Iveco Daily Euro 4 Repair Manual

”Thisdocumentprovidesdata,characteristics,instructionsand methodologytoperformrepairinterventionsonthevehicle anditscomponents.

Anyhow,thisdocumentisaddressedtoqualifiedand specialisedpersonnel.Ivecocommercialandassistance networkpersonnelaswellasallIvecoauthorisedpointsof assistancearespecificallyqualifiedandequippedtoperform therepairinterventionsthatareindicatedinthisdocument.

Beforeperforminganyintervention,checktohaveavailable thedocumentrelatingtothevehiclemodelonwhichthe interventionisbeingperformedandalsomakesurethatall accidentpreventiondevices,suchas,asaroughguide,goggles, helmet,gloves,shoes,aswellasworktooling,liftingand transporttooling,etc.,areavailableandefficient,andfurther makesurethatthevehicleisputsuchawaythatan interventioncanbemadeinsafetyconditions.

Makinginterventionsstrictlyobservingtheindicationsgiven here,aswellasusingspecifictoolingindicated,assuresa correctrepairintervention,executiontimingobservanceand operators’safety.

Eachrepairinterventionmust befinalisedtotherecoveryof functionality,efficiencyandsafetyconditionsthatareprovided byIveco.

Eachintervention,onthevehicle,thatisfinalisedtoa modification,alterationorelse,whichisnotauthorisedby Iveco,involvestheexclusionofanyresponsibilityforIveco, and,inparticular,wherethevehicleiscoveredbyaguarantee, eachsuchinterventioninvolvesanimmediatelapseofthe guarantee.

ResponsibilityforIvecoinrepairinterventionexecutionis excluded.

Ivecoisavailabletoprovideallclarificationsnecessarytomake interventions,aswellastoprovideindicationsincasesand situationsnotincludedinthisdocument.

Dataandinformationcontainedinthisdocumentcouldresult nottobeupdatedowingtomodificationsmadebyIvecoat anymomentfortechnicalorcommercialreasons,orbecause oftheneedtoadaptthevehicletolawrequirementsin differentcountries.

Inthecaseofadifferencebetweenwhatcontainedhereand whatactuallyfoundonthevehicle,pleasecontactIveco networkbeforemakinganyintervention.”

Thedatacontainedinthispublicationmightfailtoreflectthe latestchangeswhichtheManufacturermayintroduceatany time,fortechnicalorsalespurposes,ortomeetthe requirementsoflocallegislation.

Copy,evenpartial,oftextanddrawingsisforbidden.

PublicationEditedby: IVECOS.p.A. CustomerService LungoSturaLazio,15 10156Torino(TO)-Italy

Print 603.93.651 -1st Ed.2006

Producedby:

B.U.TECHNICALPUBLISHING IvecoTechnicalPublications LungoSturaLazio,15 10156Torino(TO)-Italy

PRELIMINARY REMARKS

ManualsforrepairsaresplitintoSections,eachoneofwhichismarkedbyanumeral;thecontentsofthesesectionsareindicated inthegeneraltableofcontents.

EachsectionisgenerallydedicatedtoamainUnit(e.g.:engine,gearbox,electricsystem,etc.).

Sectionswithmechanicalcontentsincludetechnicaldata,tighteningtorquecollections,toollists,connections—disconnectionsof unitsto/fromthevehicle,overhaulsatthebenchandrelatingtroubleshooting.

Ontheelectric/electronicsystemsectiontherearethedescriptionsoftheelectricnetworkandvehicleelectronicsystems,electric schemes,componentselectriccharacteristics,componentscodesandtroubleshootingrelatingtothecentralunitsspecificofthe electricsystem.

Themanualusespropersymbolsinitsdescriptions;thepurposeofthesesymbolsistoclassifycontainedinformation.Inparticular, therehavebeendefinedasetofsymbolstoclassifywarningsandasetforassistanceoperations.

SYMBOLS-WARNINGS

Dangerforpersons

Missingorincompleteobservanceoftheseprescriptionscancauseseriousdangerforpersons’safety.

Dangerofseriousdamageforthevehicle

Partialorcompletenonobservanceoftheseprescriptionscancauseseriousdamagestothevehicleandsometimes guaranteelapsetoo.

! NOTE

Generaldanger

Itincludesthedangersofabovedescribedsignals.

Environmentprotection

Itindicatescorrectbehaviourinorderthatvehicleuseisenvironmentallyfriendlyasmuchaspossible.

SYMBOLS-ASSISTANCEOPERATIONS

Removal Disconnection Intake

Refitting Connection Exhaust Removal Disassembly Operation Fittinginplace Assembly ρ Compressionratio

Tightentotorque Tolerance Weightdifference α

Tightentotorque+anglevalue Rollingtorque

Pressorcaulk Rotation

Regulation Adjustment Angle Angularvalue

Visualinspection Fittingpositioncheck Preload Measurement Valuetofind Check Numberofrevolutions

Equipment Temperature Surfaceformachining Machinefinish bar Pressure Interference Strainedassembly

Thickness Clearance

Lubrication Damp Grease

Oversized Higherthan…. Maximum,peak

Undersized Lessthan Minimum

Selection Classes

Oversizing Sealant Adhesive Temperature<0 °C Cold Winter

Airbleeding Temperature>0 °C Hot Summer

Replacement Originalspareparts

PRODUCTCODE

Eachtitleorsubtitleconcerningoperationsbeingperformedisprecededbyasix-figurenumbernamedPRODUCTCODE. Thisnumberrepresentsthe PRODUCTCODE referredtobytherepairoperationcontainedinbothREPAIRTIMESand TROUBLECODEdocument. Asaquickreferencethereareshownbelowtheguidelinestoreadthiscode(seeRepairTiming,too).

ProductCode:

PRODUCTUNITSUB-ASSEMBLY

ThefirstandsecondfiguresidentifythePRODUCTwithinmotorvehicle.

Example:

Product50=Vehiclechassis; Product52=Axles; Product53=Transmission; Product76=Electricssystem.

PRODUCTUNITSUB-ASSEMBLY COMPONENT

PRODUCTUNITSUB-ASSEMBLY COMPONENT

UnitCode: ThethirdandfourthfiguresidentifytheUNITwithinthePRODUCT.

Example:

Product50=Vehiclechassis; Unit01=Chassis; Unit02=Bumpers; Unit03=Alternator.

Sub-assemblyCode:

PRODUCTUNITSUB-ASSEMBLY COMPONENT

PRODUCTUNITSUB-ASSEMBLY COMPONENT

PRODUCTUNITSUB-ASSEMBLY COMPONENT

ThefifthandsixthfiguresexactlyidentifytheSUB-ASSEMBLYandComponentofaUnitwithinaPRODUCT.

Example:

Product50=Vehiclechassis; Unit01=Chassis; Sub-assembly40=Chassiscrossmembers; Sub-assembly13=Rotor.

GENERALWARNINGS

Warningsshowncannotberepresentativeofalldangersituationspossiblyoccurring.Therefore,itissuggestedtocontact immediatesuperiorswhereadangersituationoccurswhichisnotdescribed.

Usebothspecificandgeneral-purposetoolingsaccordingtotheprescriptionscontainedinrespectiveuseand maintenancehandbooks.Checkusestateandsuitabilityoftoolsnotsubjectedtoregularcheck.

Themanualhandlingofloadsmustbeassessedinadvancebecauseitalsodepends,besidesweight,onitssizeandon thepath.

Handlingbymechanicalmeansmustbewithhoistersproperasforweightaswellasforshapeandvolume.Hoisters, ropesandhooksusedmustcontainclearindicationsonmaximumcarryingcapacityacceptable.Theuseofsaidmeans iscompulsorilypermittedtoauthorisedpersonnelonly. Staydulyclearoftheload,and,anyhow,neverunderit.

Indisassemblingoperations,alwaysobserveprovidedprescriptions;preventmechanicalpartsbeingtakenoutfrom accidentallystrikingworkshoppersonnel.

Workshopjobsperformedinpairsmustalwaysbeperformedinmaximumsafety;avoidoperationswhichcouldbe dangerousfortheco-operatorbecauseoflackofvisibilityorofhis/hernotcorrectposition.

Keeppersonnelnotauthorisedtooperationsclearofworkingarea.

Learnoperationandsafetyknowledgenecessaryrelatingtothevehiclepriortoeachinterventiononit.Scrupulously observeallsafetywarningsonthevehicle.Applysuitablesignalsforthevehiclesbeingrepaired.Oncetherepair interventionhasbeencompleted,beforestartingupthevehicle,performallchecksindicatedonparagraph“Controls careofuser”ofUseandMaintenancehandbook.

Inlackofvisibilityinoperatingfromthevehicle,chargeapersononthegroundwithassistance.Donotleaveunmanned avehicleinmotionduringrepairinterventions.

Keepthevehiclestationarybyproperchocks.

Inthecaseofaninterventiononavehicleliftedfromtheground,checkthevehicletobequitesteadyonspecialsupport standsand,inthecaseofliftingbymeansofalift,checkmanual/automaticsafetiestobeactivated.

Whenitisnecessarytoperformaninterventiononmethane-fedvehicles,observetheindicationscontainedinsidethe document,aswellasallspecificsafetyregulationsprovided.

Onlyremoveradiatorcapwhentheengineiscoldbycautiouslyunscrewingitinordertoletsystemresidualpressure out.

Inflammablefuelandallinflammablefluidsandliquidsmustbehandledwithcare,accordingtowhatcontainedonharmful materials12-pointcards.Refuellingmustbeperformedoutdoorswiththeengineoff,avoidinglitcigarettes,freeflames orsparksinordertopreventsuddenfires/bursts.Adequatelystoreinflammable,corrosiveandpollutingfluidsandliquids accordingtowhatprovidedbyregulationsinforce.Compulsorilyavoidtousefoodcontainerstostoreharmfulliquids. Avoidtodrillorborepressurisedcontainers,andthrowclothsimpregnatedwithinflammablesubstancesintosuitable containers.

Wornout,damagedorconsumablepartsmustbereplacedbyIvecooriginalspares.

Duringworkshopactivity,alwayskeeptheworkplaceclean;timelyclearorcleanfloorsfromaccidentalliquidoroilspots. Electricsocketsandelectricequipmentnecessarytoperformrepairinterventionsmustmeetsafetyrules.

Foreveryinterventiononvehiclehydraulic,pneumatic,conditioningandAIR-BAGsystems,scrupulouslyobserve indicationsspecifiedinrelatingmanualsections.

GENERAL WARNINGS

Puton,whererequiredbytheintervention,garmentsandprotectionsprovidedinaccidentpreventionrules;contact withmovingpartscancauseseriousinjuries.Usesuitable,preferablytight-fittedgarments,andavoidtousejewels, scarves,etc.

Donotleavetheengineinmotionatworkshoplocationsnotprovidedwithapipetoscavengeexhaustgasoutside.

Avoidtobreathefumescomingfromheatingorfrompaintweldingbecausetheycancausedamagestohealth;operate outdoorsorinsuitablyventilatedareas.Puton properinspiratorifpaintpowderispresent.

Avoidcontactwithhotwaterorsteamcomingfromtheengine,radiatorandpipingsbecausetheycouldcauseserious burns.Avoiddirectcontactwithliquidsandfluidspresentinvehiclesystems;whereanaccidentalcontacthasoccurred, referto12-pointcardsforprovisionstomake.

Cleanunitsorassembliesdetachedfromthevehicleandcarefullychecktheirintegritybeforeoverhaul.Tidyupdetached ordisassembledpartswiththeirsecuringelements(screws,nuts,etc.)intospecialcontainers.

Checkfortheintegrityofthepartswhichpreventscrewsfrombeingunscrewed:brokenwashers,dowels,clips,etc. Self-lockingnutswithaninsertmadeofnylonmustalwaysbereplaced.

Avoidcontactofrubberpartswithdieseloil, petrolorothernotcompatiblesubstances.

Beforewashingunderpressuremechanicalparts,protectelectricconnectors,andcentralunits,ifpresent.

Tighteningscrewsandnutsmustalwaysbeaccordingtoprescriptions;IVECOcommercialandassistancenetworkis availabletogiveallclarificationsnecessarytoperformrepairinterventionsnotprovidedinthisdocument.

Beforewelding:

- Disconnectallelectroniccentralunits,takepowercableoffbatterypositiveterminal(connectittochassisbonding) anddetachconnectors.

- Removepaintbyusingpropersolventsorpaintremoversandcleanrelevantsurficeswithsoapandwater.

- Awaitabout15minutesbeforewelding.

- Equipwithsuitablefireresistantprotectionstoprotect hosesorothercomponentswherefluidsorothermaterials flowwhichmaycatchfireeasilyonwelding.

Shouldthevehiclebesubjectedtotemperaturesexceeding80°C(dryerovens),disassembledriveelectroniccentral units.

Thedisposalofallliquidsandfluidsmustbeperformedwithfullobservanceofspecificrulesinforce.

GENERAL WARNINGSONTHEELECTRICSYSTEM

Ifaninterventionhastobemadeontheelectric/electronicsystem,disconnectbatteriesfromthesystem;inthiscase, alwaysdisconnect,asafirstone,thechassisbondingcablefrombatteriesnegativeterminal.

Beforeconnectingthebatteriestothesystem, makesurethatthesystemiswellisolated.

Disconnecttheexternalrechargingapparatusfromthepublicutilitynetworkbeforetakingapparatuspinsoffbattery terminals.

Donotcausesparkstobegeneratedincheckingifthecircuitisenergised.

Donotuseatestlampincheckingcircuitcontinuity,butonlyusepropercontrolapparatuses.

Makesurethattheelectronicdeviceswiringharnesses(length,leadtype,location,strapping,connectiontoscreening braiding,bonding,etc.)complywithIVECOsystemandarecarefullyrecoveredafterrepairormaintenance interventions.

Measurementsindriveelectroniccentralunits,pluggedconnectionsandelectricconnectionstocomponentscanonly bemadeonpropertestinglineswithspecialplugsandplugbushes.Neveruseimpropermeanslikewires,screwdrivers, clipsandthelikeinordertoavoidthedangerofcausingashortcircuit,aswellasofdamagingpluggedconnections,which wouldlatercausecontactproblems.

NOTE

Tostartuptheengine,donotusefastchargers.Startupmustonlybeperformedwitheitherseparatebatteriesorspecial truck.

Awrongpolarisationofsupplyvoltageindriveelectroniccentralunits(forinstance,awrongpolarisationofbatteries) cancausethemtobedestroyed.

Disconnectthebatteriesfromthesystemduringtheirrechargingwithanexternalapparatus.

Onconnecting,onlyscrewupconnector(temperaturesensors,pressuresensorsetc.)nutsatprescribedtightening torque.

Beforedisconnectingthejunctionconnectorfrom anelectroniccentralunit,isolatethesystem.

Donotdirectlysupplyelectroniccentralunits servocomponentsatnominalvehiclevoltage.

Cablesmustbearrangedsuchastoresulttobeparalleltoreferenceplane,i.e.ascloseaspossibletochassis/body structure.

Oncetheinterventionontheelectricsystemhasbeencompleted,recoverconnectorsandwiringharnessesaccording tooriginalarrangement.

Keymemorisationproceduresareinfluencedbyelectromagneticjamming(mobilephones,etc.).Therefore,duringkey memorisation:

1Payattentionthatjammingsourcesarenotpresentinthecabornearthekeys.

2.Keysnotinseredinthepanelmustbeatleast1meteraway.

Connectorspresentmustbeseenfromcableside.Connectorsviewscontainedinthemanualarerepresentativeofcable side.

Bondingandscreening

Negativeleadsconnectedtoasystembondedpointmustbebothasshortandpossibleand“star“-connectedtoeachother,trying thentohavetheircenteringtidilyandproperlymade(Figure1,re.M).

Further,followingwarningsaretobecompulsorilyobservedforelectroniccomponents:

-Electroniccentralunitsmustbeconnectedtosystembondingwhentheyareprovidedwithametallicshell.

-Electroniccentralunitsnegativecablesmustbeconnectedbothtoasystembondingpointsuchasthedashboardopening bonding(avoiding“serial“or“chain“connections),andtobatterynegativeterminal.

-Analogbonding(sensors),althoughnotconnectedtobatterynegativesystem/terminalbonding,musthaveoptimalisolation. Consequently,particularlyconsideredmustbeparasiticresistancesinlugs:oxidising,clinchingdefects,etc.

-Screenedcircuitsbraidingmustonlyelectricallycontactthe endtowardsthecentralunitenteredbythesignal(Figure2).

-Ifjunctionconnectorsarepresent,unscreenedsection d,nearthem,mustbeasshortaspossible(Figure2).

-Cablesmustbearrangedsuchastoresulttobeparalleltoreferenceplane,i.e.ascloseaspossibletochassis/bodystructure.

OPTIONALELECTRICALANDMECHANICALPARTSINSTALLATIONS

Accessoriesmounting,additionsandmodificationsonthevehiclearetobeperformedcomplyingwithIVECOmounting instructions(specificdocument“Instructionsfortransformationandpreparation”isavailableatAssistanceNetworkworkshops).

Itisremindedthat,especiallyabouttheelectricsystem,severalelectricsocketsareprovidedforasseries(oroptional)socketsin ordertosimplifyandnormalisetheelectricalinterventionthatiscareofpreparationpersonnel. Foranyexceptiontomountinginstructions,IVECO’sauthorisationisnecessary. Lackofobservanceofabovedescribedprescriptionsinvolvesguaranteelapse.

Itisabsolutelyforbiddentomakemodificationsorconnections toelectriccentralunitswiringharnesses;inparticular, thedatainterconnectionlinebetweencentralunits(CANline)istobeconsideredinviolable.

Power

1kW=1.36metricHP

1kW=1.34HP

1metricHP=0.736kW

1metricHP=0.986HP 1HP=0.746kW 1HP=1.014metricHP

Torque

1Nm=0.1019kgm 1kgm=9.81Nm

Revolutionspertimeunit

1rad/s=1rpmx0.1046 1rpm=1rad/sx9.5602

Pressure

1bar=1.02kg/cm2 1kg/cm2 =0.981bar 1bar=105 Pa

Whereaccuracyisnotparticularlyneeded:

- Nmunitisforthesakeofsimplicityconvertedintokgmaccordingtoratio10:1 1kgm=10Nm; - barunitisforthesakeofsimplicityconvertedintokg/cm2 accordingtoratio1:1 1kg/cm2 =1bar.

Temperature

0° C=32° F

1° C=(1x1.8+32) ° F

Print603.93.651—1st edition

Vehicleidentificationplate

Platelegend

Chassis Stamping (atthefrontonthechassisright-handside-member)

Manufacturertag

Forvehicleidentificationaccording totheECdirective (onthefrontcrosspiece)

COMPOSITIONOFMODELS

ASSEMBLIES

MODELS

29L10 29L12 29L14 35S10 35S12 35S14 35S18 35C10 35C12 35C14 35C15 35C18 40C10 40C12 40C15 40C18

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

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

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

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

F1CE0481F*C(DPFseries)146CV

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

F1CE0481H*C(DPFseries)176CV o

Singledisk 9” 1/4 o o o o o o o o

Singledisk 10” 1/2 • • o o • • • • o o • •

Singledisk 11 o o o o o ZF5S300 V V V V V V V V V V V ZF6S400O.D. V V V V V ZF6S400AO.D. V V V V V V V V V V V V V V V V 5817 o o o o o o o 5818 5819 o o o o 5823

NDAR.S. o o o o o o o NDAR.G. o o o o o 450511 o o o o 450517/2

Rack-and-pinion Poweredsteering o o o o o o o o o o o o o o o o

FRONTMECHANICALSUSPENSIONS: independentwithtransverseleafspring(MK3) o o o o o o o o o o o independentwithtorsionbars (•) (•) (•) (•) (•) o o o o

REAR MECHANICAL Parabolic o o o o o o o Z Z Z Z Z Z Z Z Z MECH NIC SUSPENSIONS: -singleleaf o o o o o o o -reinforced o o o o o o o Semi-elliptical

s s s s s s s s Semi-elliptic withleafspring z z z z z z z z z

COMPOSITIONOFMODELS

ASSEMBLIES

MODELS 45C15 45C18 50C15 50C18 60C15 60C18 65C15 65C18

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

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

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

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

F1CE0481F*C(DPFseries)146CV o o o o

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

Singledisk 9” 1/4

Singledisk 10” 1/2

Singledisk 11 o o o o o o o o ZF5S300

ZF6S400O.D.

V V V V V V V V ZF6S400AO.D. V V V V V V V V 5817 5818 5819 o o o o 5823 o o o o NDAR.S. NDAR.G. 450511 o o o o 450517/2 o o o o

Rack-and-pinion Powersteering o o o o o o o o

FRONTMECHANICALSUSPENSIONS: independentwithtransverseleafspring(MK3) independentwithtorsionbars o o o o o o o o Parabolic Z Z Z Z Z Z Z Z -singleleaf -reinforced Semi-elliptical s s s s s s s s Semi-elliptic withleafspring z z z z z z z z