Iveco Daily Euro 4 2006-2009 Manual en Instrukcja Napraw

8/18/2019 Iveco Daily Euro 4 2006-2009 Manual en Instrukcja Napraw
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MECHANICAL ELECTRIC/ELECTRONIC
Produced by:
”This document provides data,characteristics, instructionsand 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.
Publication Edited by:
10156 Torino (TO) - Italy
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.
PRELIMINARY REMARKS
General danger
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.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
SYMBOLS - WARNINGS
!
SYMBOLS - ASSISTANCE OPERATIONS
Press or caulk Rotation
Hot
Summer
Replacement
Each title or subtitle concerning operations being performed is preceded by a six-figure number named PRODUCT CODE. This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and TROUBLE CODE document. As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).
Product Code:
The first and second figures identify the PRODUCT within motor vehicle.
Example :
Product 50 = Vehicle chassis; Product 52 = Axles; Product 53 = Transmission; Product 76 = Electric ssystem.
Unit Code:
The third and fourth figures identify the UNIT within the PRODUCT.
Example :
Sub-assembly Code:
The fifth and sixth figures exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT.
Example :
Product 50 = Vehicle chassis; Unit 01 = Chassis; Sub-assembly 40 = Chassis cross members; Sub-assembly 13 = Rotor.
PRODUCT CODE
5 0
GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph “Controls care of user” of Use and Maintenance handbook.
In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave unmanned a vehicle in motion during repair interventions.
Keep the vehicle stationary by proper chocks.
In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special support stands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated.
When it is necessary to perform an intervention on methane-fed vehicles, observe the indications contained inside the document, as well as all specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out.
Inflammable fueland all inflammable fluidsand 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, alwayskeep 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.
!
Clean units or assembliesdetached fromthe vehicle andcarefully 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.
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.
Print 603.93.651 Base - March 2006V
GENERAL WARNINGS ON THE ELECTRIC SYSTEM
To startup the engine, do notuse fast chargers. Start up must only be performed with either separate batteriesor 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.
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, clipsand the like in order to avoidthe danger of causinga shortcircuit, as well as of damaging plugged connections, which
would later cause contact problems.
Connectorspresent must be seen fromcableside. Connectorsviewscontained in the manual are representative of cable side.
!
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.
1. NEGATIVE CABLES “STAR “ CONNECTION TO SYSTEM BONDING M
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR d. DISTANCE! 0
88039
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Accessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mounting instructions (specific document “Instructions for transformation and preparation” is available at Assistance Network workshops). It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel. For any exception to mounting instructions, IVECO’s authorisation is necessary.
Lack of observance of above described prescriptions involves guarantee lapse.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular, the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP 1 kW = 1.34 HP 1 metric HP = 0.736 kW 1 metric HP = 0.986 HP 1 HP = 0.746 kW 1 HP = 1.014 metric HP
Torque
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602
Pressure
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
DAILY EURO 4
UPDATE DATA
Section
Wheels and tyres 9
Maintenance 13
Print 603.43.671
SECTION 1
REPLENISHING FLUIDS 13. . . . . . . . . . . . . . . . . . .
Print 603.43.671
(on the front crosspiece)
Engine
1) Approval number
2) Chassis number
3) PTT - Total weight on ground 4) MTC - Total combined weight
5) Max. weight permitted on the front axle
6) Max. weight permitted on the rear axle
7) Specific indication of type
8) Wheelbase (mm)
Figure 1
Figure 2
IDENTIFICATION DATA
COMPOSITION OF MODELS
3 5 C
1 8
F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV o o o o
F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV o o o o
F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV o o o F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV o o
F1CE0481F*C (DPF series) 146 CV
F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV o o
F1CE0481H*C (DPF series) 176 CV o
Single disk 9” 1/4 o o o o o o o o
Single disk 10” 1/2
Single disk 11 o o o o o
ZF 5 S300 V V V V V V V V V V V
ZF 6 S400 O.D. V V V V V
ZF 6 S400A O.D. V V V V V V V V V V V V V V V V
5817 o o o o o o o
5818
5823
NDA R.G. o o o o o
450511 o o o o
450517/2
Rack-and-pinion Powered steering o o o o o o o o o o o o o o o o
FRONT MECHANICAL SUSPENSIONS: independent with transverse leaf spring (MK3)
o o o o o o o o o o o
independent with torsion bars (•) (•) (•) (•) (•) o o o o
REAR Parabolic o o o o o o o Z Z Z Z Z Z Z Z Z MECHANICAL SUSPENSIONS:
- single leaf 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 s
Semi-elliptic with leaf spring
z z z z z z z z z
REAR AIR SUSPENSIONS V V V V V V V V V V V V V V V V

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
s Standard on chassis cabs, Alternatively on Vans— Chassis Cowls and Cut Aways
Z Standardon Vans, Chassis Cowls andCut Aways — Alternatively on Chassis Cabs
S Single rear wheels L Light with single rear wheels C Twin rear wheels
COMPOSITION OF MODELS
F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV
F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV
F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV
F1CE0481F*C (DPF series) 146 CV o o o o
F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV
F1CE0481H*C (DPF series) 176 CV o o o o
Single disk 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
NDA R.S.
NDA R.G.
Rack-and-pinion
Power steering o o o o o o o o FRONT MECHANICAL SUSPENSIONS: independent with transverse leaf spring (MK3)
independent with torsion bars o o o o o o o o
Parabolic Z Z Z Z Z Z Z Z
- single leaf
Semi-elliptic with leaf spring
z z z z z z z z
REAR AIR SUSPENSIONS V V V V V V V V
O.D. = Over Drive (•) Optional extra (with max load of 1900 kg) o 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
s Standard on chassis cabs, Alternatively on Vans— Chassis Cowls and Cut Aways
Z Standardon Vans, Chassis Cowls andCut Aways — Alternatively on Chassis Cabs
S Single rear wheels L Light with single rear wheels C Twin rear wheels
A LIGHT ROAD VEHICLES
45 C
65 C
MARKET VEHICLE (V.M.)
STANDARD VEHICLE (V.C.B.)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RANGE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CHASSIS CABS AND DERIVATIVES
45 C
65 C
E4 = Euro 4
ENGINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
PROGRAMMING FAMILY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VANS AND DERIVATIVES
A Mechanical suspension: front with transverse leaf spring.
B Mechanical suspension: front with torsion bars.
C Mechanical front suspension with transverse leaf spring — rear air suspension.
D Mechanical front suspension with torsion bars — rear air suspension.
29 L10 (•) - 29 L12 (•) - 29 L14 ( ) • - • - • - •
CHASSIS
CAB • - • - •
45 C15 (•) - 50 C15 (•) - 50 C18 (•) 60 C15 (•) - 60 C18 (•) 65 C15 (•) - 65 C18 (•)
29 L10 D (•) - 29 L12 D (•) - 29 L14 D (•) - • - • - • -
CHASSIS • - • - • -
6 + 1 • - • - • -
40 C12 D (•) - 45 C15 D (•) - 45 C18 D (•) 50 C18 D (•) - 60 C15 D (•) - 60 C18 D (•) - 65 C15 D (•) - 65 C18 D (•)
35 S12 CC (•) - 35 S 14 CC (•) - 35 S18 CC (•) -
CHASSIS 35 C12 CC (•) - 35 C15 CC (•) - 35 C18 CC (•) - 40 C12 CC - 40 C15 CC (•) - 40 C18 CC (•)
COWL 45 C15 CC - 45 C18 CC (•)
• - •• - •60 C18 CC (•) - 65 C18 CC (•)
35 S12 CCR (•) - 35 S14 CCR (•) - 35 S18 CCR(•)
CHASSIS 35 C12 CCR (•) - 35 C15 CCR (•) - 35C18CCR(•) 40 C12 CCR (•) - 40 C15 CCR (•) - 40C18CCR(•)
SHORT 45 C15 CCR (•) - 45 C18 CCR (•)
• - •• - •
60 C18 CCR (•) - 65 C18 CCR (•)
(•) Also available in the A (automatic transmission) and /P (pneumatic rear suspensions) versions.
SUSPENSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
35 C10 CA • - 35 C12 CA •
40 C10 CA (•) - 40 C12 CA (•) A CUT-AWAY
45 C18 CA (•) - 50 C18 CA (•) 60 C18 CA (•) - 65 C18 CA (•)
• - •• - •
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 (•) -
SEMI-GLAZE
35 S18 SV (•) 35 C10 SV (•) - 35 C12 SV (•) - 35 C15 SV (•) - 35 C18 SV (•)
D VAN 40 C10 SV ( •
) - 40 C12 SV ( •
) - 40 C15 SV ( •
) -40 C18 SV (•) - • - •• - •
50 C15 SV (•) - 50 C18 SV (•)
VENDOR 35 S12 CV (•) - 35 S14 CV (•) VERSION 35 C12 CV (•) - 40 C12 CV -
CITY 45 C15 CV (•) - 45 C18 CV (•)
VAN 50 C15 CV (•) - 50 C18 CV (•)
• - •
35 C14 (•) - 35 C18 (•)
35 C14 CCRC (•) - 35 C18 CCRC
CAMPER VAN
(•) Also available in the A (automatic transmission) and /P (pneumatic rear suspensions) versions.
VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
10 GENERAL DAILY EURO 4
Base - March 2006 Print 603.93.651
1 3000 mm (T25C - T30C - T35C - T40C - T25V - T30V - T35V - T40V - T50V)
2 3000 L mm
3 3300 mm (T25V - T30V - T35V - T40V - T50V)
4 3450 mm
5 3750 mm
6 3950 L mm
7 4100 mm
(T50C - T65C)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
WHEELBASE
A 5 SPEED (5 S 300)
B 6 SPEED (6 S 400 O.D.)
C 6 SPEED (6 S 400 A O.D.)
A Automated O.D. Over Drive
1 2 3 4 5 6 7 8 9 10 11 12 13 14
GEARBOX
LEFT-HAND DRIVE (T25C - T30C - T35C - T40C - T50C)
1
LEFT-HAND DRIVE AND INTERNAL HEIGHT 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
A
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
DRIVE — INTERNAL HEIGHT OF LOADING BAY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MANDATORY MARKET OPTIONAL EXTRAS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
OPTIONAL EXTRAS REQUIRED BY THE CUSTOMER
1 2 3 4 5 6 7 8 9 10 11 12 13 14
REPLENISHING FLUIDS
IVECO RECOMMENDED LUBRICANTS PARTS TO BE REPLENISHED Quantity Litres kg
Quantity of oil in circulation in the car- tridge f ilter and heat exchanger
1.4 1.23
Urania Daily
4.3 3
3.78 2.65
Urania LD 5 Quantity of oil in circulation in the car-
tridge f ilter and heat exchanger 1 0.88
Total dry engine capacity 7.6 6.79
Sump capacity: - max level - min level
6.6 4.29
5.81 3.78
Max. gradient negotiable by vehicle uphill/downhill with oil at minimum level 30%!
Gearbox
ZF 6S 400 O.D. 2.2 1.98
ZF 6S 400 A O.D. 2.7 2.43
Front axle:
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 -
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
Paraflu11(3)
(1) Hot or temperate climate (2) Specific for cold climes. (3) 100% Paraflu to be diluted with water to 50%
3595
F 1 A E N G I N E 1DAI LY EU RO 4
B a s e - M a r ch 2 0 0 6Print 6 0 3 .9 3 .6 5 1
SECTION 2
5401 Engine
2 F 1 A E N G IN E DAI LY EU RO 4
Base - March 20 06 Print 6 03 .93 .65 1
B a s e - M a r ch 2 0 0 6Print 6 0 3 .9 3 .6 5 1
F1A Engine
Page
M A I N O P E R A T IO N S O N E N G IN E M O U NT E D ON VE HICLE 7. . . . . . . . . . . . . . . . . . . . . . . . .
- S e r v i c e p r o ce d u r e s t o b e p e r f o r m ed a f t e r r e p l a c i n g h i g h - pr e s s u re f e e d i ng s y s te m a n d / or e x h a u s t g a s p o s t -
treatment system components 8. . . . . . . . . . . .
- Removal 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Power ste eri ng syste m air ble ed 13. . . . . . . . . . .
REPLACING BELTS 14. . . . . . . . . . . . . . . . . . . . . . .
- P o we r st e e ri n g p u mp - al t e rn a to r be l t r e pl a ce m en t 1 4
- Disasse mbly 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- R ep la ci n g a i r- co nd it i on i ng co mp re ss or dr i ve be l t 1 4
- Disasse mbly 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Repl acing timin g dri ve bel t 1 5. . . . . . . . . . . . . . . .
- Disasse mbly 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembli ng 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refi tting 1 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C YLI ND ER H EAD RE MOVAL AND R EF IT TING 1 9
- Removal 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refi tting 2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T H R OT T L E V A L VE A S S E M B L Y R E M O V AL - R E FI T T IN G 2 3
4 F 1 A E N G IN E DAI LY EU RO 4
Base - March 20 06 Print 6 03 .93 .65 1
Page
- Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Descr ipti on 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Descr ipti on 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
E XH AU ST P IP E A SS EM BL Y R EM OV AL /R EF IT TI NG 2 7 - Removal 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refi tting 2 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R E M O VA L / RE F I T TI N G O F E X H A US T P I P E A S S E MB L Y C O M PO N E NT S ( S Y S TE M S E Q U IP P E D W I T H D . P . F . CATALYST) 28. . . . . . . . . . . . . . . . . . . . . . . . . .
- Ex haust sil ence r re mo val 28. . . . . . . . . . . . . . . . .
- Repl acin g D.P.F. catalyst 29. . . . . . . . . . . . . . . . . .
- Refi ttingl 2 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- D.P.F. catalyst r emoval 2 8. . . . . . . . . . . . . . . . . . .
- Replacin g dif fer en ti al sensor ( del ta -p) 29. . . . . . . .
ENGINE VIE WS 3 0. . . . . . . . . . . . . . . . . . . . . . . . . .
EMISSIONS 3 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS 4 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE 63. . . . . . . . . . . . . . . . . . .
OVERHAULING ENGINE 6 8. . . . . . . . . . . . . . . . . .
D IS ASS EM BL IN G TH E E NGI NE AT T HE B EN CH 6 8
REPAIRS 7 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Che cks and me asur emen ts 78. . . . . . . . . . . . . . . .
- C he ck in g h ea d m at in g s ur fa e o n c yl in de r b lo ck 7 8
CRANKSHAFT 7 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Measu ri ng main j our nals an d crank pi ns 7 9. . . . . .
- Ch eckin g cr an kshaft 80. . . . . . . . . . . . . . . . . . . . .
- Re placin g ti mi ng con tr ol ge ar 82. . . . . . . . . . . . . .
ENGINE ASSEMBLY 82. . . . . . . . . . . . . . . . . . . . . .
- Asse mbli ng mai n bear in gs 8 2. . . . . . . . . . . . . . . . .
- Me asu ri ng ma in j ou rn al a sse mb ly c le ar an ce 8 2. . .
- Ch eckin g cr an kshaft en d fl oat 83. . . . . . . . . . . . . .
- Asse mbl ing r ear seal 84. . . . . . . . . . . . . . . . . . . . .
E NGINE FLYWHE EL 85. . . . . . . . . . . . . . . . . . . . . .
- R ep la ci n g b ea r in g su pp or t in g ge ar bo x in pu t sh a ft 8 5
C ONNECTING ROD — PISTON ASSEMBLY 86. . .
- Piston s 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Piston pin s 87. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Co ndi ti on s f or c or re ct p in -pi st on co upl in g 8 7. . . .
- Piston ri ngs 87. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Bushes 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checki ng ben din g 89. . . . . . . . . . . . . . . . . . . . . . .
- A ss em bl in g c on ne ct in g r od -p is to n a ss em bl y 8 9. . .
- C he ck in g f o r c on n ec ti ng r o d — p is to n d is to rt io n 9 0
- Fi tting pi ston r ings 90. . . . . . . . . . . . . . . . . . . . . . .
- A s se m b l i ng c o n n e c t i n g r o d — p i s to n a s s e m b li e s in cyl inder bar re ls 90. . . . . . . . . . . . . . . . . . . . . . .
- Measuri ng crankpi n asse mbl y cl ear an ce 91. . . . . .
- Ch ecki ng pi ston protrusion 91. . . . . . . . . . . . . . .
CYLINDE R HEADS 92. . . . . . . . . . . . . . . . . . . . . . .
- Di sassembl y 92. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Re movi ng valves 92. . . . . . . . . . . . . . . . . . . . . . . .
- Ch eckin g cyli nde r h ead se al 93. . . . . . . . . . . . . . .
- Ch eckin g cyl inder h ead matin g surf ace 93. . . . . . .
VALVES 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- R em ov in g d ep os it s, r e fa ci n g a n d c he ck in g v al v es 9 3
- C h e c k in g c l e a r a n c e b e t we e n v a l v e s t e m a n d v a l v e gu ide an d centri ng valves 9 4. . . . . . . . . . . . . . . . .
VALVE GUIDE 94. . . . . . . . . . . . . . . . . . . . . . . . . . .
B a s e - M a r ch 2 0 0 6Print 6 0 3 .9 3 .6 5 1
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VALVE SEATS 95. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Re cutti ng and re pl aci ng valve se ats 95. . . . . . . . . .
VALVE SPRINGS 96. . . . . . . . . . . . . . . . . . . . . . . . .
TIMING SYSTEM 99. . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaf t 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Che cks 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checki ng cam li ft and pi n ali gnment 100. . . . . . . . .
- Assembl in g over he ad 1 02. . . . . . . . . . . . . . . . . . . .
- Assembl ing fr ont seal ri ng 10 3. . . . . . . . . . . . . . . . .
- Re fi tti ng cyl inder head 106. . . . . . . . . . . . . . . . . . .
- Camshaf t drive 107. . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pump 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Vacuu m pump 117. . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pre ssu re con tr ol val ve 118. . . . . . . . . . . . . . . .
- Oil fil ter 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil vapour reci rcul ati on syste m 119. . . . . . . . . . . .
- De scri pti on 119. . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oper ation 121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Water pump 123. . . . . . . . . . . . . . . . . . . . . . . . . .
- Ther mostat 123. . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- T ur bo ch ar ge r ( K KK K 0 3- 20 74 -C CB 5 . 88 t yp e) 1 25
REPAIRS 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pr essur e re li ef val ve 12 6. . . . . . . . . . . . . . . . . . . . .
- Checki ng pre ssu re r el ie f valve 126. . . . . . . . . . . . . .
- G A RR E T G T 1 7 v a ri a bl e g e o m et r y turbosupercharger 127. . . . . . . . . . . . . . . . . . . . . .
- Gen er al 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Ope ration at lo w e ngin e rpm 127. . . . . . . . . . . . . .
- Ope ration at h igh en gine rpm 1 27. . . . . . . . . . . . .
- P r o p or t i o n a l s o l e n o i d v a l v e c o n t r ol l i n g t u r b o c h ar g e r actuator 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Actuator 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRS 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Che cki ng and adj usti ng the actuator 129. . . . . . . . .
E X H A US T G A S R E C I RC U L A TI O N ( E G R ) S Y S T EM (EXHAUST GAS RECIRCULATION) 13 0. . . . . . .
- EGR system ope ration 130. . . . . . . . . . . . . . . . . . .
- Mai n syste m compone nts 13 1. . . . . . . . . . . . . . . . .
- E. G.R. val ve 131. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Modu lator sol enoi d valve 13 1. . . . . . . . . . . . . . . . .
- Ai r fl ow rate met er ( flo w me ter) 131. . . . . . . . . . .
- Heat ex changer 132. . . . . . . . . . . . . . . . . . . . . . . . - Thr ottle val ve assembly 13 2. . . . . . . . . . . . . . . . . .
E X H A US T P O L LU T A NT R E D U CT I ON S Y S TE M W I T H DPF CATALYST (ON REQUEST) 133. . . . . . . . .
- Gen er al 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D .P .F . (D IE SE L P AR TI CU LA TE F IL TE R) C AT AL YS T 1 3 4
- Descr i pti on 13 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
P AR TI CU LA TE F IL TE R R EG EN ER AT IO N S YS TE M 1 35
- Ope rati on 1 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Force d re ge ner ati on 136. . . . . . . . . . . . . . . . . . . . .
- Ref il li ng en gine oil 1 36. . . . . . . . . . . . . . . . . . . . . . .
FUEL SUPPLY 13 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH-PRESSURE ELECTRONIC INJECTION SYSTE M (MS 6. 3 - E DC 16) 137. . . .
- Gen er al 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM OPERATION 1 39. . . . . . . . . . . . . . . . . . . .
MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE
K ee p t o t he f o ll ow i ng i n st ru c ti on s b ef or e d oi n g a ny w or k o n t h e e ng i ne i n vo l vi ng c om po ne nt s o f t h e f u el s up pl y s y st em .
- B ef o re d o in g a n y w o rk o n t h e e n gi n e, p er f or m t h e e n g i n e/ v eh i c le f a ul t d i ag n os i s w i th s p ec i f ic I V EC O d i ag n os i s
e q ui p me n t a n d p r in t o u t t h e r e su l t s. - R e pl a c em en t o f t h e M S 6 .3 o r E D C 1 6 c on t r ol u n it m u st b e a u t h or i ze d b y t h e Help Desk. R e p l a c i ng o p e ra t i o n
r e q ui r e s r e p ro g r a mm i n g a s d e s c ri b e d i n s p e c i f ic s e c t i o n.
- F ol l o wi n g c o mp o ne n t s i n f e ed s y s te m c a nn o t b e o v er h au l ed b u t h a ve t o b e r e pl a c ed : p r e s su r e r e li e f v a l v e, i f p r es e nt , f u el p re s su r e s e ns o r, h y dr a ul i c a c c um u la t or , c o mp l et e C P1 H h i g h p r es s u re f e ed p u mp , p r es s ur e c o n tr o l v a lv e , e l e c t ri c i n j e c t o rs .
- A l l t h e p a r t s o f t h e C o mm o n R a i l s y s t em a r e p a ck a ge d b y t h e s u p pl i e r i n s h ee t s o f o i l ed p a p er a n d a r e s t o r ed i n c a r d bo a r d b o x e s . T h e y m u s t t h e r ef o r e b e p r o t ec t e d a g a i n s t m o i s t u r e a n d u n p a c ke d j u s t p r i o r t o a s s e mb l y .
- T h e g r e a te s t c a re m u st b e t a ke n o v er t h e c l e an l i ne s s o f p a rt s , m a k i ng s u re t h at w h en h a nd l in g o r a s se m bl i n g ( s ta r ti n g w i t h s t ra i g ht f or w ar d f i l te r a n d p r e- f i l te r r e pl a c em en t ) n o d i rt o f f o re i gn b o di e s c a n g e t i n s i d e. F or t h i s r e as o n, t h e p l ug s p ro t ec t i ng t h e h y dr a ul i c p a rt s a n d s e ns o rs m u st b e r em o ve d j u s t p ri o r t o p o si t i on i n g i n t h ei r s e at s .
- T a ke c a re o v er t h e d i r e ct i o n o f a s s em b ly f o r a l l e l ec t r ic a l c o n ne c t io n s. - A l l t h re a de d c o n ne c t io n s m u st b e t i g ht e n ed t o t h e p r es c r ib e d t o r q ue .
- A l l t h e q u ic k - co u pl i n g c o n ne c t or s ( o n t h e e n gi n e t h ey a r e f o un d o n t h e h i gh - pr e ss u re p u mp a n d o n t h e d i es e l d ra i n m a n i f o l d ) m u s t b e f u l l y i n s e r t e d . T o d r i v e t h e m o u t , p r e s s o n t h e t a b s a t t h e b a s e o f t h e c o n n e c t o r s .
Electro-injector
N o ne o f t h e c o u pl i n gs / un i o ns / nu t s o n t h e i n j ec t o r b o d y m a y b e h a nd l ed . I t i s n e it h er n e ce s sa r y n o r p e rm i t te d t o d i s m a n t l e t h e n o z z l e b o d y o r t h e e l e c t r o m a g n e t . I f w o rk i ng o n t h e h i g h - pr e ss u re p i pe , t h e h e xa g on o n t h e i n j e c t or s i de m u st b e k e p t s t a ti o n ar y w i t h a w r en c h . B ef o re w o rk i ng o n p i pe s , m a k e s u r e t h e i n j e c t or i s s t a ti o n ar y i n i t s s e at o n t h e c y l i n de r h e ad .
When assembling/disassembling the injector drain, the retaining spring must not be removed from its seat in the injector: p u sh i n g t h e s p ri n g t o wa r ds t h e e n g i n e a n d a p pl y i ng a v e rt i c al f o rc e o n t h e c o n n e ct o r f r ee s t h e r e ci r c ul a t io n . W h e n
a s se m bl i n g, r e st t h e r e c i r cu l at i o n c o n n e ct o r i n i t s s e at a n d a p p l y a v e rt i c al f o rc e w h il e k e ep i ng t h e r e ta i ni n g s p ri n g p r es s ed i n t h e d i r e ct i o n o f t h e e n g i ne . F i t t i ng i n h a s t o b e e a s y . R e pl a c in g o n e o r m o re e l ec t r ic a l i n j ec t o rs r e qu i r es c e n tr a l u n i t p ro g ra m mi n g a s d e sc r i be d i n s p ec i f ic s e c ti o n.
CP1H High-pressure pump
I f w o rk i ng o n t h e h i g h - pr e ss u re p i pe , t h e h e xa g on o n t h e p u m p s i d e m u st b e k e p t s t a ti o n ar y w i t h a w r en c h. B ef o re w o rk i ng o n t h e h i g h - pr e ss u re p i pe , m a k e s u r e t h e p u m p i s s e cu r ed i n i t s s e at .
High-pressure pipes
E a c h h i g h - pr e s s u re p i p e m u s t b e r e p l ac e d a f t e r d i s a s s e mb l y o p e ra t i o n s . T h e c o u p l i n g s m u s t b e t i g h t e n e d o r l o o s e n e d w i t h t h e i n j e c t o r s , h y d r a u l i c a c c u m u l a t o r ( r a i l ) a n d h i g h - p r e s s u r e p u m p w e ll s e c ur e d a n d t a ki n g c a re t o k e ep t h e h e x a go n o n t h e c o m p on e nt s i d e s t a t i on a ry , s p ac e p er m it t i ng .
Hydraulic accumulator (rail) and accessories
T h e p r e s s u r e s e n s o r c a n b e a s s e m b l e d f i v e c o n s e c u t i v e t i m e s ; a f t e r t h a t , i t m u s t b e r e p l a c e d . T h e y m u s t b e l u b r i c a t e d
w i t h a t h i n l a y e r o f o i l b e f o r e b e i n g m o u n t e d . .
R e p l ac i n g t h e s e n s o r r e q ui r e s c e n t r a l u n i t p r o gr a m mi n g a s d e s c ri b e d i n s p e c i fi c s e c t i o n .
F1A ENGINE 7DA I L Y EURO 4
Print 6 0 3 .9 3 .6 5 1 Base - Mar ch 2 0 0 6
Service procedures to be performed after replacing high-pressure feeding system and/or exhaust gas post-treatment systemcomponents
T o e n s u r e c o r r e c t o p e r a t i o n o f t h e e n g i n e , t h e C P 1 c o n t r o l u n i t 1 6 s t or e s, i n t h e m e mo r y n o n- l a bi l e a r ea , t h e i n f or m at i o n r e la t i ve t o t h e e n gi n e p a ra m et e rs o r ig i na l ly s e t o r a c qu i r ed d u r i ng e n g i n e o p e r a t i o n .
A s a r e s u l t , a f t e r a n y o f t h e o p e r a t i o n s b e l o w i s c a r r i e d o u t :
- r e p l ac i n g o n e o r s e v e r a l i n j e c t o rs ,
- r e p l ac i n g a l l t h e i n j e c t or s ,
- r e pl a c in g t h e a i r f l o w m e t e r,
- r e p la c i ng t h e h y dr a ul i c a c c um u la t or p r es s u re s e ns o r ( c o m mo n r a i l ) ,
- r e pl a c in g t h e E D C c o n t ro l u n i t 1 6 ;
- c h a n g i n g t h e e n g i n e o i l ,
- r e p la c i n g t h e D . P .F . c a t a l y s t ,
- r e p l ac i n g t h e f i l t e r d i f f e r e nt i a l p r e s s u r e ( D p ) s e n s o r ,
- r e p l ac i n g a n y s i g n i f i c an t c o m p o n e n t a s r e g ar d s e m i s s i o n levels,
- p e r fo r m i ng f o r c e d r e g e n e ra t i o n ,
the control unit shall be programmed again by means of the I V EC O M O DU S - E .A . SY . - I T 2 0 00 d i ag n os i s i n s tr u me n t, a n d
the replacement procedure for the concerned component s h a l l b e p e r f o r m e d , i n a c c o r d a n c e w i t h t h e i n d i c a t i o n s o f t h e d i a g no s i s i n s t r u me n t s u s e d .
8 F1A ENGINE DA I L Y EURO 4
Base - M arch 2 0 0 6 P rint 6 0 3 .9 3 .6 5 1
Figure 1 Removal
P l a c e t h e v e h i c l e o n t h e p i t o r a u t o l i f t .
L i f t t h e e n g i ne h o o d ( 2 8 ) , u n d o t h e f a s t e n i ng s c r e ws ( 2 8 ) a n d th en remove th e h ood; remove su pportin g rod (30).
D i s c on n e ct n e g at i v e c a b l e ( 1 1 ) a n d p o s i t i v e c a b l e ( 4 ) f r o m b at te ry ( 10 ), t he n r em ov e t he l at t er f ro m t he e ng in e c ompartmen t.
D i s c on n e ct e l e c tr i c c o n n e c t io n s ( 5 , 7 , 8 a n d 9 ) a n d e n g i n e c a b l e ( 6 ) f r o m t h e E D C c o n t r o l u n i t , t h e n r e l e a s e t h e e n g i n e
c a b l e f r o m t h e s t r a p s s e c u r i n g t h e s a m e t o t h e c a b .
U n h o o k c a b l e ( 3 1 ) f r o m t h e h o o d o p e n i n g c o n t r o l d e v i c e s .
Disc on n ec t fron t h eadlamp elec tric c on n ec tion s (12).
R e m o ve s c r e ws ( 1 9 ) , t h e n t a k e o f f c o v er ( 1 8 ) .
R e m o v e f a s t e n i n g s c r e w s ( 3 2 ) , t h e n t a k e o f f h e a d l a m p i n s e r t s (13).
D o n o t c h a ng e t h e a s s em b l y p o s i t i on o f h e a dl a m p i n s e r t ( 1 3 ) t h r e a d e d b u s h ( 1 4 , d e t a i l D).
NOTE
R e mo v e t h e s c re w s a n d/ o r f a st e ni n g n u ts , t h en r e mo v e c rosspiec e (33).
R e mo v e t h e s c re w s a n d/ o r f a st e ni n g n u ts , t h en r e mo v e bu mper (17).
R e m o v e e x p a n s i o n t a n k ( 3 ) c a p ( 2 ) .
A c t a s f o l l o w s , f r o m u n d e r t h e v e h i c l e ( s e e f i g u r e 4 ) :
- u n d o f a s t e ni n g s c r e w s ( 8 a n d 1 0 ) , t h e n r e m o v e l o w e r s i d e gu ards (11);
- u n d o f a s t e ni n g s c r e w s ( 1 5 ) , t h e n r e m o v e l o w e r c e n t ra l gu ard (12).
A pp l y a t u be ( 1 6) t o r a di a to r p i pe u n io n ( d et a il C) , t h en u ns cr ew c ap ( 15 ) a nd d ra in t he c oo la nt i nt o a s ui t ab le c on tain er.
I f t h e v e h i cl e i s e q u ip p e d w i t h a c a b a i r - c o n di t i o n i ng u n i t , p r o c e e d a s f o l l o w s .
- F i t t h e u n i t 9 9 3 0 9 1 4 6 p i p e s t o c o n n e c t i on s ( 1 ) and (24), then blow th e gas off th e a i r -c o nd i ti o ni n g s y st e m a s d e sc r ib e d i n t h e r e sp ec t iv e c h ar t er o f t h e ” B od y wo r k a n d c h assis” sec tion .
- D i sc o nn e ct e l ec t ri c c o nn e ct i on ( 2 3) f r om d r y i n g f i l t e r p r e s s u r e s w i t c h ( 2 2 ) .
- D i s c on n e ct p i p es ( 2 0 ) f r o m a i r - co n d i ti o n e r c ompressor (21).
- R u t s ( 2 7) , t h en d i sc o nn e ct p i pe s ( 2 5) f r om expan sion valve c on n ec tor (26).
NOTE
S ea l t he a ir -c on di ti on in g u ni t p ip es a nd t he ir r es pe ct i ve m ou nt s, t o p re ve nt m oi st ur e a nd i m p ur i t i e s f r o m p e n et r a t i ng i n t o t h e s y s t em .
NOTE
F 1 A E N G I N E 9D AIL Y E U RO 4
P rint 603.93. 651 Bas e - March 2006
Figure 2R e mo v e n u ts ( 2 3) , t h en p ro p er l y p l ac e r e mo t e- c on t ro l s w i t ch / f us e h o l d er ( 2 2 ) a s i d e.
D i sc o nn e ct p i pe ( 2 1) f r om t h e h e at e x ch a ng e r a n d t h e tu rboblower.
D i sc o nn e ct p i pe ( 1 3) f r om t h e h e at e x ch a ng e r a n d t h e th rottle valve assembly .
R e m ov e f a s t en i n g s c r e w s ( 1 2 ) , t h e n r e m o ve t h e r a d i a t o r / he a t e x c ha n g er a s s em b l y t o g e t h e r w i t h t h e c o n de n s e r- d r yi n g f i l t e r , p i p e s a n d a i r c o n v e y o r ( i f a n y ) .
R e m o v e o i l f i l l i n g c a p ( 2 ) , t h e n t a k e s o u n d - p r o o f i n g c o v e r ( 1 ) off.
D i s co n n e ct t a n k ( 5 ) p r e ss u r e s e n s o r e l e c tr i c c o n ne c t i on ( 3 ) .
R e m o v e t a n k ( 5 ) f a s t e n i n g n u t s ( 4 ) , t h e n t a k e t h e t a n k o f f t h e wall.
D i s c o n n e c t e l e c t r i c c o n n e c t i o n ( 6 ) o f t h e l e v e l s e n s o r p l a c e d u n d e r t a n k ( 5 ) .
D i s c on n e ct o r r e m o ve t h e c o o l a n t p i p e s :
- ( 1 4) , fr o m t h er m os t at ( 11 ) ;
- ( 1 5) , f r om e n gi n e o il h e a t e xc ha n ge r ( 1 0) ;
- ( 19 ), fr om pi pe (1 7) ;
- ( 1 8) , f r om ra di a to r ( 1 6) ;
- ( 2 0) , fr o m t h e c y li n de r he a d.
P r op e rl y o b st r uc t t h e t u rb o bl o we r a i r o u tl e t t o a v o i d c a s u al p e n et r a t i on o f f o r e i gn b o d i es i n t o t h e
tu rboblower an d, th erefore, damage to th e latter.
NOTE
10 F 1 A E N G I N E DAIL Y E U RO 4
Figure 3D i s c on n e ct c a b h e a t e r p i p e ( 2 3 ) f r o m E . G . R . e x c h a n g er o u t l et p i p e ( 2 2 ) .
Disc on n ec t:
- v a c uu m p i p e ( 2 7 ) f r o m t h e E . G .R . v a l v e ;
- p i p e ( 1 ) , f r o m c o a l e s c e nc e f i l t e r ( 2 5 ) ;
- p i p e ( 2 1 ), f r o m p i p e ( 1 9 ) .
D i s c on n e ct e l e c t ri c c o n ne c t i on ( 1 5 ) f r o m a i r f l o w m e t e r ( 1 6 ) . R e m o ve a i r p i p es ( 1 4 a n d 1 9 ) , t o g e t he r w i t h a i r f l o w m e t e r ( 1 6 ) , f r o m t u r b o b lo w e r ( 2 0 ) a n d a i r f i l t e r ( 1 3 ) .
D i s c o n n e c t t h e e l e c t r i c c o n n e c t i o n f r o m V G T s o l e n o i d v a l v e ( 1 2 , o n l y 1 3 6 H P e n g i n e ) .
D i s c o n n e c t t h e e l e c t r i c c o n n e c t i o n f r o m E G R s o l e n o i d v a l v e (11).
D i s c on n e ct t h e e l e c t r i c c o n n e c ti o n s ( 1 8 ) f r o m a l t e r n a to r ( 1 7 ) .
D i s c o n n e c t t h e e l e c t r i c c o n n e c t i o n f r o m o i l l e v e l s e n s o r ( 2 6 ) .
D i sc o nn e ct t h e f u el p i pe s ( 3 ) f r om t h e l o w- pr e ss u re p i pe assembly .
D i s c on n e ct t h e e l e c tr i c c o n ne c t i on ( 6 ) f r o m a i r - co n d i ti o n e r c ompressor (8).
D i s c on n e ct t h e e l e c tr i c c o n ne c t i on ( 5 ) f r o m s t a r t i n g m o t o r (4).
P l a c e a c o n t a i n e r u n d e r t h e p o w e r s t e e r i n g p u m p t o r e c o v e r th e sy stem oil, th en disc on n ec t oil in let an d delivery pipes (9)
a n d ( 1 0 ) .
D i s c o n n e c t t h e e n g i n e g r o u n d c a b l e ( 7 ) .
A p p ly t o o l 9 9 3 6 05 4 4 ( 2 ) t o t h e e n g i ne b r a ck e t s t o r e m o ve th e en gin e from its own c ompartmen t an d sligh tly pu ll th e
same
P r op e rl y o b st r uc t t h e t u rb o bl o we r a i r o u tl e t t o a v o i d c a s u al p e n et r a t i on o f f o r e i gn b o d ie s i n t o t h e
tu rboblower.
NOTE
P rint 603.93. 651 Bas e - March 2006
Refitting
T o r ef it t he e ng in e a ss em bl y, c ar ry o ut t he o pe ra ti on s d es c ri be d f or r em ov al i n r ev er se o rd er , f ol l ow i ng t he se instructions:
- B ef o re r e f i t ti n g t h e g e ar b ox t o t h e e n gi n e, i t i s n e ce s sa r y to remove the pressure plate bearing from the
d i ap h ra g m s p ri n g b y o p en i n g o u t t h e r e ta i ni n g c i rc l i p. F i t t h e p r e s s u r e p l a t e b e a r i n g o n t h e s l e e v e o f t h e d r i v e i np ut s h af t c o ve r, c on n ec t in g i t t o t h e c l ut c h r el ea se l ev er . S pr ea d t he g ea rb ox i n pu t s ha ft w it h M ol i ko te m o l y bd e n u m d i s u l ph i d e g r e a se . A s r eg ar ds t he 5 S 3 00 - 6 S 4 00 O .D . g ea rb ox u ni ts , p r o c e e d a s f o l l o w s . E ng ag e a g ea r t o l et t h e m a in s ha ft t u rn , r ot a ti n g t h e p r o p e l l e r s h a f t c o n n e c t i n g f l a n g e . P u s h t h e g e a r b o x f u l l y i n s o t h at t h e p re ss ur e p la t e b ea ri ng c ou pl es w it h t h e d i a p hr a g m s p r i ng c o r r ec t l y .
A s r eg ar ds t h e 6 S 4 0 0 O . D . g e a rb ox u ni t s, f ol l ow t h ep r o c ed u r e s d e s c r i b ed i n t h e s p e c i fi c c h a p t er .
- P a y s p e c i a l a t t e n t i on t o t h e o p e r a t io n s n e e d ed t o i n s t a l l the engine assembly in the engine bay.
- C he ck t h e c o nd it i on s o f t h e c oo l an t p ip es o r s l ee ve s a nd o f t he a i r d u c ts . R e p la c e t h e m i f t h ey s h ow a ny s ig n o f deterioration.
- C h ec k t h e f l e xi b l e m o u n t in g s o f t h e a s se mb l i es : e n gi n e a nd g ea rb ox . R ep la c e t h em i f t h ey s ho w a ny s ig n o f deterioration.
- Ch ec k t hat t he e xh au st pi pe m embe rs h av e n ot d et e ri o ra t ed a n d a r e n o t a b ou t t o d et e ri o ra t e. I f t h i s i s
s o , r e p l ac e t h e m a l o n g w i t h t h e f l ex i bl e p a rt s f o r s e cu r in g them.
- T i gh t en t h e s c r e ws o r n u t s t o t h e r e q ui r ed t o rq u e.
- M e ti c u lo u sl y c h e c k t h e s t a t e o f t h e v a c uu m p i p e. I t m u st s ho w n o s i gn o f c ra ck i ng , c u tt i ng , s c or in g o r o f b ei n g c ru sh ed . R ep la ce i t i f t h er e i s a ny d ou bt a t a ll a bo ut i t s s o u n d n e s s . W h e n m o u n t i n g i t , m a k e s u r e t h e p i p e d o e s n o t c o me i n t o c o nt a c t w i t h s ha r p m et a l p a rt s o r c o rn e rs o r w it h a ny p ar ti c ul ar ly h ot p ar ts . I n a dd it i on , a ft er a s s e m b l y , t h e p i p e m u s t h a v e n o b e n d s o r c o n s t r i c t i o n s , i t s r ad iu s o f c u rv at u re s h ou l d b e b ro ad a nd i t m us t b e s ec ur ed t o t he v ac uu m p um p f it ti ng w it h a s ui ta bl e clamp.
- m a ke s u re t h a t f u e l p i pe s r a pi d e n ga g em e nt f i t ti n g s a r e a c c ur a te l y c l e an , a n d r e su l t t o h a ve b e en f u l ly i n s er t ed a nd n ot g oi ng t o b e d is co nn ec te d a ft er t he ir b ei ng c o n n e c t ed t o r e l a ti n g e n g a ge m e nt u n i o n s .
- F i ll t h e c o o l i ng s y s te m w i t h c o ol a n t.
- F i l l t h e h y d r a u l i c p o we r s t e e r i n g c i r c ui t a n d b l e e d t h e a i r a s d e s c ri b e d u n d e r t h e r e l e va n t h e a di n g .
- C h ec k t h e l e v el o f o i l i n t h e e n gi n e a n d g e a r bo x .
- r e ch a rg e c l i ma t e c o nt r ol s y s te m ( i f p r es e nt ) a s d e sc r i be d i n c h a pt e r r e la t i ng t o s e c ti o n ” B od y a n d c h a s s i s” ;
- c h ec k t h e i n c l i n at i o n o f l i g ht f r om h e ad l i gh t s , i f n e ed ed .
- n o c o ol a nt l ea ks f ro m c o ol a nt h os e a nd c a b i n t er io r h e at i n g h o s e c o n ne c t io n s l ee v es . T i gh t en h o se c l i ps , i f necessary;
- n o o i l l e ak s f r o m b e t w ee n c o v e r a n d c y l in d er h e ad , o i l
s ump a nd c ra nk ca se , o il f il te r a nd h ou si ng , h ea te xc h a ng e r a n d c r an k ca s e o r f r om l u br i c at i on c i r cu i t l i n es ;
- n o f u el l ea ks f ro m i n je ct i on p um p a nd i n je c to r l i ne s. T i g h t en f i t t i n g s i f n e c e s s ar y ;
- check that injection pump control linkage allows the flow r eg ul at io n t o p er fo rm i ts f ul l t ra ve l i n b ot h d ir ec ti on s. O t he rw i se a dj u st t h e t r av el b y a ct i ng o n n u ts ( 1- 2 , F ig . 6);
- check that the engine shut-off device is working properly;
- c h ec k t h a t t h e i n di c a to r l i g ht s o n t h e i n s tr u me n t p a n el a nd r el at i ng t o t h e d ev ic es d is c on ne ct ed w he n t h e e n g i n e w a s r e m ov e d a r e w o r ki n g p r o pe r l y .
C h e c k t h e l e v e l o f o i l i n t h e t a n k a n d t o p i t u p i f n e c e s s a r y . L i f t t h e v e h i c l e a t t h e f r o n t , s t a r t u p t h e e n g i n e a n d l e t i t i d l e f o r s o m e t i m e . C h ec k t h er e i s n o o i l l e a k ag e f r o m t h e h y d r au l i c c i rc u i t a n d c h e c k t h e l e v e l i n t h e t a n k . S l o w l y t u r n t h e s t e e r i n g w h e e l i n b o t h d i r e c t i o n s o f s t e e r i n g s o t h a t t h e a i r i n t h e h y d r a u l i c s y s t e m c o m e s o u t . C he ck t he l ev el o f o il i n t he t a nk a ga in a nd t o p u p i f n ec es sa ry .
501430 Power steering system air bleed
Checks and tests
S t a rt u p e n g i n e, l e av e r u n n i ng a t a s p ee d s l i gh t l y i n e xc es s o f i dl e s pe ed a nd w ai t f or c o ol an t t o h ea t s u f f i c i e n t l y t o o p e n t h e r m o s t a t . T h e n c h e c k t h e f o l - lowing:
When positioning the engine in the engine bay, take special care not to damage the top pipe of the
p o we r s t ee r in g a n d t h e s o un d pr o of - he a tp ro o f c l a d d i n g o f t h e e n g i n e b a y . O n c e p o si t i on e d, m e ti c u lo u s ly c h ec k t h at t h e t o p p i p e o f t h e p o w e r s t e e r i n g i s s o u n d . B ef o re u s in g i t a g a in , c h e ck t h a t t h e p ow e r s t e er i ng o i l a nd c oo l an t c on t ai n n o i mp ur it i es . I f t h ey d o, f i l t e r w i t h s u i t a b l e m e s h f i l t e r s . F o r a n y t o p p i n g u p , r e fe r t o t h e R E P L E NI S H IN G F L UI D S t a b l e i n t h e “ G E N ER A L ” s e c t i o n .
NOTE
Print 6 0 3 .9 3 .6 5 1 Base - Mar ch 2 0 0 6
Figure 5
D i sa ss em bl e t h e c o mp re ss or d ri ve b el t , i f t he re i s o ne , a s d e s c ri b e d u n d e r t h e r e l e va n t h e a di n g . S l a c k e n o f f t h e t e n s i o n o f t h e b e l t ( 1 ) u s i n g a s p e c i f i c w r e n c h o n t h e a u t o m a t i c t i g h t e n e r ( 2 ) a n d r e m o v e t h e b e l t .
543910 Power steering pump-alternator belt replacement
Disassembly
Assembly M ou nt t h e d ri ve b el t ( 1) t ak i ng c a re t o p os i ti o n i t s r i bs c o rr e ct l y i n t h e r e sp e ct i v e r a c e s o f t h e p u ll e y s. R el ea se t he a ut om at ic t ig ht en er ( 2) . T ur n t he c r an k sh a ft b y o n e t u r n t o s e tt l e t h e b el t . M o u n t t h e c o m p r e s s o r d r i v e b e l t , i f t h e r e i s o n e , a n d a d ju s t t h e t e n si o n a s d e sc r i be d u n de r t h e r e le v an t
heading.F i t t h e m i dd l e s o un d pr o of i n g g u a r d b a ck o n .
543910 Replacing air-conditioning compressor drive belt
Disassembly
9 0 1 5 5
C u t e l a s t i c b e l t ( 3 ) , a s i t c a n n o t b e r e u s e d .
Figure 6
Assembly F it t h e f l ex i bl e b el t ( 3) e qu i pp ed w it h t o ol 9 93 6 01 9 1 ( 2) o n t h e p u l le y ( 4) a n d a p pl y t h e t o o l o n t h e p u l le y ( 1) . F i t t h e d r i v e r i n g ( 5 ) o n t h e f l e x i b l e b e l t ( 3 ) a n d f a s t e n
the ring on the compressor support. T ur n t he d ri ve s ha ft c lo ck wi se u nt il t he b el t f it s p e rf e c tl y o n t h e p u ll e y ( 1 ).
Base - M arch 2 0 0 6 P rint 6 0 3 .9 3 .6 5 1
REPLACING BELTS
R e m o ve t h e a i r - c o n di t i o n er c o m pr e s s or d r i v e b e l t ( 1 1 ) ( i f th ere is on e) an d th e water pu mp / altern ator drive belt as
desc ribed u n der th e relevan t h eadin gs. R e m o ve t h e f a n ( 1 0 ) f r o m t h e e l e c t r o m ag n e t ic c o u pl i n g ( 8 ) . D is co nn ec t t he e le ct ri ca l c on ne ct i on ( 9) f ro m t he elec tromagn etic c ou plin g (8). T ak e o ut t he f i xi ng s cr ew s ( 2) a nd ( 3) a nd r em ov e t he m o u nt i n g t o g e t he r w i t h t h e e l e c tr o m a gn e t i c c o u p l i n g ( 8 ) . T a k e o u t t h e s c r e w s a n d r e m o v e t h e f i x e d t i g h t e n e r ( 4 ) a n d
th e au tomatic tigh ten er (5). R e m o ve s c r e ws ( 7 ) , t h e n d i s a ss e m bl e p u l l ey ( 6 ) . R e m o v e t h e w i r i n g f r o m t h e t i m i n g c o v e r ( 1 2 ) a n d d i s m a n t l e
th is. T a ke o f f t h e c ap ( 2 ) a n d r e m o ve t h e s o un d pr o of i ng c o ve r (20). D i s a ss e m bl e v a l v e g e a r c o v er ( 1 2 ) . D i s c o n n e c t t h e p i p e s ( 1 9 ) f r o m t h e p i p e ( 1 8 ) . D i s c on n e ct t h e e l e c t r i c c o n n e c t io n ( 2 8 ) f r o m s e n so r ( 2 7 ) . T a k e o u t t h e f i x i n g s c r e ws ( 2 6 ) a n d r e m o v e t h e e x p a n s io n
tan k (29); disc on n ec t th e elec tric al c on n ec tion for th e level i n d i c a t o r f r o m t h e e x p a n s i o n t a n k a n d p u t t h e t a n k ( 2 9 ) a s i d e
appropriately . T a k e o u t t h e s c r e w s ( 2 3 ) a n d r e m o v e t h e b r a c k e t ( 2 2 ) f i x i n g
th e sou n dproofin g c over (20). R e m o v e t h e p l u g s ( 2 4 ) f r o m t h e o v e r h e a d a n d t h e p l u g ( 1 4 ) f r o m t h e o i l p u m p — v a c uu m p u m p a s s e m b l y m o u n ti n g . T u rn t h e c r an ks h af t c l o c kw i se s o a s t o b e a bl e t o i n se r t t h e p i n s 9 9 3 6 0 61 4 ( 2 5 ) t h r o ug h t h e h o l e s i n t h e p l u g s ( 2 4 ) i n t o t h e r e le v an t h o le s o f t h e c a ms h af t s a n d p i n 9 9 36 0 61 5 ( 1 5)
th rou gh th e h ole in th e plu g (14) in to th e c ran ksh aft. L o o s e n t h e s c r e w ( 1 7 ) s e c u r i n g t h e a u t o m a t i c t i g h t e n e r ( 1 6 ) a n d r e m o v e t h e t i m i n g b e l t ( 1 3 ) .
541257 Replacing timing drive belt
R e m o ve , b y f o l l o w in g t h e p o w e r u n i t d e t a c h me n t p r o c e d ur e s , th e radiator assembly togeth er with th e h eat exc h an ger an d th e dry in g filter c on den ser(if an y ), th en plac e it aside properly .
Disassembly
Figure 7
P rint 603.93. 651 Bas e - March 2006
Figure 9 When electrical injectors mounted on the vehicle must be r e p la c e d , m e e t f o l l o wi n g w a r n i ng s : - w h er e e l ec t ri c a l i n j ec t o rs a r e d i s m ou n t ed a n d d o n o t
n e e d t o b e r e p l a c e d , t h e i r m o u n t i n g p o s i t i o n h a s t o b e n o t ed d o w n i n o r de r t o r em o un t t h e m l a t e r i n t h e s a me p o s i t i o n ; t h i s i s d o n e t o a v o i d t o r e p r o g r a m t h e c e n t r a l unit;
- a f t er r e pl a c in g o n e o r m o re i n j ec t o rs , t h e c e nt r al u n i t h a s to be reprogrammed; - b e fo r e m o u n t in g a n e w e l e c t ri c a l i n j ec t o r, n o te d o wn
I M A c o d e p r in t ed o n t h e i n j e c t or , b e c a us e t h e c o d e i s d i ff i c ul t t o r ea d a f t er t h e i n j ec t o r h a s b ee n m o un t ed ;
- w h er e t h e c e n t r al u n i t i s r e pl a ce d , r e pr o gr a m t h e n e w c en t ra l u ni t w it h t he I M A c o d es o f t h e e le ct r ic al i nj ec t or s m o un t ed o n t h e e n gi n e a n d c o p y d o wn t h e r ec t i f ic a ti o n c o ef f i ci e nt s ( Z FC ) o f r e pl a c ed c e nt r al u n i t; w h er e i t i s n o t p o ss i bl e , t h ey m u st b e r e se t a n d s e lf - l ea r ni n g p r oc e ss m u s t b e s t a r t e d u p a g a i n .
D u ri n g e n gi n e r u nn i n g, E D C 1 6 c e nt r al u n i t p e rf o rm s s o me c h ec k s o n e l ec t r ic a l i n j ec t o rs m i ni m um f l o w r a te .
I n c e rt a i n c o n di t i on s ( o ve r ru n : v e hi c l e d e ce l er a ti o n w i t h p ed al r el ea se d) a n i nc r ea si n g ( ve ry s ma ll ) f ue l q ua nt i ty s t a rt i n g f r om z e ro i s i n j ec t ed a n d i t s e ff e ct o n e ng i ne r o ta t i on s m o o th n e s s i s o b s er v e d . I n j ec t i on s t a rt t h re s ho l d i s d e te c t ed a n d s t o re d b y t h e c e nt r al unit. T hi s s el f- le ar ni ng p ro ce ss i s c ar ri ed o ut o n e ac h s in gl e cylinder. T h e re f o r e, r e p la c i n g a n e l e c t r ic a l i n j e c t o r i n v o l v es t h e n e e d o f r ep r og r am mi n g t h e c e nt r al u n i t b y e n te r in g t h e I M A c o de s o f n ew e le ct r ic a l i nj ec t or s a nd r es et t in g t he r ec t if i ca t io n f a c t o rs ( Z F C) o f t h e c y l i n d e r c o n s i d e r e d. R e pl a c in g a l l e l ec t r ic a l i n j ec t o rs e x te n ds t h e n e ed o f r e se t t in g
to all the rectification coefficients (ZFC) of each single e l e c t ri c a l i n j e c t o r.
1 0 5 0 6 7
At assistance, code written in clear has to be used (3, Figure 9)
for central unit replacement and reprogramming procedures. In the table there is shown the conversion of OCR characters into Arial characters.
1 0 5 0 6 6
Figure 10
1. IMA Matrix code- 2. Bosch spare part no.- 3 . I MA c ode i n c l e a r - 4 . I ve co s pa re pa rt n o. - 5 . C od e -
6. Series no. - 7. Production date
Electrical injectors are not assigned any more to classes Min (01)- M ed ( 02 ) - M ax ( 03 ); t her ef or e, f lo w r at e de vi at io ns f ro m d es ig n v al ue s a re de te ct ed, d ur in g f in al c he ck s te p, by t he manufacturer on each single injector and printed with I.M.A. (Injector Menge Abgleichung) [Injector Quantity Offset] code on injector magnet. At engine production plant, I.M.A. code is read on line from an automatic reading station, converted into bar code, printed on engine identification label and applied on the engine itself. At vehicles production plant, at line end, E.D.C. 16 central unit is programmed automatically reading the engine identification label.
Conversion table of OCR characters into ARIAL characters
Print 6 0 3 .9 3 .6 5 1 Base - Mar ch 2 0 0 6
755010 REPLACING THE ELECTRIC INJECTORS
Figure 11
Thoroughly clean the seat of the electro-injectors, taking care no foreign bodies get into the cylinder barrels. Fit a fresh gasket (12) onto the electro-injector (10) and fit this in the overhead.
Complete assembly by carrying out the operations described for disassembly in reverse order, taking the following
precautions:
- With each disassembly, the fuel pipes must be replaced with fresh ones.
- Tighten the nuts, screws and fittings to the prescribed torque.
- To tighten the fittings of the fuel pipes, use the wrench in the 99317915 series and the torque wrench 99389829.
- After assembly,replenish the coolant as described under the relevant heading.
Check assembly of the timing sensor as described under the relevant heading.
Partly drain the coolant off from the radiator. Remove the plug (21, Figure 9) and detach the soundproofing cover (20, Figure 9). Disconnect the pipes (19, Figure 9) from the pipe (18, Figure 9). Remove fastening screws (26, Figure 9), then take off expansion tank (29, Figure 9) and disconnect level gauge electric connections (6, figure 7) and sensor (27) electric connections (28, figure 7) from the expansion tank.
Disconnect the pipe (20, Figure 12) from the coalescence filter (1, Figure 12). Disconnect the electrical connections (1) from the electro-injectors (10) and (2) from the fuel pressure sensor (8). Press the springs (3) in the direction shown by the arrow and disconnect thefittings of thepipe (4) to recover fuel from the electro-injectors (10). Disconnect the fuel pipes (7) from the electro-injectors (10) and from the hydraulic accumulator (9). Take out the screws (6) and the brackets (5) fixing the electro-injectors (10) to the cylinder head. Using tool 99342153 (11) extract the electro-injectors (10) from the overhead.
Removal
Refitting
1 0 8 5 6 0
Ta ke o ff t he c ams ha ft d ri ve bel t, as de sc ri bed i n t he r e s pe c t i v e c h a p t er ( o p e ra t i o n 5 4 1 2 5 7 ). D i sc o nn e c t c o o l a nt p i pe s ( 1 5) a n d ( 1 4 ) f r om p i pe ( 1 3) . D i sc o n ne c t t h e e l ec t r ic c o n ne c t io n f r om p r es s u re s e ns o r (18). R e mo v e t h e f a st e ni n g s c r ew s , t h e n t a ke o f f e x pa n si o n t a n k ( 1 7) b y d i sc o n ne c t in g f r om t h e l a t te r t h e e l ec t r ic c o n ne c ti o n f r o m t h e l e v e l s e n s o r . R e mo v e o i l d i ps t i ck p i pe ( 1 2) f r om t h e i n l et m a ni f o ld . D i s c o n n e c t o i l v a p o u r p i p e s ( 2 0 ) a n d ( 1 9 ) f r o m c o a l e s c e n c e f i l t e r ( 1 ) , t h e n r e m o v e t h e l a t t e r f r o m t h e o v e r h e a d .
D i sc o n ne c t p i pe ( 2 ) f r om t h e h e a t e x ch a ng e r e n gi n e c o o la n t o u t l e t p i p e.
T a k e o f f e l e c t r i c i n j e c t o r s ( 4 ) , a s d e s c r i b e d i n t h e ” R e p l a c i n g the electric injectors” chapter (operation 775010).
D i s c o n n e c t t h e e l e c t r i c c o n n e c t i o n s f r o m p h a s e s e n s o r ( 3 ) , w a te r t e mp e ra t u re s e ns o r ( 8 ), a i r p re s su r e/ t em p er a tu r e s en so r ( 9) , p re he at i ng p lu gs ( 6) , t h ro t tl e v al ve a ss em bl y a c t u a t o r ( 1 0 ) , f u e l p r e s su r e s e n s o r ( 1 6 ) . Take fuel pi pe (7) off hydraul ic acc umu lator (5 ), h i g h - pr e s s ur e p u m p a n d i n l e t m a n i f ol d .
Print 6 0 3 .9 3 .6 5 1 Base - Mar ch 2 0 0 6
540610 CYLINDER HEAD REMOVAL AND REFITTING
T a k e o f f t h e o v e r h e a d g a s k e t . T a ke o u t t h e t a pp et s a n d c a r e fu l l y p u t t h em a s id e . U s i n g t h e b u s h i n g 9 9 3 5 5 0 4 1 , t a k e o u t t h e g l o w p l u g s . T a k e o u t t h e s c r e w s f i x i n g t h e c y l i n d e r h e a d a n d d e t a c h t h i s f r o m t h e c r a n k c a s e . R e m o v e t h e c y l i n d e r h e a d g a s k e t .
Figure 13
L o os e n c l a m p ( 9 ), t h en t a k e t h e a i r c o n v ey o r o f f . T a k e a i r s u c t i o n s l e e v e ( 1 0 ) o f f t u r b o b l o w e r ( 8 ) . D is c on n ec t t h e o il p ip e ( 11 ) f ro m t he c y li n de r h ea d a nd f ro m
the turbocharger (8). L o os e n t h e c l a mp ( 7 ) a n d d i sc o nn e c t t h e o i l p i p e ( 5 ) f r o m
the crankcase union. T ak e o ut t h e s c re ws a nd d is c on n ec t t h e e xh au st p ip e ( 4) f r o m t h e t u r b oc h a r g er ( 8 ) . T a k e o f f t h e n u t s ( 3 ) a n d r e m o v e t h e t u r b o c h a r g e r ( 8 ) w i t h i t s g a sk e t f r om t h e e x ha u st m a ni f o ld .
T a ke o u t t h e s c r ew s a n d r e m o ve t h e o v er h ea d t o ge t he r w i th the pins 99360614.
Cl ose t he t urboc harger air out let/i nlet appropriat el y t o preven t f oreign bodi es a c c i d e nt a l l y g e t t i n g i n s i d e a n d d a m ag i n g i t .
NOTE
T he p in s 9 93 6 06 1 4 a p pl i ed s o a s n ot t o a lt er t h e timing after removing the timing belt must be
r em ov ed f ro m t h e o v er he ad o nl y i f t h is i s t o b e removed.
NOTE
1 0 8 5 6 1
D is c on n ec t t h e v ac u um p ip es f ro m E .G .R . v al ve ( 2) a nd turboblower (if any) actuator (6).
Base - M arch 2 0 0 6 P rint 6 0 3 .9 3 .6 5 1
Refitting
Refitting requires carrying out the operations for removal in reverse order, while taking the following precautions:
Check that the timing tools: - 99360614 (6, Figure 13) and 99360608 (8, Figure 13)
are inserted in the overhead;
- 99360615 (11, Figure 13) is inserted in the crankcase as described in “Replacing timing belt.”
Check that the mating surfaces of the cylinder head and crankcase are clean. Keep the cylinder head gasket clean. Position the cylinder head gasket with the lettering ”TOP” facing the cylinder head.
Figure 14
Diagram of the tightening sequence for the cylinder head fixing screws:
- 1st phase: pre-tightening with torque wrench
• screws 1-2-3-4-5-6 to a torque of 100 ±5 Nm;
• screws 7-8-9-10 to a torque of 50 ±2.5 Nm.
- 2nd phase: angle closing
• screws 1-2-3-4-5-6 90° ±5°;
• screws 7-8-9-10 60° ±3°.
- 3rd phase: angle closing
• screws 1-2-3-4-5-6 90° ±5°;
• screws 7-8-9-10 60° ±3°.
- Tighten the screws and nuts to the prescribed torque.
- The seals and gaskets must not be reused, but replaced with new ones.
75494
Mount the cylinder head. Insert the screws and tighten them, in three successive stages, following the order and method shown in the following figure.
To tighten the glow plugs, use the bushing 99355041 and torque wrench 99389819.
A
It is essential to keep the gasket sealed in itspackage until just before assembly.
NOTE
The angle closure is done with tool 99395216.NOTE
If the engine has run for a period equivalent to = 25,000 km, the toothed timing drive belt must be replaced with a fresh one, no matter what its state of wear.
NOTE
Figure 16
Figure 15
Figure 17
Figure 18
L o c k r o ta t i on o f t h e h i gh - pr e ss u re p u mp g e ar ( 1 ) b y a p pl y i ng tool SP. 2263 (2) as illustrated in the figure. Remove the nut
( 3 ) a n d t a k e o u t t h e t o o l ( 2 ) .
U si ng t oo l 9 9 34 0 03 5 ( 2) a pp li ed a s s ho wn i n t h e f i gu re , e xt r ac t t h e g e a r ( 1) f ro m

Iveco Daily Euro 4 2006-2009 Manual en Instrukcja Napraw

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