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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
B.U. TECHNICAL PUBLISHING
10156 Torino (TO) - Italy
Iveco Technical Publications
Lungo Stura Lazio, 15
Print 603.93.651 - 1st Ed. 2006 10156 Torino (TO) - Italy
PRELIMINARY REMARKS
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections — disconnections of
units to/from the vehicle, overhauls at the bench and relating troubleshooting.
On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.

SYMBOLS - WARNINGS

Danger for persons


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

Danger of serious damage for the vehicle


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

General danger
! It includes the dangers of above described signals.

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

NOTE It indicates an additional explanation for a piece of information.

Print 603.93.651 I Base - March 2006


SYMBOLS - ASSISTANCE OPERATIONS

Removal
Intake
Disconnection

Refitting
Exhaust
Connection

Removal
Operation
Disassembly

Fitting in place
Compression ratio
Assembly

Tolerance
Tighten to torque
Weight difference

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Regulation Angle
Adjustment Angular value

Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check

Equipment Temperature

Surface for machining


Pressure
Machine finish bar

Oversized
Interference
Higher than .
Strained assembly
Maximum, peak
Undersized
Thickness
Less than .
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 C
Sealant
Cold
Adhesive
Winter
Temperature > 0 C
Air bleeding Hot
Summer
Replacement
Original spare parts

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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).

Product Code: 5 0 7 6
PRODUCT UNIT SUB-ASSEMBLY PRODUCT UNIT SUB-ASSEMBLY
COMPONENT COMPONENT

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

Example :

Product 50 = Vehicle chassis;


Product 52 = Axles;
Product 53 = Transmission;
Product 76 = Electric ssystem.

Unit Code: 0 1 0 3
PRODUCT UNIT SUB-ASSEMBLY PRODUCT UNIT SUB-ASSEMBLY
COMPONENT COMPONENT

The third and fourth figures identify the UNIT within the PRODUCT.

Example :

Product 50 = Vehicle chassis;


Unit 01 = Chassis;
Unit 02 = Bumpers;
Unit 03 = Alternator.

Sub-assembly Code: 4 0 1 3
PRODUCT UNIT SUB-ASSEMBLY PRODUCT UNIT SUB-ASSEMBLY
COMPONENT COMPONENT

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.

Print 603.93.651 III Base - March 2006


GENERAL WARNINGS

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

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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.

Print 603.93.651 V Base - March 2006


GENERAL WARNINGS ON THE ELECTRIC SYSTEM

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

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

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

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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

Print 603.93.651 VII Base - March 2006


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

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

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE


INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F

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Base - March 2006 Print 603.93.651
INDEX OF SECTIONS

Section

General information 1

Engine 2

Clutch 3

Gearbox 4

Propeller shafts 5

Rear axles 6

Front axle 7

Front and rear suspensions 8

Wheels and tyres 9

Steering system 10

Pneumatic system - Brakes 11

Bodywork and chassis frame 12

Maintenance 13

Electric/Electronic System 14

Print 603.93.651 Base - March 2006


DAILY EURO 4 GENERAL 1

Print 60 3.43 .6 71

SECTION 1
General

Page

IDENTIFICATION DATA . . . . . . . . . . . . . . . . . . 3

- Vehicle Identification Plate . . . . . . . . . . . . . . . . 3

COMPOSITION OF MODELS . . . . . . . . . . . . . . 4

ALPHANUMERICAL CODING FOR


BUS IDENTIFICATION . . . . . . . . . . . . . . . . . 6

REPLENISHING FLUIDS . . . . . . . . . . . . . . . . . . . 13

Print 603.93.651 Base - March 2006


DAILY EURO 4 GENERAL 3

IDENTIFICATION DATA
Vehicle identification plate Figure 1

Plate legend
1) Approval number
2) Chassis number
3) PTT - Total weight on ground
4) MTC - Total combined weight
5) Max. weight permitted on the front axle
6) Max. weight permitted on the rear axle
7) Specific indication of type
8) Wheelbase (mm)
9) Type of engine
10) Engine rating
11) Permitted smoke level
12) Place of manufacture
13) Number of vehicle axles

108534

Figure 2

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

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

108533

Print 603.93.651 Base - March 2006


4 GENERAL DAILY EURO 4

COMPOSITION OF MODELS
MODELS

ASSEMBLIES
F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV o o o o
F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV o o o o
F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV o o o
F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV o o
F1CE0481F*C (DPF series) 146 CV
F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV o o
F1CE0481H*C (DPF series) 176 CV o
Single disk 9” 1/4 o o o o o o o o

Single disk 10” 1/2 o o o o


Single disk 11 o o o o o
ZF 5 S300 V V V V V V V V V V V
ZF 6 S400 O.D. V V V V V
ZF 6 S400A O.D. V V V V V V V V V V V V V V V V

5817 o o o o o o o
5818
5819 o o o o
5823
NDA R.S. o o o o o o o
NDA R.G. o o o o o
450511 o o o o
450517/2
Rack-and-pinion Powered steering o o o o o o o o o o o o o o o o
FRONT MECHANICAL SUSPENSIONS:
o o o o o o o o o o o
independent with transverse leaf spring (MK3)
independent with torsion bars o o o o
( ) ( ) ( ) ( ) ( )
REAR Parabolic o o o o o o o Z Z Z Z Z Z Z Z Z
MECHANICAL
- single leaf o o o o o o o
SUSPENSIONS:
- reinforced o o o o o o o
Semi-elliptical s s s s s s s s s
Semi-elliptic
z z z z z z z z z
with leaf spring

REAR AIR SUSPENSIONS V V V V V V V V V V V V V V V V

O.D. = Over Drive s Standard on chassis cabs, Alternatively on Vans — Chassis Cowls
( ) Optional extra (with max load of 1900 kg) and Cut Aways
o Standard Z Standard on Vans, Chassis Cowls and Cut Aways — Alternatively
with ZF 6 S 400 A O.D. gearbox on Chassis Cabs
S Single rear wheels
V Alternative L Light with single rear wheels
Vehicles with front suspension with transverse leaf spring C Twin rear wheels
Vehicles with front suspension with torsion bars
z Chassis cabs only, as an alternative

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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 o o o o
Single disk 9” 1/4
Single disk 10” 1/2
Single disk 11 o o o o o o o o
ZF 5 S300
ZF 6 S400 O.D. V V V V V V V V
ZF 6 S400A O.D. V V V V V V V V

5817
5818
5819 o o o o
5823 o o o o
NDA R.S.
NDA R.G.
450511 o o o o
450517/2 o o o o
Rack-and-pinion Power steering o o o o o o o o
FRONT MECHANICAL SUSPENSIONS:
independent with transverse leaf spring (MK3)
independent with torsion bars o o o o o o o o
Parabolic Z Z Z Z Z Z Z Z
- single leaf
- reinforced
Semi-elliptical s s s s s s s s
Semi-elliptic
z z z z z z z z
with leaf spring

REAR AIR SUSPENSIONS V V V V V V V V

O.D. = Over Drive s Standard on chassis cabs, Alternatively on Vans — Chassis Cowls
( ) Optional extra (with max load of 1900 kg) and Cut Aways
o Standard Z Standard on Vans, Chassis Cowls and Cut Aways — Alternatively
V Alternative on Chassis Cabs
Vehicles with front suspension with transverse leaf spring S Single rear wheels
Vehicles with front suspension with torsion bars L Light with single rear wheels
z Chassis cabs only, as an alternative C Twin rear wheels

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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

RANGE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

A LIGHT ROAD VEHICLES

PROGRAMMING FAMILY

1 2 3 4 5 6 7 8 9 10 11 12 13 14

A T 25C 29 L

B T 30C 35 S

C T 35C 35 C
CHASSIS CABS AND DERIVATIVES
D T 40C 40 C

50 C
E T 50C
45 C

60 C
F T 65C
65 C

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DAILY EURO 4 GENERAL 7

PROGRAMMING FAMILY

1 2 3 4 5 6 7 8 9 10 11 12 13 14

H T 25V 29 L

K T 30V 35 C

J T 35V 35 C

VANS AND DERIVATIVES


L T 40V 40 C

50 C
M T 50V
45 C

60 C
N T 65V
65 C

ENGINE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

A F1A E4 LD - 96 CV

B F1A E4 LD - 116 CV

C F1A E4 LD - 136 CV

D F1C E4 HD - 146 CV

E F1C E4 HD - 176 CV

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

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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 6 7 8 9 10 11 12 13 14
29 L10 ( ) - 29 L12 ( ) - 29 L14 ( )
35 S10 ( ) - 35 S12 ( ) - 35 S14 ( ) - 35 S18 ( )
35 C10 ( ) - 35 C12 ( ) - 35 C15 ( ) - 35 C18 ( )
CHASSIS
1 40 C10 ( ) - 40 C15 ( ) - 40 C18 ( )
CAB
45 C15 ( ) - 50 C15 ( ) - 50 C18 ( )
60 C15 ( ) - 60 C18 ( )
65 C15 ( ) - 65 C18 ( )

29 L10 D ( ) - 29 L12 D ( ) - 29 L14 D ( ) -


35 S10 D ( ) - 35 S12 D ( ) - 35 S14 D ( ) -
CHASSIS 35 S18 D ( ) - 35 C10 D ( ) - 35 C12 D ( ) -
6 CAB 35 C15 D ( ) - 35 C18 D ( ) - 40 C10 D ( ) -
6+1 40 C12 D ( ) - 45 C15 D ( ) - 45 C18 D ( )
50 C18 D ( ) - 60 C15 D ( ) - 60 C18 D ( ) -
65 C15 D ( ) - 65 C18 D ( )

35 S12 CC ( ) - 35 S 14 CC ( ) - 35 S18 CC ( ) -
35 C12 CC ( ) - 35 C15 CC ( ) - 35 C18 CC ( ) -
CHASSIS 40 C12 CC - 40 C15 CC ( ) - 40 C18 CC ( )
0
COWL 45 C15 CC - 45 C18 CC ( )
50 C15 CC ( ) - 50 C18 CC ( )
60 C18 CC ( ) - 65 C18 CC ( )

35 S12 CCR ( ) - 35 S14 CCR ( ) - 35 S18 CCR( )


CHASSIS 35 C12 CCR ( ) - 35 C15 CCR ( ) - 35C18CCR( )
R COWL 40 C12 CCR ( ) - 40 C15 CCR ( ) - 40C18CCR( )
45 C15 CCR ( ) - 45 C18 CCR ( )
SHORT
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 6 7 8 9 10 11 12 13 14

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

29 L10 V ( ) - 29 L12 V ( ) - 29 L14 V ( )


35 S10 V ( ) - 35 S12 V ( ) - 35 S14 V ( )
35 S18 V ( )
35 C10 V ( ) - 35 C12 V ( ) - 35 C15 V ( )
35 C18 V ( )
4 VAN
40 C12 V ( ) - 40 C15 V ( ) - 40 C18 V ( )
45 C15 V ( ) - 45 C18 V ( )
50 C15 V ( ) - 50 C18 V ( )
60 C15 V ( ) - 60 C18 V ( )
65 C15 V ( ) - 65 C18 V ( )

29 L10 SV ( ) - 29 L12 SV ( ) - 29 L14 SV ( )


35 S10 SV ( ) - 35 S12 SV ( ) - 35 S14 SV ( ) -
35 S18 SV ( )
35 C10 SV ( ) - 35 C12 SV ( ) - 35 C15 SV ( ) -
SEMI GLAZE
SEMI-GLAZE 35 C18 SV ( )
V
D VAN 40 C10 SV ( ) - 40 C12 SV ( ) - 40 C15 SV ( ) -
40 C18 SV ( ) -
45 C15 SV ( ) - 45 C18 SV ( )
50 C15 SV ( ) - 50 C18 SV ( )

VENDOR 35 S12 CV ( ) - 35 S14 CV ( )


VERSION 35 C12 CV ( ) - 40 C12 CV -
U 45 C15 CV ( ) - 45 C18 CV ( )
CITY
VAN 50 C15 CV ( ) - 50 C18 CV ( )

5 COMBI 29 L14 C ( ) - 35 S14 C ( )

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

CHASSIS-
COWL
9 SHORT 35 S14 CCRC ( ) - 35 S18 CCRC -
35 C14 CCRC ( ) - 35 C18 CCRC
VERSION FOR
CAMPER VAN

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

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10 GENERAL DAILY EURO 4

WHEELBASE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

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

3000 L mm
2
(T25V - T30V - T35V - T40V - T50V)

3300 mm
3
(T25V - T30V - T35V - T40V - T50V)

3450 mm
4
(T25C - T30C - T35C - T40C - T50C - T65C)

3750 mm
5
(T30C - T35C - T40C - T50C - T65C)

3950 L mm
6
(T30V - T35V - T40V - T50V - T65V)

4100 mm
7
(T35C - T40C)

4350 mm
8
(T50C - T65C)

4750 mm
9
(T50C - T65C)

Base - March 2006 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 — INTERNAL HEIGHT OF LOADING BAY

1 2 3 4 5 6 7 8 9 10 11 12 13 14

LEFT-HAND DRIVE
1
(T25C - T30C - T35C - T40C - T50C)

LEFT-HAND DRIVE AND INTERNAL HEIGHT OF


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

LEFT-HAND DRIVE AND INTERNAL HEIGHT OF


LOADING BAY H2 = 1900 mm 2
(T25V - T30V - T35V - T40V - T50V)

LEFT-HAND DRIVE AND INTERNAL HEIGHT OF


LOADING BAY H3 = 2100 mm 3
(T30V - T35V - T40V - T50V)

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

RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF


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

RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF


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

RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF


LOADING BAY H3 = 2100 mm C
(T30V - T35V - T40V - T50V - T65V)

MANDATORY MARKET OPTIONAL EXTRAS

1 2 3 4 5 6 7 8 9 10 11 12 13 14

OPTIONAL EXTRAS REQUIRED BY THE CUSTOMER

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Base - March 2006 Print 603.93.651


DAILY EURO 4 GENERAL 13

REPLENISHING FLUIDS
IVECO RECOMMENDED LUBRICANTS PARTS TO BE REPLENISHED Quantity
Litres kg
Quantity of oil in circulation in the car-
1.4 1.23
tridge filter and heat exchanger
Total dry engine capacity 5.7 5.02
Sump capacity:
- max level 4.3 3.78
Urania Dailyy - min level 3 2.65
Urania LD 5
Quantity of oil in circulation in the car-
tridge filter and heat exchanger 1 0.88
Total dry engine capacity 7.6 6.79
Sump capacity:
- max level 6.6 5.81
- min level 4.29 3.78

! Max. gradient negotiable by vehicle uphill/downhill with oil at minimum level 30%

Gearbox
ZF 5S 300 2 1.8
Tutela TRUCK GEARLITE
ZF 6S 400 O.D. 2.2 1.98
ZF 6S 400 A O.D. 2.7 2.43
Front axle:
5817 - -
5818 - -
5819 - -
5823 - -
Rear axles:
Tutela W140/M-DA (SAE 80W90) NDA R.S. 1.35 1.21

Tutela W90/M-DA (SAE 80W90) NDA R.G. 1.35 1.21

Tutela W140/M-DA (SAE 85W140) 450511 1.9 1.65

Tutela W140/M-DA (SAE 85W140) 450517/2 3 2.7

Tutela GI/A Power steering 1.4 1.3

Tutela TRUCK DOT SPECIAL Brake circuit 1.11 1

Arexons DP1 Windscreen washer 5 4.5

Paraflu11 * Cooling system 9 -

* = Protective anti-freeze (concentration 50%, freezing point —35 C)

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

Figure

95 35

50 10 SAE 40
32 0 SAE 30

SAE
14 -10 20W

SAE
5 -15
15W/40
SAE SAE 5W 30
-13 -25 10W
oF oC 108535

Base - March 2006 Print 603.93.651


DAILY EURO 4 F1A ENGINE 1

SECTION 2
5401 Engine

Page

F1A ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

F1C ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Print 603.93.651 Base - March 2006


DAILY EURO 4 F1A ENGINE 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 post-
treatment system components . . . . . . . . . . . . 8
POWER UNIT REMOVAL/REFITTING . . . . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Checks and tests . . . . . . . . . . . . . . . . . . . . . . . 13
- Power steering system air bleed . . . . . . . . . . . 13
REPLACING BELTS . . . . . . . . . . . . . . . . . . . . . . . 14
- Power steering pump-alternator belt replacement 14
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Replacing air-conditioning compressor drive belt 14
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Replacing timing drive belt . . . . . . . . . . . . . . . . 15
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REPLACING THE ELECTRIC INJECTORS . . . . . 17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CYLINDER HEAD REMOVAL AND REFITTING 19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REPLACING HIGH-PRESSURE PUMP CPH1 . . . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REPLACING WATER PUMP . . . . . . . . . . . . . . . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PREHEATING PLUG REMOVAL/REFITTING . . . 23
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
THROTTLE VALVE ASSEMBLY REMOVAL-REFITTING 23

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 — PISTON ASSEMBLY . . . 86

EXHAUST PIPE ASSEMBLY REMOVAL/REFITTING 27 - Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - Measuring piston diameter . . . . . . . . . . . . . . . . 87

REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY - Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87


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

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 79 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 94


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

Base - March 2006 Print 603.93.651


DAILY EURO 4 F1A ENGINE 5

Page Page
- Boring valve guides . . . . . . . . . . . . . . . . . . . . . . 94 - Turbocharger (KKK K03-2074-CCB 5.88 type) 125
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
- Recutting and replacing valve seats . . . . . . . . . . 95 - Pressure relief valve . . . . . . . . . . . . . . . . . . . . . 126
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 96 - Checking pressure relief valve . . . . . . . . . . . . . . 126
ROCKER ARMS — TAPPETS . . . . . . . . . . . . . . . . 96 - GARRET GT 17 variable geometry
turbosupercharger . . . . . . . . . . . . . . . . . . . . . . 127
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ASSEMBLING CYLINDER HEADS . . . . . . . . . . . 97
- Operation at low engine rpm . . . . . . . . . . . . . . 127
- Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
- Operation at high engine rpm . . . . . . . . . . . . . 127
- Overhead removal . . . . . . . . . . . . . . . . . . . . . . 98
- Proportional solenoid valve controlling turbocharger
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 99
actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 - Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 - Checking and adjusting the actuator . . . . . . . . . 129
- Checking cam lift and pin alignment . . . . . . . . . 100 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
- Assembling overhead . . . . . . . . . . . . . . . . . . . . 102 (EXHAUST GAS RECIRCULATION) . . . . . . . 130

- Assembling front seal ring . . . . . . . . . . . . . . . . . 103 - EGR system operation . . . . . . . . . . . . . . . . . . . 130

- Refitting cylinder head . . . . . . . . . . . . . . . . . . . 106 - Main system components . . . . . . . . . . . . . . . . . 131

- Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . 107 - E.G.R. valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - Modulator solenoid valve . . . . . . . . . . . . . . . . . 131

- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - Air flow rate meter (flow meter) . . . . . . . . . . . 131

OIL VACUUM PUMP ASSEMBLY (GPOD) . . . . . 117 - Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 132

- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 - Throttle valve assembly . . . . . . . . . . . . . . . . . . 132

- Characteristic data . . . . . . . . . . . . . . . . . . . . . . 117 EXHAUST POLLUTANT REDUCTION SYSTEM WITH


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

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
- Fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
- Checking idling adjustment . . . . . . . . . . . . . . . . 139
- High-pressure pump CPH1 . . . . . . . . . . . . . . . 149
- Fuel cut-off in release phase . . . . . . . . . . . . . . . 139
- Checking cylinder balancing on idling . . . . . . . . 139 - Pressure control valve . . . . . . . . . . . . . . . . . . . 150
- Checking regular engine rotation (anti-sawing) . 139 - Replacing pressure regulator . . . . . . . . . . . . . . . 150
- Checking smokiness at exhaust on acceleration 139
- Hydraulic accumulator (rail) . . . . . . . . . . . . . . . 151
- Checking exhaust gas recirculation (E.G.R.) . . . 139
ELECTRO-INJECTORS . . . . . . . . . . . . . . . . . . . . 152
- Checking top speed limit . . . . . . . . . . . . . . . . . 139
- Checking regular rotation on acceleration . . . . 139 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

- Checking glow plug control unit . . . . . . . . . . . . 139 - Replacing an electrical injector . . . . . . . . . . . . . 152
- Checking activation of air-conditioning system . 139 ELECTRIC/ELECTRONIC COMPONENTS . . . . . 153
- Checking fuel pump . . . . . . . . . . . . . . . . . . . . . 139
- Electronic control unit EDC 16 . . . . . . . . . . . . 153
- Checking diesel warming . . . . . . . . . . . . . . . . . 140
- Glow plug electronic control unit . . . . . . . . . . . 154
- Checking cylinder position . . . . . . . . . . . . . . . . 140
- Checking pilot and main injection timing . . . . . 140 - Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

- Checking injection pressure closed cycle . . . . . 140 SENSORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154


- Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 - Engine speed sensor . . . . . . . . . . . . . . . . . . . . . 154
- Correcting flow rate according to water
temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 - Camshaft timing sensor . . . . . . . . . . . . . . . . . . 154

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

- After run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 - Brake pedal position sensor . . . . . . . . . . . . . . . 155


- Cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 - Vehicle speed sensor . . . . . . . . . . . . . . . . . . . . 155
- Cylider balancin . . . . . . . . . . . . . . . . . . . . . . . . 141
- Differential pressure sensor - deltap ( p .... 155
- Synchronisation search . . . . . . . . . . . . . . . . . . . 141
- Exhaust gas temperature sensor . . . . . . . . . . . . 155
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 146
- PWM (Pulse Width Modulation) controls . . . . 156

Base - March 2006 Print 603.93.651


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.

Print 603.93.651 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 Print 603.93.651


DAILY EURO 4 F1A ENGINE 13

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

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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