 55: SYSTEM FOR RIGHT HAND DRIVE
VEHICLES . . . . . . . . . . . . . . . . . . . 404
Print 603.93.281/A Base - May 2004

Page
Print 603.93.281/A
CHART 56: ABS 8 . . . . . . . . . . . . . . . . . . . . . . . 405
CHART 57: ESP8 . . . . . . . . . . . . . . . . . . . . . . . . 406
CHART 58: 6 AS 300 VD AUTOMATIC

GEARBOX . . . . . . . . . . . . . . . . . . . 407
cardiagn.com
Base - May 2004 Print 603.93.281/A

CIRCUIT CHARTS
Notes and specifications

Unless otherwise specified the charts are to be considered valid for all engines and for all truck and van versions.
The vehicle conditions considered for laying wiring circuitries are:
- engine off
- ignition key off
- handbrake on
- gearbox in neutral
- fluids at normal level
- doors closed
The relays used have an internal resistance (in parallel with the coil) of 680 Ω to reduce over-voltage on the system due to
switching of the switches.
In charts 22 A-B the component distinguished by the symbol is the socket for the converter.
In chart 33 the connection distinguished by the symbol Y is valid only for vehicles with "parallel" braking system.
cardiagn.com
In chart 34B the component distinguished by the symbol ∆ is present only on vehicles with reserve air tank.
Chart 38 shows a van with sliding side doors.
Component codes concerning chart 35D (82010A/B/C connectors - for all tables)
1 Sensor on evaporator
2 Fan motor
3 Fan electronic control module
4 Air mixing gear motor
5 Re-circulation gear motor
6 Electronic climate control unit (82010)
7 Treated air sensor
8 Fan control potentiometer
9 Required temperature potentiometer
10 Climate control module
11 Microswitch for MAX DEF function
12 Control panel lighting
Colour codes for cabling not supplied by IVECO
Code Colour Code Colour

A Light Blue M Brown
B White N Black
C Orange R Red
G Yellow S Rose
H Grey V Green
L Blue Z Purple
Print 603.93.281 Base - May 2004

Chart 1A: Start
cardiagn.com
49949
Base - May 2004 Print 603.93.281

Chart 1B: Start (.10 - .12)
cardiagn.com
77046
Print 603.93.281 Base - May 2004

Chart 2A: Preheating (.9)
cardiagn.com
49948
Base - May 2004 Print 603.93.281

Chart 2B: Preheating (.11)
cardiagn.com
49947
49947
Print 603.93.281 Base - May 2004

Chart 2C: Preheating (.13 - .15)
cardiagn.com
49946
49946
Base - May 2004 Print 603.93.281

Chart 2D: Preheating (.10 - .12)
cardiagn.com
74257
74257
Print 603.93.281 Base - May 2004

Chart 2E: Pre-heating (.10 - .12 - .14 - .17 - EDC16)
cardiagn.com
85715
Base - May 2004 Print 603.93.281

Chart 3: Recharge
cardiagn.com
49945
Print 603.93.281 Base - May 2004

Chart 4: Instruments
cardiagn.com
49944
Base - May 2004 Print 603.93.281

Chart 5: Tachometer
cardiagn.com
49943
Print 603.93.281 Base - May 2004

Chart 6A: Rpm counter (.9)
cardiagn.com
49942
Base - May 2004 Print 603.93.281

Chart 6B: Rpm counter (.11)
cardiagn.com
49941
Print 603.93.281 Base - May 2004

Chart 6C: Rpm counter (.10 - .12 - .13 - .15)
cardiagn.com
49940
Base - May 2004 Print 603.93.281

Chart 6D: Rpm counter (.10 - .12 - .14 - .17 - EDC16)
cardiagn.com
90163
Print 603.93.281 Base - May 2004

Chart 7A: Optical indicators (.9 - .11)
cardiagn.com
49939
Base - May 2004 Print 603.93.281

Chart 7B: Optical indicators
cardiagn.com
49938
Print 603.93.281 Base - May 2004

Chart 8: Outside lighting (cab instruments)
cardiagn.com
49937
Base - May 2004 Print 603.93.281

Chart 9A: Outside lighting (position lights)
cardiagn.com
49936
Print 603.93.281 Base - May 2004

Chart 9B: Outside lighting (cab position lights van)
cardiagn.com
49935
Base - May 2004 Print 603.93.281

Chart 10: Flood and dipped lights
cardiagn.com
49934
Print 603.93.281 Base - May 2004

Chart 11A: Back and front fog lights
cardiagn.com
49933
Base - May 2004 Print 603.93.281

Chart 11B: Back and front fog lights(van)
cardiagn.com
49932
Print 603.93.281 Base - May 2004

Chart 12: Front light setting
cardiagn.com
49931
Base - May 2004 Print 603.93.281

Chart 13A: Direction and emergency lights
cardiagn.com
49930
Print 603.93.281 Base - May 2004

Chart 13B: Direction and emergency lights (van)
cardiagn.com
49929
Base - May 2004 Print 603.93.281

Chart 14A: Stop lights
cardiagn.com
49928
Print 603.93.281 Base - May 2004

Chart 14B: Stop lights (van)
cardiagn.com
49927
Base - May 2004 Print 603.93.281

Chart 15A: Backup lights
cardiagn.com
49926
Print 603.93.281 Base - May 2004

Chart 15B: Backup lights (van)
cardiagn.com
49925
Base - May 2004 Print 603.93.281

Chart 16: Horn
cardiagn.com
49924
Print 603.93.281 Base - May 2004

Chart 17: Windscreen and front light washer
cardiagn.com
49923
Base - May 2004 Print 603.93.281

Chart 18A: Windscreen defroster
cardiagn.com
49922
Print 603.93.281 Base - May 2004

Chart 18B: Windscreen defroster (.10 - .12)
cardiagn.com
74258
Base - May 2004 Print 603.93.281

Chart 19: Radio set
cardiagn.com
49921
Print 603.93.281 Base - May 2004

Chart 20A: Internal lighting and cigarette lighter
cardiagn.com
49920
Base - May 2004 Print 603.93.281

Chart 20B: Internal lighting (van)
cardiagn.com
49919
Print 603.93.281 Base - May 2004

Chart 20C: Internal lighting 6+1 vehicle
cardiagn.com
49918
Base - May 2004 Print 603.93.281

Chart 20D: Internal lighting and cigarette lighter (F1A)
cardiagn.com
74259
Print 603.93.281 Base - May 2004

Chart 21A: Immobilizer (.9)
cardiagn.com
49917
Base - May 2004 Print 603.93.281

Chart 21B: Immobilizer (.11)
cardiagn.com
49916
Print 603.93.281 Base - May 2004

Chart 21C: Immobilizer (.10 - .12 - .13 - .15)
cardiagn.com
49915
Base - May 2004 Print 603.93.281

Chart 21D: Immobilizer (.10-.12-.14 - .17 EDC16)
cardiagn.com
90159
Print 603.93.281 Base - May 2004

Chart 22A: Diagnosis connection (.9 - .11)
cardiagn.com
49914
Base - May 2004 Print 603.93.281

Chart 22B: Diagnosis connection (.10-.12-.13-.15-.14-.17)
cardiagn.com
85716
Print 603.93.281 Base - May 2004

Chart 23A: Engine cooling (.9)
cardiagn.com
49912
Base - May 2004 Print 603.93.281

Chart 23B: Engine cooling (.11)
cardiagn.com
49911
Print 603.93.281 Base - May 2004

Chart 23C: Engine cooling (.13-.15)
cardiagn.com
49910
Base - May 2004 Print 603.93.281

Chart 23D: Engine cooling (.10 - .12)
cardiagn.com
74260
Print 603.93.281 Base - May 2004

Chart 23E: Engine cooling (.10 - .12 - .14 - .17 - EDC16)
cardiagn.com
85717
Base - May 2004 Print 603.93.281

Chart 24A: EGR/exhaust gas electronic control system (.9)
cardiagn.com
49909
Print 603.93.281 Base - May 2004

Chart 24B: EGR/exhaust gas electronic control system for EDC (.13)
cardiagn.com
49908
Base - May 2004 Print 603.93.281

Chart 24C: EGR/exhaust gas electronic control system for EDC (.10 - .12)
cardiagn.com
74261
Print 603.93.281 Base - May 2004

Chart 24D: EGR Exhaust gas electronic control system for EDC (.10 - .12 - .14 - .17 - EDC16)
cardiagn.com
85718
Base - May 2004 Print 603.93.281

Chart 25A: Spark lead variator (.9)
cardiagn.com
49907
Print 603.93.281 Base - May 2004

Chart 25B: Spark lead variator (.11)
cardiagn.com
49906
Base - May 2004 Print 603.93.281

Chart 26A: E.D.C. (.13)
cardiagn.com
49905
Print 603.93.281 Base - May 2004

Chart 26B: E.D.C. with VGT (.15)
cardiagn.com
49904
Base - May 2004 Print 603.93.281

Chart 26C: E.D.C. with WASTE GATE (.13)
cardiagn.com
49903
Print 603.93.281 Base - May 2004

Chart 26D: E.D.C. without EGR (.10 - .12)
cardiagn.com
74262
Base - May 2004 Print 603.93.281

Chart 26E: E.D.C WITHOUT EGR (.10 - .12 - .14 - .17 - EDC16)
cardiagn.com
90161
Print 603.93.281 Base - May 2004

Chart 27A: Heated fuel filter (.9 - .11) / OPT 2287
cardiagn.com
49902
Base - May 2004 Print 603.93.281

Chart 27B: Heated fuel filter (.13 - .15)
cardiagn.com
49901
Print 603.93.281 Base - May 2004

Chart 27C: Heated fuel filter (.10 - .12)
cardiagn.com
74263
Base - May 2004 Print 603.93.281

Chart 27D: Heated fuel filter (.10 - .12 - .14 - .17 - EDC16)
cardiagn.com
85720
Print 603.93.281 Base - May 2004

Chart 28A: Power window operator and passenger side / OPT 693
cardiagn.com
49900
Base - May 2004 Print 603.93.281

Chart 28B: Power window operator side / OPT 4028
cardiagn.com
49899
Print 603.93.281 Base - May 2004

Chart 28C: Power window operator and passenger side (.10 - .12)
cardiagn.com
74264
Base - May 2004 Print 603.93.281

Chart 29: Heated rearview mirrors / OPT 697
cardiagn.com
49898
Print 603.93.281 Base - May 2004

Chart 30: Rearview mirror adjustment / OPT 2714
cardiagn.com
49897
Base - May 2004 Print 603.93.281

Chart 31: Heated windscreen / OPT 685
cardiagn.com
49896
Print 603.93.281 Base - May 2004

Chart 32: Heated rear window / OPT 6815
cardiagn.com
49895
Base - May 2004 Print 603.93.281

Chart 33: ABS/EBD/ABD / OPT 2091
cardiagn.com
49894
Print 603.93.281 Base - May 2004

Chart 34A: E.C.A.S. without reserve air reservoir (.9-.10-.11-.12-.13-.14-.17)
cardiagn.com
49893
Base - May 2004 Print 603.93.281

Chart 34B: E.C.A.S. with reserve air reservoir (.9-.10-.11-.12-.13-.14-.17)
cardiagn.com
49892
Print 603.93.281 Base - May 2004

Chart 34C: Vb Techniek (35C - 40C - 45C)
cardiagn.com
86165
Base - May 2004 Print 603.93.281

Chart 34D: Vb Techniek (60C - 65C - 50C)
cardiagn.com
86166
Print 603.93.281 Base - May 2004

Chart 35A: Automatic conditioner (.9) / OPT 6650
cardiagn.com
49890
Base - May 2004 Print 603.93.281

Chart 35B: Automatic conditioner (.11) / OPT 6650
cardiagn.com
49889
Print 603.93.281 Base - May 2004

Chart 35C: Automatic conditioner (.13-.15) / OPT 6650
cardiagn.com
49888
Base - May 2004 Print 603.93.281

Chart 35D: Automatic conditioner (.9 - .10 - .11 - .12 - .13 - .14 - .15 - .17) / OPT 6650
cardiagn.com
49887
Print 603.93.281 Base - May 2004

Chart 35E: Automatic conditioner (.10 - .12) / OPT 6650
cardiagn.com
74265
Base - May 2004 Print 603.93.281

Chart 35F: Automatic air conditioning (.10 - .12 - .14 - .17 - EDC16)
cardiagn.com
85721
Print 603.93.281 Base - May 2004

Chart 36: Electronic tachograph / OPT 5130 - 5131
cardiagn.com
49886
Base - May 2004 Print 603.93.281

Chart 37A: Air bag and pre-tensioners / OPT 4495 - 4496
cardiagn.com
49885
Print 603.93.281 Base - May 2004

Chart 37B: Air bag and pretensioners
cardiagn.com
49884
Base - May 2004 Print 603.93.281

Chart 38: Door lock with anti-theft / OPT 6890
cardiagn.com
49883
Print 603.93.281 Base - May 2004

Chart 39A: Front differential lock / OPT 131
cardiagn.com
49882
Base - May 2004 Print 603.93.281

Chart 39B: Rear differential lock / OPT 131
cardiagn.com
49881
Print 603.93.281 Base - May 2004

Chart 40: 13-pole power connection / OPT 6520
cardiagn.com
49880
Base - May 2004 Print 603.93.281

Chart 41A: Total PTO (.9 - .11)
cardiagn.com
49879
Print 603.93.281 Base - May 2004

Chart 41B: Total PTO (.10 - .12 - .13 - .15)
cardiagn.com
49878
Base - May 2004 Print 603.93.281

Chart 41C: Total PTO (EDC 16)
cardiagn.com
90160
Print 603.93.281 Base - May 2004

Chart 42A: Heated operator seat bus version / OPT 6628
cardiagn.com
49877
Base - May 2004 Print 603.93.281

Chart 42B: Heated seats / OPT 6644
cardiagn.com
49876
Print 603.93.281 Base - May 2004

Chart 43: Day lights for Northern Europe vehicles / OPT 2536
cardiagn.com
49875
Base - May 2004 Print 603.93.281

Chart 44: Door lock / OPT 6536
cardiagn.com
49874
Print 603.93.281 Base - May 2004

Chart 45A: Telma Scudati retarder (.9 - .11) / OPT 235
cardiagn.com
49873
Base - May 2004 Print 603.93.281

Chart 45B: Telma retarder (.10 - .12 - .13 - .15) / OPT 235
cardiagn.com
49872
Print 603.93.281 Base - May 2004

Chart 46: Electrical battery sectioner / OPT 2532
cardiagn.com
49871
Base - May 2004 Print 603.93.281

Chart 47A: Cruise Control
cardiagn.com
49870
Print 603.93.281 Base - May 2004

Chart 47B: Cruise Control (EDC 16)
cardiagn.com
90162
Base - May 2004 Print 603.93.281

Chart 48: Engine water heater / OPT 6654
cardiagn.com
49869
Print 603.93.281 Base - May 2004

Chart 49: Electrical control sliding side door
cardiagn.com
49868
Base - May 2004 Print 603.93.281

Chart 50: Rotating sliding door
cardiagn.com
49867
Print 603.93.281 Base - May 2004

Chart 51: Electrical pit on pavilion / OPT 640
cardiagn.com
49866
Base - May 2004 Print 603.93.281

Chart 52: Scudati central emergency control / OPT 2546
cardiagn.com
49865
Print 603.93.281 Base - May 2004

Chart 53: System for North Africa vehicles
cardiagn.com
49864
Base - May 2004 Print 603.93.281

Chart 54: System for bus vehicles with 2-tone horn
cardiagn.com
49863
Print 603.93.281 Base - May 2004

Chart 55: System for right hand drive rotating sliding door vehicles
cardiagn.com
49862
Base - May 2004 Print 603.93.281

Chart 56: ABS 8
cardiagn.com
101883

Chart 57: ESP8
cardiagn.com
101884

Card 58: 6 AS 300 VD automatic gearbox
cardiagn.com
101885

cardiagn.com

14+ +electric Electronic+System

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DAILY ELECTRIC/ELECTRONIC SYSTEM 1

ABBREVIATIONS AND GRAPHIC SYMBOLS . . . 7

GENERAL CONDITIONS FOR LAYING ELECTRIC

- Earth points on the vehicle . . . . . . . . . . . . . . . 19

CONCEPT OF EARTH AND ELECTROMAGNETIC

- Ultrasonic cable welding . . . . . . . . . . . . . . . . . 22

MAIN COMPONENTS OF POWER

- BOSCH KCBI 14V 110A Alternator . . . . . . . . 23

- EV 12V - 2.3 kW Starter motor . . . . . . . . . . . 24

- General remote control switch (T.G.C.) . . . . . 28

- Components of the injection system (E. 8140) 29

8140.43C ID/TCA (.11) ENGINE HARNESS . . . . . 30

8140.43S UNIJET (.13) ENGINE HARNESS . . . . . . 32

INJECTION CABLE - V.G.T (.15) . . . . . . . . . . . . 34

Print 603.93.281 Base - May 2004

JUNCTION CONNECTORS . . . . . . . . . . . . . . . . 53 - Connection between cab roof lamp and right

- Connection between cab/bonnet cable and 13 - General Information . . . . . . . . . . . . . . . . . . . . 82

Base - May 2004 Print 603.93.281/A

- Identification of fuses . . . . . . . . . . . . . . . . . . . 87 - Electro-hydraulic modulator/control unit . . . . 132/3

- Identification of relays/diode holders . . . . . . . 88 - Four parallel channel system (II) . . . . . . . . . . . 132/4

OPTICAL INDICATORS . . . . . . . . . . . . . . . . . . . 89 - Electro-hydraulic modulator/control unit . . . . 132/4

- Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 - Steering angle sensor . . . . . . . . . . . . . . . . . . 132/13

- System components . . . . . . . . . . . . . . . . . . . . 106 - ESP control unit programming . . . . . . . . . . . 132/14

- Key teaching procedure . . . . . . . . . . . . . . . . . 109 6AS 300 VD AUTOMATIC TRANSMISSION . . . 132/15

ABS/EBD/ABD . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 - Description of operation . . . . . . . . . . . . . . . 132/15

- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 - Electronic control . . . . . . . . . . . . . . . . . . . . . 132/16

- Location of components . . . . . . . . . . . . . . . . . 117 - System control unit . . . . . . . . . . . . . . . . . . . 132/17

- Sensor on phonic wheel . . . . . . . . . . . . . . . . . 118 - Connector control unit pin-out —

SYSTEM WITH 4 PARALLEL CHANNELS (11) . 125 - Gearbox actuator . . . . . . . . . . . . . . . . . . . . . 132/20

- Electrohydraulic control unit/modulator . . . . . 126 - Clutch actuator . . . . . . . . . . . . . . . . . . . . . . . 132/22

- Electrohydraulic modulator . . . . . . . . . . . . . . . 127 - Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132/24

- Pressure increase . . . . . . . . . . . . . . . . . . . . . . 127 - Accelerator pedal . . . . . . . . . . . . . . . . . . . . . 132/26

- Electronic control unit . . . . . . . . . . . . . . . . . . 132 - PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132/27

ABS 8/ESP 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132/1 - Diagnosis instruments . . . . . . . . . . . . . . . . . . 132/30

Print 603.93.281/A Base - May 2004

- MODUS - IT 2000 - E.A.S.Y. connection . . . 132/31 - Clutch pedal switch . . . . . . . . . . . . . . . . . . . . 155

- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 132/32 - Electromagnetic junction fan . . . . . . . . . . . . . . 156

ELECTRONIC INJECTION SYSTEM . . . . . . . . . . 133 - Preheat plug electronic centre

- Control unit connection to cab-bonnet cable

- Pressure limiter . . . . . . . . . . . . . . . . . . . . . . . . 148 - Accelerator pedal sensor . . . . . . . . . . . . . . . . 175

- Fuel pressure sensor . . . . . . . . . . . . . . . . . . . . 148 - Camshaft sensor (F1A) . . . . . . . . . . . . . . . . . . 176

- Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 - Injection cable F1A (.10 - .12) . . . . . . . . . . . . . 177

- Fuel outlets unit . . . . . . . . . . . . . . . . . . . . . . . 150 - Injection cable F1A (.14) . . . . . . . . . . . . . . . . 177/1

- Air flow meter . . . . . . . . . . . . . . . . . . . . . . . . 151 - Joint connector . . . . . . . . . . . . . . . . . . . . . . . . 178

- Atmospheric pressure sensor . . . . . . . . . . . . . 153 - Diagnostic connector . . . . . . . . . . . . . . . . . . . 179

- Fuel temperature sensor . . . . . . . . . . . . . . . . . 153 - High-pressure pump (F1A engine) . . . . . . . . . 181

- Brake pedal switches . . . . . . . . . . . . . . . . . . . . 155 F1C ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

- Injection cable F1C (.14 - .17) . . . . . . . . . . . . . 183

Base - May 2004 Print 603.93.281/A

- Outside air temperature sensor . . . . . . . . . . . 206 - Deployment of an air bag . . . . . . . . . . . . . . . . 223

- Electronic fan control module . . . . . . . . . . . . 210

Print 603.93.281/A Base - May 2004

- Drivers air bag module . . . . . . . . . . . . . . . . . . 230 VB TECHNIEK PNEUMATIC SUSPENSIONS . . . . 267

- Pretensioners . . . . . . . . . . . . . . . . . . . . . . . . . 234 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . 271

DOOR-BLOCKER WITH ANTI-THEFT - Level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 273

- Level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 260 - Removing the instrument cluster module . . . . 286

- Pneumatic supply unit . . . . . . . . . . . . . . . . . . . 261 - Operations on gearbox . . . . . . . . . . . . . . . . . 288

- Brake action compensator . . . . . . . . . . . . . . . 262 - Operation in bonnet . . . . . . . . . . . . . . . . . . . . 289

- Chassis lifting . . . . . . . . . . . . . . . . . . . . . . . . . . 264 CIRCUIT CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . 291