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DAILY EURO 4 REPAIR MANUAL MECHANICAL ELECTRIC/ELECTRONIC


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

Produced by: Publication Edited by: IVECO S.p.A. Customer Service Lungo Stura Lazio, 15 10156 Torino (TO) - Italy Print 603.93.651 - 1st Ed. 2006

B.U. TECHNICAL PUBLISHING Iveco Technical Publications Lungo Stura Lazio, 15 10156 Torino (TO) - Italy


PRELIMINARY REMARKS Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.). Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections — disconnections of units to/from the vehicle, overhauls at the bench and relating troubleshooting. On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the electric system. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.

SYMBOLS - WARNINGS Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for personsÂ’ safety.

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

!

General danger It includes the dangers of above described signals.

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

NOTE

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It indicates an additional explanation for a piece of information.

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SYMBOLS - ASSISTANCE OPERATIONS Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting in place Assembly

Compression ratio

Tighten to torque

Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Regulation Adjustment

Angle Angular value

Visual inspection Fitting position check

Preload

Measurement Value to find Check

Number of revolutions

Equipment

Temperature

Surface for machining Machine finish

bar

Pressure Oversized Higher than . Maximum, peak Undersized Less than . Minimum Selection Classes Oversizing Temperature < 0 C Cold Winter Temperature > 0 C Hot Summer

Interference Strained assembly Thickness Clearance Lubrication Damp Grease Sealant Adhesive Air bleeding Replacement Original spare parts

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PRODUCT CODE Each title or subtitle concerning operations being performed is preceded by a six-figure number named PRODUCT CODE. This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and TROUBLE CODE document. As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).

5 0

Product Code:

PRODUCT

7 6 UNIT

SUB-ASSEMBLY COMPONENT

PRODUCT

UNIT

SUB-ASSEMBLY COMPONENT

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

50 52 53 76

= = = =

Vehicle chassis; Axles; Transmission; Electric ssystem.

0 1

Unit Code: PRODUCT

UNIT

0 3 SUB-ASSEMBLY COMPONENT

PRODUCT

UNIT

SUB-ASSEMBLY COMPONENT

The third and fourth figures identify the UNIT within the PRODUCT. Example : Product Unit Unit Unit

50 01 02 03

= = = =

Vehicle chassis; Chassis; Bumpers; Alternator.

4 0

Sub-assembly Code: PRODUCT

UNIT

1 3

SUB-ASSEMBLY COMPONENT

PRODUCT

UNIT

SUB-ASSEMBLY COMPONENT

The fifth and sixth figures exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT. Example : Product Unit Sub-assembly Sub-assembly

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50 01 40 13

= = = =

Vehicle chassis; Chassis; Chassis cross members; Rotor.

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GENERAL WARNINGS

!

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check. The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path. Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it. In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel. Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position. Keep personnel not authorised to operations clear of working area. Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph Â&#x201C;Controls care of userÂ&#x201D; of Use and Maintenance handbook. In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave unmanned a vehicle in motion during repair interventions. Keep the vehicle stationary by proper chocks. In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special support stands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated. When it is necessary to perform an intervention on methane-fed vehicles, observe the indications contained inside the document, as well as all specific safety regulations provided. Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out. Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers. Worn out, damaged or consumable parts must be replaced by Iveco original spares. During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules. For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR - BAG systems, scrupulously observe indications specified in relating manual sections.

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IV

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GENERAL WARNINGS Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc. Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside. Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present. Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.

Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers. Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc. Self-locking nuts with an insert made of nylon must always be replaced. Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances. Before washing under pressure mechanical parts, protect electric connectors, and central units, if present. Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document. Before welding: - Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding) and detach connectors. - Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water. - Await about 15 minutes before welding. - Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials flow which may catch fire easily on welding. Should the vehicle be subjected to temperatures exceeding 80 C (dryer ovens), disassemble drive electronic central units.

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

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GENERAL WARNINGS ON THE ELECTRIC SYSTEM

!

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated. Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery terminals. Do not cause sparks to be generated in checking if the circuit is energised. Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses. Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance interventions. Measurements in drive electronic central units, plugged connections and electric connections to components can only be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers, clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which would later cause contact problems.

To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special truck. A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries) can cause them to be destroyed. Disconnect the batteries from the system during their recharging with an external apparatus. On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque. Before disconnecting the junction connector from an electronic central unit, isolate the system. Do not directly supply electronic central units servo components at nominal vehicle voltage. Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure. Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according to original arrangement. Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key memorisation: 1 Pay attention that jamming sources are not present in the cab or near the keys. 2. Keys not insered in the panel must be at least 1 meter away.

NOTE

Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable side.

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Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M). Further, following warnings are to be compulsorily observed for electronic components: -

Electronic central units must be connected to system bonding when they are provided with a metallic shell.

-

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

-

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

-

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

-

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

-

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

Figure 1

1.

NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

Figure 2

88039

2.

SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR d. DISTANCE ! 0

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

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

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

Power 1 kW 1 kW 1 metric HP 1 metric HP 1 HP 1 HP

= = = = = =

1.36 metric HP 1.34 HP 0.736 kW 0.986 HP 0.746 kW 1.014 metric HP

Torque 1 Nm 1 kgm

= =

0.1019 kgm 9.81 Nm

OF

THE

Revolutions per time unit 1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602 Pressure 1 bar 1 kg/cm2 1 bar

= = =

1.02 kg/cm2 0.981 bar 105 Pa

Where accuracy is not particularly needed: - Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1 1 kgm

=

10 Nm;

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

=

1 bar.

Temperature 0 C = 32 F 1 C = (1 x 1.8 + 32) F

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INDEX OF SECTIONS

Section

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General information

1

Engine

2

Clutch

3

Gearbox

4

Propeller shafts

5

Rear axles

6

Front axle

7

Front and rear suspensions

8

Wheels and tyres

9

Steering system

10

Pneumatic system - Brakes

11

Bodywork and chassis frame

12

Maintenance

13

Electric/Electronic System

14

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DAILY EURO 4

GENERAL

1

Print 60 3.43 .6 71

SECTION 1 General Page

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IDENTIFICATION DATA . . . . . . . . . . . . . . . . . .

3

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

3

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

4

ALPHANUMERICAL CODING FOR BUS IDENTIFICATION . . . . . . . . . . . . . . . . .

6

REPLENISHING FLUIDS . . . . . . . . . . . . . . . . . . .

13

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DAILY EURO 4

3

GENERAL

IDENTIFICATION DATA Vehicle identification plate

Figure 1

Plate legend 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13)

Approval number Chassis number PTT - Total weight on ground MTC - Total combined weight Max. weight permitted on the front axle Max. weight permitted on the rear axle Specific indication of type Wheelbase (mm) Type of engine Engine rating Permitted smoke level Place of manufacture Number of vehicle axles 108534

Figure 2

Manufacturer tag For vehicle identification according to the EC directive (on the front crosspiece)

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

Engine Stamping (on the right side on the engine base)

108533

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4

GENERAL

DAILY EURO 4

COMPOSITION OF MODELS MODELS ASSEMBLIES F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV

o

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

o o o

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

o

o o

o

o o

o o

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

o

F1CE0481F*C (DPF series) 146 CV o

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

o

F1CE0481H*C (DPF series) 176 CV

Single disk

9혬 1/4

Single disk Single disk

10혬 1/2

o o

o

o o

o

o

o

o

o

o

o

11

o

o

o

o

o

V V V V V V

ZF 6 S400 O.D. ZF 6 S400A O.D.

V V V V V V V V V V V V V V V V V V V V V

5817

o

o

o

o

o

o

V V V

o

ZF 5 S300

V V

o

5818 5819

o

o

o

o

o

o

o

o

o

o

o

o

5823 NDA R.S.

o

o

o

o

o

o

o

NDA R.G.

o

o

o

o

o

450511 450517/2 Rack-and-pinion Powered steering

FRONT MECHANICAL SUSPENSIONS: independent with transverse leaf spring (MK3) independent with torsion bars REAR Parabolic MECHANICAL - single leaf SUSPENSIONS: - reinforced Semi-elliptical Semi-elliptic with leaf spring REAR AIR SUSPENSIONS

O.D. = Over Drive ( ) Optional extra (with max load of 1900 kg) o Standard with ZF 6 S 400 A O.D. gearbox V Alternative Vehicles with front suspension with transverse leaf spring Vehicles with front suspension with torsion bars z Chassis cabs only, as an alternative

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o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o o o o o Z Z Z Z Z Z Z Z Z

o o o o

o

o

o

o

o

o

o

o

o

o

( ) ( ) ( ) ( ) ( )

o

s s s

s s s s s

s

z z z z z z z z z V V V V V V V V V V V V V V V V

s Standard on chassis cabs, Alternatively on Vans 혰 Chassis Cowls and Cut Aways Z Standard on Vans, Chassis Cowls and Cut Aways 혰 Alternatively on Chassis Cabs S Single rear wheels L Light with single rear wheels C Twin rear wheels

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DAILY EURO 4

GENERAL

5

COMPOSITION OF MODELS MODELS ASSEMBLIES F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV F1CE0481F*C (DPF series) 146 CV

o

o

o

o

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

Single disk Single disk Single disk

o

o

o

o

9혬 1/4 10혬 1/2 11

o

o

o

o

o

o

o

o

ZF 5 S300 ZF 6 S400 O.D.

V V V V V V V V

ZF 6 S400A O.D.

V V V V V V V V

5817 5818 o

5819

o

o

o

5823

o

o

o

o

o

o

o

o

NDA R.S. NDA R.G. o

450511

o

o

o

450517/2 Rack-and-pinion

Power steering

o

o

o

o

o

o

o

o

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

o

o

o

o

o

o

o

o

Parabolic - single leaf - reinforced

Z Z Z Z Z Z Z Z

Semi-elliptical Semi-elliptic with leaf spring

s s s s s s s s

REAR AIR SUSPENSIONS

O.D. = Over Drive ( ) Optional extra (with max load of 1900 kg) o Standard V Alternative Vehicles with front suspension with transverse leaf spring Vehicles with front suspension with torsion bars z Chassis cabs only, as an alternative

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z z z z z z z z V V V V V V V V

s Standard on chassis cabs, Alternatively on Vans 혰 Chassis Cowls and Cut Aways Z Standard on Vans, Chassis Cowls and Cut Aways 혰 Alternatively on Chassis Cabs S Single rear wheels L Light with single rear wheels C Twin rear wheels

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6

GENERAL

DAILY EURO 4

ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION CUSTOMIZED VEHICLE (V.P.) MARKET VEHICLE (V.M.)

STANDARD VEHICLE (V.C.B.)

1

2

3

4

5

6

7

8

9

10 11 12 13 14

3

4

5

6

7

8

9

10 11 12 13 14

8

9

10 11 12 13 14

RANGE

1

2

A

LIGHT ROAD VEHICLES

PROGRAMMING FAMILY

1

2

3

4

5

6

A

T 25C

29 L

B

T 30C

35 S

C

T 35C

35 C

7

CHASSIS CABS AND DERIVATIVES

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D

T 40C

40 C

E

T 50C

50 C 45 C

F

T 65C

60 C 65 C

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DAILY EURO 4

GENERAL

7

PROGRAMMING FAMILY

1

2

3

4

5

6

H

T 25V

29 L

K

T 30V

35 C

J

T 35V

35 C

L

T 40V

40 C

M

T 50V

50 C 45 C

N

T 65V

60 C 65 C

7

8

9

10 11 12 13 14

VANS AND DERIVATIVES

ENGINE

1

2

3

4

5

6

7

8

9

A

F1A E4 LD - 96 CV

B

F1A E4 LD - 116 CV

C

F1A E4 LD - 136 CV

D

F1C E4 HD - 146 CV

E

F1C E4 HD - 176 CV

10 11 12 13 14

E4 = Euro 4 LD = Light Duty HD = Heavy Duty

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8

GENERAL

DAILY EURO 4

SUSPENSION

1

2

3

4

5

6

7

8

9

10 11 12 13 14

A Mechanical suspension: front with transverse leaf spring. B

Mechanical suspension: front with torsion bars.

C

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

D

Mechanical front suspension with torsion bars — rear air suspension.

VERSION

1

2

3

4

5

1

6

0

R

6

7

8

9

10 11 12 13 14 ) - 29 L12 ( ) - 29 L14 ( ) ) - 35 S12 ( ) - 35 S14 ( ) - 35 S18 ( ) ) - 35 C12 ( ) - 35 C15 ( ) - 35 C18 ( ) ) - 40 C15 ( ) - 40 C18 ( ) ) - 50 C15 ( ) - 50 C18 ( ) ) - 60 C18 ( ) ) - 65 C18 ( )

CHASSIS CAB

29 L10 ( 35 S10 ( 35 C10 ( 40 C10 ( 45 C15 ( 60 C15 ( 65 C15 (

CHASSIS CAB 6+1

29 L10 D ( ) - 29 L12 D ( ) - 29 L14 D ( ) 35 S10 D ( ) - 35 S12 D ( ) - 35 S14 D ( ) 35 S18 D ( ) - 35 C10 D ( ) - 35 C12 D ( ) 35 C15 D ( ) - 35 C18 D ( ) - 40 C10 D ( ) 40 C12 D ( ) - 45 C15 D ( ) - 45 C18 D ( ) 50 C18 D ( ) - 60 C15 D ( ) - 60 C18 D ( ) 65 C15 D ( ) - 65 C18 D ( )

CHASSIS COWL

35 S12 CC ( ) - 35 S 14 CC ( ) - 35 S18 CC ( ) 35 C12 CC ( ) - 35 C15 CC ( ) - 35 C18 CC ( ) 40 C12 CC - 40 C15 CC ( ) - 40 C18 CC ( ) 45 C15 CC - 45 C18 CC ( ) 50 C15 CC ( ) - 50 C18 CC ( ) 60 C18 CC ( ) - 65 C18 CC ( )

CHASSIS COWL SHORT

35 S12 CCR ( ) - 35 S14 CCR ( ) - 35 S18 CCR( ) 35 C12 CCR ( ) - 35 C15 CCR ( ) - 35C18CCR( ) 40 C12 CCR ( ) - 40 C15 CCR ( ) - 40C18CCR( ) 45 C15 CCR ( ) - 45 C18 CCR ( ) 50 C15 CCR ( ) - 50 C18 CCR ( ) 60 C18 CCR ( ) - 65 C18 CCR ( )

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

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DAILY EURO 4

GENERAL

9

VERSION

1

2

3

4

5

A

4

V

6

7

8

CUT-AWAY

VAN

SEMI GLAZE SEMI-GLAZE D VAN

9

10 11 12 13 14

35 C10 CA ( ) - 35 C12 CA ( ) 40 C10 CA ( ) - 40 C12 CA ( ) 45 C18 CA ( ) - 50 C18 CA ( ) 60 C18 CA ( ) - 65 C18 CA ( )

29 L10 V ( ) - 29 L12 V ( ) - 29 L14 V ( ) 35 S10 V ( ) - 35 S12 V ( ) - 35 S14 V ( ) 35 S18 V ( ) 35 C10 V ( ) - 35 C12 V ( ) - 35 C15 V ( ) 35 C18 V ( ) 40 C12 V ( ) - 40 C15 V ( ) - 40 C18 V ( ) 45 C15 V ( ) - 45 C18 V ( ) 50 C15 V ( ) - 50 C18 V ( ) 60 C15 V ( ) - 60 C18 V ( ) 65 C15 V ( ) - 65 C18 V ( )

29 L10 SV ( ) - 29 L12 SV ( ) - 29 L14 SV ( ) 35 S10 SV ( ) - 35 S12 SV ( ) - 35 S14 SV ( ) 35 S18 SV ( ) 35 C10 SV ( ) - 35 C12 SV ( ) - 35 C15 SV ( ) 35 C18 SV ( ) 40 C10 SV ( ) - 40 C12 SV ( ) - 40 C15 SV ( ) 40 C18 SV ( ) 45 C15 SV ( ) - 45 C18 SV ( ) 50 C15 SV ( ) - 50 C18 SV ( )

U

VENDOR VERSION CITY VAN

35 S12 CV ( ) - 35 S14 CV ( ) 35 C12 CV ( ) - 40 C12 CV 45 C15 CV ( ) - 45 C18 CV ( ) 50 C15 CV ( ) - 50 C18 CV ( )

5

COMBI

29 L14 C ( ) - 35 S14 C ( )

8

CAMPER

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

9

CHASSISCOWL 35 S14 CCRC ( ) - 35 S18 CCRC SHORT 35 C14 CCRC ( ) - 35 C18 CCRC VERSION FOR CAMPER VAN

( ) Also available in the A (automatic transmission) and /P (pneumatic rear suspensions) versions. Print 603.93.651

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10

GENERAL

DAILY EURO 4

WHEELBASE

1

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2

3

4

5

6

7

8

9

10 11 12 13 14

1

3000 mm (T25C - T30C - T35C - T40C - T25V - T30V T35V - T40V - T50V)

2

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

3

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

4

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

5

3750 mm (T30C - T35C - T40C - T50C - T65C)

6

3950 L mm (T30V - T35V - T40V - T50V - T65V)

7

4100 mm (T35C - T40C)

8

4350 mm (T50C - T65C)

9

4750 mm (T50C - T65C)

Print 603.93.651


DAILY EURO 4

GENERAL

11

GEARBOX

1

2

3

4

5

6

7

8

9

10 11 12 13 14

A

5 SPEED

(5 S 300)

B

6 SPEED

(6 S 400 O.D.)

C

6 SPEED

(6 S 400 A O.D.)

A Automated O.D. Over Drive

Print 603.93.651

Base - March 2006


12

GENERAL

DAILY EURO 4

DRIVE Â&#x2014; INTERNAL HEIGHT OF LOADING BAY

1

2

3

4

5

6

7

8

9

10 11 12 13 14

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

1

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

1

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

2

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

3

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

A

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

A

RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H2 = 1900 mm (T25V - T30V - T35V - T40V - T50V)

B

RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H3 = 2100 mm (T30V - T35V - T40V - T50V - T65V)

C

MANDATORY MARKET OPTIONAL EXTRAS

1

2

3

4

5

6

7

8

9

10 11 12 13 14

OPTIONAL EXTRAS REQUIRED BY THE CUSTOMER

1 Base - March 2006

2

3

4

5

6

7

8

9

10 11 12 13 14 Print 603.93.651


DAILY EURO 4

GENERAL

13

REPLENISHING FLUIDS IVECO RECOMMENDED LUBRICANTS

Urania Dailyy Urania LD 5

PARTS TO BE REPLENISHED

kg

1.4

1.23

5.7

5.02

4.3 3

3.78 2.65

1 7.6

0.88

6.6 4.29

5.81 3.78

2

1.8

ZF 6S 400 O.D.

2.2

1.98

ZF 6S 400 A O.D.

2.7

2.43

-

-

Quantity of oil in circulation in the cartridge filter and heat exchanger Total dry engine capacity Sump capacity: - max level - min level Quantity of oil in circulation in the cartridge filter and heat exchanger Total dry engine capacity Sump capacity: - max level - min level

!

Quantity Litres

6.79

Max. gradient negotiable by vehicle uphill/downhill with oil at minimum level 30% Gearbox ZF 5S 300 Tutela TRUCK GEARLITE

Front axle: 5817 5818 5819 5823

Rear axles: Tutela W140/M-DA (SAE 80W90)

NDA R.S.

1.35

1.21

Tutela W90/M-DA (SAE 80W90)

NDA R.G.

1.35

1.21

Tutela W140/M-DA (SAE 85W140)

450511

1.9

1.65

Tutela W140/M-DA (SAE 85W140)

450517/2

3

2.7

Tutela GI/A

Power steering

1.4

1.3

Tutela TRUCK DOT SPECIAL

Brake circuit

1.11

1

Arexons DP1

Windscreen washer

5

4.5

Paraflu11 *

Cooling system

9

-

* = Protective anti-freeze (concentration 50%, freezing point Â&#x2014;35 C)

Print 603.93.651

Base - March 2006


14

GENERAL

DAILY EURO 4

International lubricant description

FL Group products

Engine oil meets specifications: ACEA B5 with synthetic base SAE 5W30 ACEA E3/E5 with mineral base SAE 15W40

Urania Daily Urania LD5

Differential and wheel hub oil meets specifications: API GL-5 with mineral base SAE 85W140 API GL-5 with mineral base SAE 80W90

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

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

Tutela Truck Gearlite

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

Tutela GI/A

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

Tutela MR 2

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

Tutela MR 3

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

Tutela TRUCK DOT SPECIAL

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

Tutela Professional SC 35

Concentrated protective radiator fluid ethylene glycol based containing corrosion inhibitors, in conformity with Iveco Standard 18-1830 (1) Hot or temperate climate (2) Specific for cold climes. (3) 100% Paraflu to be diluted with water to 50%

Paraflu11(3)

Figure

Base - March 2006

95

35

50

10 SAE 40

32

0

14

-10

5

-15

-13 oF

-25 oC

SAE 30 SAE 20W

SAE 15W/40 SAE 10W

SAE 5W 30 108535

Print 603.93.651


F1A ENGINE

DAILY EURO 4

1

SECTION 2 5401

Engine Page

Print 603.93.651

F1A ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

F1C ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

157

Base - March 2006


F1A ENGINE

DAILY EURO 4

3

F1A Engine Page MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . .

7

- Service procedures to be performed after replacing high-pressure feeding system and/or exhaust gas posttreatment system components . . . . . . . . . . . . 8 POWER UNIT REMOVAL/REFITTING . . . . . . . .

9

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

- Checks and tests . . . . . . . . . . . . . . . . . . . . . . .

13

- Power steering system air bleed . . . . . . . . . . .

13

REPLACING BELTS . . . . . . . . . . . . . . . . . . . . . . .

14

- Power steering pump-alternator belt replacement

14

- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Replacing air-conditioning compressor drive belt

14

- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Replacing timing drive belt . . . . . . . . . . . . . . . .

15

- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

REPLACING THE ELECTRIC INJECTORS . . . . .

17

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

CYLINDER HEAD REMOVAL AND REFITTING

19

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

REPLACING HIGH-PRESSURE PUMP CPH1 . . .

22

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

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

22

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

PREHEATING PLUG REMOVAL/REFITTING . . .

23

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

THROTTLE VALVE ASSEMBLY REMOVAL-REFITTING 23

Print 603.93.651

Base - March 2006


4

F1A ENGINE

DAILY EURO 4

Page

Page

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

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

79

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

24

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

80

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

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

82

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

82

HEAT EXCHANGER REMOVAL/REFITTING . . .

24

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

82

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Measuring main journal assembly clearance . . .

82

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

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

83

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

25

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

84

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . .

85

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

25

- Replacing bearing supporting gearbox input shaft

85

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

CONNECTING ROD 혰 PISTON ASSEMBLY . . .

86

EXHAUST PIPE ASSEMBLY REMOVAL/REFITTING

27

- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

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

87

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

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

87

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

87

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

87

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

88

- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89

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

89

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

89

- Assembling connecting rod-piston assembly . . .

89

- Checking for connecting rod 혰 piston distortion

90

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

90

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

28

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

29

- Refittingl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

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

28

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

29

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . .

30

EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

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

34

CHARACTERISTICS CURVES . . . . . . . . . . . . . . .

35

- Assembling connecting rod 혰 piston assemblies in cylinder barrels . . . . . . . . . . . . . . . . . . . . . . .

90

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .

39

- Measuring crankpin assembly clearance . . . . . .

91

ASSEMBLY DATA 혰 CLEARANCES . . . . . . . . . .

40

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

91

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . .

92

EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . .

52

- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

92

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . .

63

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

92

OVERHAULING ENGINE . . . . . . . . . . . . . . . . . .

68

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

93

DISASSEMBLING THE ENGINE AT THE BENCH

68

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

93

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . .

78

- Removing deposits, refacing and checking valves

93

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

78

- Checking head mating surfae on cylinder block

78

- Checking clearance between valve stem and valve guide and centring valves . . . . . . . . . . . . . . . . .

94

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .

79

VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . .

94

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

94

Base - March 2006

Print 603.93.651


F1A ENGINE

DAILY EURO 4

Page

5

Page

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

94

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

125

VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .

95

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126

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

95

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

126

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .

96

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

126

ROCKER ARMS — TAPPETS . . . . . . . . . . . . . . . .

96

- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97

- GARRET GT 17 variable geometry turbosupercharger . . . . . . . . . . . . . . . . . . . . . .

127

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

97

- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

- Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98

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

127

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

98

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

127

TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .

99

- Proportional solenoid valve controlling turbocharger actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99

- Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

128

- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129

- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

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

129

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

100

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

102

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

130

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

103

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

130

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

106

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

131

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

107

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

131

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .

115

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

131

- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

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

131

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

117

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

132

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

117

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

132

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

117

EXHAUST POLLUTANT REDUCTION SYSTEM WITH DPF CATALYST (ON REQUEST) . . . . . . . . . 133

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

117

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

118

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

118

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

118

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

119

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119

COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121

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

- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133

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

134

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134

PARTICULATE FILTER REGENERATION SYSTEM

135

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135

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

136

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

136

FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

123

HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM (MS 6.3 - EDC 16) . . . .

137

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

123

- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .

123

SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . .

139

TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . .

124

- Self-diagnosis — BLINK CODE . . . . . . . . . . . . .

139

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124

Print 603.93.651

Base - March 2006


6

F1A ENGINE

DAILY EURO 4

Page

Page

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

139

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

146

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

139

- Fuel filter “UFIfilters” . . . . . . . . . . . . . . . . . . . .

147

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

139

- Fuel filter “Filtrauto” . . . . . . . . . . . . . . . . . . . . .

148

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

139

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

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

148

139

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

139

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

149

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

139

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

150

- Checking regular engine rotation (anti-sawing) .

139

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

150

- Checking smokiness at exhaust on acceleration

139

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

151

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

139

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

139

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

152

- Checking regular rotation on acceleration . . . .

139

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152

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

139

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

152

- Checking activation of air-conditioning system .

139

ELECTRIC/ELECTRONIC COMPONENTS . . . . .

153

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

139

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

153

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

140

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

140

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

154

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

140

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

154

- Checking injection pressure closed cycle . . . . .

140

SENSORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154

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

140

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

154

- Correcting flow rate according to water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

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

154

- Correcting flow rate to avoid noise, smoke or overloading . . . . . . . . . . . . . . . . . . . . . . . . .

140

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

155

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

140

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

155

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

140

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

155

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

140

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

155

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

140

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

155

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

141

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

141

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

155

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

141

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

155

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

141

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

155

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

141

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

155

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

141

- Differential pressure sensor - deltap ( p

....

155

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

141 - Exhaust gas temperature sensor . . . . . . . . . . . .

155

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . .

146

ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . .

156

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

156

Base - March 2006

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DAILY EURO 4

F1A ENGINE

7

MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE

Keep to the following instructions before doing any work on the engine involving components of the fuel supply system. - Before doing any work on the engine, perform the engine/vehicle fault diagnosis with specific IVECO diagnosis equipment and print out the results. - Replacement of the MS6.3 or EDC 16control unit must be authorized by the Help Desk. Replacing operation requires reprogramming as described in specific section. - Following components in feed system cannot be overhauled but have to be replaced: pressure relief valve, if present, fuel pressure sensor, hydraulic accumulator, complete CP1H high pressure feed pump, pressure control valve, electric injectors. - All the parts of the Common Rail system are packaged by the supplier in sheets of oiled paper and are stored in cardboard boxes. They must therefore be protected against moisture and unpacked just prior to assembly. - The greatest care must be taken over the cleanliness of parts, making sure that when handling or assembling (starting with straightforward filter and pre-filter replacement) no dirt of foreign bodies can get inside. For this reason, the plugs protecting the hydraulic parts and sensors must be removed just prior to positioning in their seats. - Take care over the direction of assembly for all electrical connections. - All threaded connections must be tightened to the prescribed torque. - All the quick-coupling connectors (on the engine they are found on the high-pressure pump and on the diesel drain manifold) must be fully inserted. To drive them out, press on the tabs at the base of the connectors. Electro-injector None of the couplings/unions/nuts on the injector body may be handled. It is neither necessary nor permitted to dismantle the nozzle body or the electromagnet. If working on the high-pressure pipe, the hexagon on the injector side must be kept stationary with a wrench. Before working on pipes, make sure the injector is stationary in its seat on the cylinder head. When assembling/disassembling the injector drain, the retaining spring must not be removed from its seat in the injector: pushing the spring towards the engine and applying a vertical force on the connector frees the recirculation. When assembling, rest the recirculation connector in its seat and apply a vertical force while keeping the retaining spring pressed in the direction of the engine. Fitting in has to be easy. Replacing one or more electrical injectors requires central unit programming as described in specific section. CP1H High-pressure pump If working on the high-pressure pipe, the hexagon on the pump side must be kept stationary with a wrench. Before working on the high-pressure pipe, make sure the pump is secured in its seat. High-pressure pipes Each high-pressure pipe must be replaced after disassembly operations. The couplings must be tightened or loosened with the injectors, hydraulic accumulator (rail) and high-pressure pump well secured and taking care to keep the hexagon on the component side stationary, space permitting. Hydraulic accumulator (rail) and accessories The pressure sensor can be assembled five consecutive times; after that, it must be replaced. They must be lubricated with a thin layer of oil before being mounted.. Replacing the sensor requires central unit programming as described in specific section.

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Base - March 2006


8

F1A ENGINE

DAILY EURO 4

Service procedures to be performed after replacing high-pressure feeding system and/or exhaust gas post-treatment system components To ensure correct operation of the engine, the CP1 control unit 16 stores, in the memory non-labile area, the information relative to the engine parameters originally set or acquired during engine operation. As a result, after any of the operations below is carried out: - replacing one or several injectors, - replacing all the injectors, - replacing the air flow meter, - replacing the hydraulic accumulator pressure sensor (common rail), - replacing the EDC control unit 16; - changing the engine oil, - replacing the D.P.F. catalyst, - replacing the filter differential pressure (Dp) sensor, - replacing any significant component as regards emission levels, - performing forced regeneration, the control unit shall be programmed again by means of the IVECO MODUS - E.A.SY. - IT 2000 diagnosis instrument, and the replacement procedure for the concerned component shall be performed, in accordance with the indications of the diagnosis instruments used.

Base - March 2006

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F1A ENGINE

DAILY EURO 4

Refitting To refit the engine assembly, carry out the operations described for removal in reverse order, following these instructions: - Before refitting the gearbox to the engine, it is necessary to remove the pressure plate bearing from the diaphragm spring by opening out the retaining circlip. Fit the pressure plate bearing on the sleeve of the drive input shaft cover, connecting it to the clutch release lever. Spread the gearbox input shaft with Molikote molybdenum disulphide grease. As regards the 5 S 300 - 6 S 400 O.D. gearbox units, proceed as follows. Engage a gear to let the main shaft turn, rotating the propeller shaft connecting flange. Push the gearbox fully in so that the pressure plate bearing couples with the diaphragm spring correctly. As regards the 6 S 400 O.D. gearbox units, follow the procedures described in the specific chapter. - Pay special attention to the operations needed to install the engine assembly in the engine bay. - Check the conditions of the coolant pipes or sleeves and of the air ducts. Replace them if they show any sign of deterioration. - Check the flexible mountings of the assemblies: engine and gearbox. Replace them if they show any sign of deterioration. - Check that the exhaust pipe members have not deteriorated and are not about to deteriorate. If this is so, replace them along with the flexible parts for securing them. - Tighten the screws or nuts to the required torque. - Meticulously check the state of the vacuum pipe. It must show no sign of cracking, cutting, scoring or of being crushed. Replace it if there is any doubt at all about its soundness. When mounting it, make sure the pipe does not come into contact with sharp metal parts or corners or with any particularly hot parts. In addition, after assembly, the pipe must have no bends or constrictions, its radius of curvature should be broad and it must be secured to the vacuum pump fitting with a suitable clamp. - make sure that fuel pipes rapid engagement fittings are accurately clean, and result to have been fully inserted and not going to be disconnected after their being connected to relating engagement unions. - Fill the cooling system with coolant. - Fill the hydraulic power steering circuit and bleed the air as described under the relevant heading. - Check the level of oil in the engine and gearbox. - recharge climate control system (if present) as described in chapter relating to section ”Body and chassis”;

13

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

Checks and tests Start up engine, leave running at a speed slightly in excess of idle speed and wait for coolant to heat sufficiently to open thermostat. Then check the following:

- no coolant leaks from coolant hose and cab interior heating hose connection sleeves. Tighten hose clips, if necessary; - no oil leaks from between cover and cylinder head, oil sump and crankcase, oil filter and housing, heat exchanger and crankcase or from lubrication circuit lines; - no fuel leaks from injection pump and injector lines. Tighten fittings if necessary; - check that injection pump control linkage allows the flow regulation to perform its full travel in both directions. Otherwise adjust the travel by acting on nuts (1-2, Fig. 6); - check that the engine shut-off device is working properly; - check that the indicator lights on the instrument panel and relating to the devices disconnected when the engine was removed are working properly.

501430

Power steering system air bleed

Check the level of oil in the tank and top it up if necessary. Lift the vehicle at the front, start up the engine and let it idle for some time. Check there is no oil leakage from the hydraulic circuit and check the level in the tank. Slowly turn the steering wheel in both directions of steering so that the air in the hydraulic system comes out. Check the level of oil in the tank again and top up if necessary.

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

Print 603.93.651

Base - March 2006


14

F1A ENGINE

DAILY EURO 4

REPLACING BELTS 543910 Replacing air-conditioning compressor drive belt Disassembly Figure 5

90155

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

Assembly Fit the flexible belt (3) equipped with tool 99360191 (2) on the pulley (4) and apply the tool on the pulley (1). Fit the drive ring (5) on the flexible belt (3) and fasten the ring on the compressor support. Turn the drive shaft clockwise until the belt fits perfectly on the pulley (1).

543910

Power steering pump-alternator belt replacement Disassembly Figure 6

75248

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

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

Base - March 2006

Print 603.93.651


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2008 IVECO DAILY 4 Service Repair Manual  
2008 IVECO DAILY 4 Service Repair Manual  
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