2006-2011 Iveco Daily Euro 4 Repair Manual – PDF DOWNLOAD
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2006-2011 Iveco Daily Euro 4 Repair Manual – PDF DOWNLOAD
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Language: English
Brand: Iveco
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2006-2011 Iveco Daily Euro 4 Repair Manual – PDF DOWNLOAD
DAILY EURO 4
REPAIR MANUAL
MECHANICAL
ELECTRIC/ELECTRONIC
FOREWORD:
”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 tomake 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.
VIDEO PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
2006-2011 Iveco Daily Euro 4 Repair Manual – PDF DOWNLOAD
DAILY EURO 4 1
REPAIR MANUAL 1
MECHANICAL ELECTRIC/ELECTRONIC 1
PRELIMINARY REMARKS 3
SYMBOLS -WARNINGS 3
SYMBOLS – ASSISTANCE OPERATIONS 4
PRODUCT CODE 5
GENERAL WARNINGS 6
GENERAL WARNINGS ON THE ELECTRIC SYSTEM 8
Bonding and screening 9
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS 10
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES 10
UPDATE DATA 11
INDEX OF SECTIONS 13
SECTION 1 – General 15
General 15
IDENTIFICATION DATA 17
Vehicle identification plate 17
COMPOSITION OF MODELS 18
ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION 20
REPLENISHING FLUIDS 27
SECTION 2 – Engine 29
Engine 29
F1A Engine 31
MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE 35
Service procedures to be performed after replacing high-pressure feeding system and/orexhaust gas post-treatment system components 36
POWER UNIT REMOVAL/REFITTING 37
Removal 37
Refitting 41
Checks and tests 41
Power steering system air bleed 41
REPLACING BELTS 42
Power steering pump-alternator belt replacement 42
Disassembly 42
Assembly 42
Replacing air-conditioning compressor drive belt 42
Disassembly 42
Assembly 42
Replacing timing drive belt 43
Disassembly 43
Assembling 44
REPLACING THE ELECTRIC INJECTORS 45
Removal 46
Refitting 46
CYLINDER HEAD REMOVAL AND REFITTING 47
Removal 47
Refitting 49
REPLACING HIGH-PRESSURE PUMP CPH1 50
Removal 50
Refitting 50
REPLACING WATER PUMP 50
Removal 50
Refitting 50
PREHEATING PLUG REMOVAL/REFITTING 51
Removal 51
Refitting 51
THROTTLE VALVE ASSEMBLY REMOVAL REFITTING 51
Removal 51
Refitting 51
E G R VALVE REMOVAL/REFITTING 52
Removal 52
Refitting 52
HEAT EXCHANGER REMOVAL/REFITTING 52
Removal 52
Refitting 52
BURNT GAS EXHAUST SYSTEM 53
Description 53
OXICAT – OXYDIZER CATALYST 53
Description 53
EXHAUST PIPE ASSEMBLY REMOVAL/REFITTING 55
Removal 55
Refitting 55
REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY COMPONENTS (SYSTEMS EQUIPPEDWITH D P F CATALYST) 56
Exhaust silencer removal 56
D P F catalyst removal 56
Refitting 56
Replacing D P F catalyst 57
Replacing differential sensor(delta-p) 57
ENGINE VIEWS 58
EMISSIONS 61
ENGINE IDENTIFICATION CODE 62
CHARACTERISTIC CURVES 63
GENERAL SPECIFICATIONS 67
ASSEMBLY DATA — CLEARANCES 70
TOOLS 75
EXPERIMENTAL TOOLS 80
TIGHTENING TORQUE 91
OVERHAULING ENGINE 96
DISASSEMBLING THE ENGINEAT THE BENCH 96
REPAIRS 106
CYLINDER BLOCK 106
Checks and measurements 106
Checking head mating surface on cylinderblock 107
CRANKSHAFT 107
Measuring main journals and crankpins 107
Checking crankshaft 108
Replacing timing control gear 110
ENGINE ASSEMBLY 110
Assembling main bearings 110
Measuring main journal assembly clearance 110
Checking crankshaft end float 111
Assembling rear seal 112
ENGINE FLYWHEEL 113
Replacing bearing supporting gearbox input shaft 113
CONNECTING ROD – PISTON ASSEMBLY 114
Pistons 114
Disassembly 114
Measuring piston diameter 115
Piston pins 115
Conditions for correct pin-piston coupling 115
Piston rings 115
Connecting rods 116
Bushes 117
Checking connecting rod 117
Checking bending 117
Assembling connecting rod-piston assembly 117
Checking for connecting rod – piston distortion 118
Fitting piston rings 118
Assembling connecting rod – piston assemblies in cylinder barrels 118
Measuring crankpin assembly clearance 119
Checking piston protrusion 119
CYLINDER HEADS 120
Disassembly 120
Removing valves 120
Checking cylinder head seal 121
Checking cylinder head mating surface 121
VALVES 121
Removing deposits, refacing and checking valves 121
Checking clearance between valve stem andvalve guide and centring 122
VALVE GUIDE 122
Replacing valve guide 122
Boring valve guides 122
VALVE SEATS 123
Recutting and replacing valve seats 123
VALVE SPRINGS 124
ROCKER ARMS – TAPPETS 124
ROCKER ARMS – TAPPETS 124
Checks 125
ASSEMBLING CYLINDER HEADS 125
Overhead 126
Overhead removal 126
TIMING SYSTEM 127
Description 127
Camshaft 128
Checks 128
Checking cam lift and pin alignment 128
Assembling overhead 130
Assembling front seal ring 131
Refitting cylinder head 134
Camshaft drive 135
LUBRICATION 143
General 143
OIL VACUUM PUMP ASSEMBLY (GPOD) 145
Oil pump 145
Characteristic data 145
Vacuum pump 145
Oil pressure control valve 146
Oil filter 146
Modine heat exchanger 146
Oil vapour recirculation system 147
Description 147
COOLING 149
Description 149
Operation 149
Electromagnetic pulley 151
Water pump 151
Thermostat 151
TURBOCHARGING 152
Description 152
Turbocharger (KKK K03-2074-CCB 5 88 type) 153
REPAIRS 154
Pressure relief valve 154
Checking pressure relief valve 154
GARRET GT 17 variable geometry turbo supercharger 155
General 155
Operation at low engine rpm 155
Operation at high engine rpm 155
Proportional solenoid valve controlling turbocharger actuator 156
Actuator 156
REPAIRS 157
Checking and adjusting the actuator 157
EXHAUST GAS RECIRCULATION (EGR) SYSTEM (Exhaust gas recirculation) 158
EGR system operation 158
Main system components 159
E G R valve 159
Modulator solenoid valve 159
Air flow rate meter (flow meter) 159
Heat exchanger 160
Throttle valve assembly 160
EXHAUST POLLUTANT REDUCTION SYSTEM WITH DPF CATALYST (ON REQUEST) 161
General 161
D P F (Diesel Particulate Filter) CATALYST 162
Description 162
PARTICULATE FILTER REGENERATION SYSTEM 163
Operation 163
Forced regeneration 164
Refilling engine oil 164
FUEL SUPPLY 165
HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM (MS 6 3 – EDC 16) 165
General 165
SYSTEM OPERATION 167
Self-diagnosis — BLINK CODE 167
Immobilizer recognition 167
Checking fuel temperature 167
Checking engine coolant temperature 167
Checking quantity of fuel injected 167
Checking idling adjustment 167
Fuel cut-off in release phase 167
Checking cylinder balancing on idling 167
Checking regular engine rotation (anti-sawing) 167
Checking smokiness at exhaust on acceleration 167
Checking exhaust gas recirculation (E G R ) 167
Checking top speed limit 167
Checking regular rotation on acceleration 167
Checking glow plug control unit 167
Checking activation of air-conditioning system 167
Checking fuel pump 167
Checking diesel warming 168
Checking cylinder position 168
Checking pilot and main injection timing 168
Checking injection pressure closed cycle 168
Fuel supply 168
Correcting flow rate according to water temperature 168
Correcting flow rate to avoid noise, smoke or overloading 168
De-rating 168
Injection timing electronic test 168
Speed governor 168
Engine starting 168
Cold starting 169
Warm starting 169
Run up 169
After run 169
Cut-off 169
Cylinder balancing 169
Synchronization search 169
OPERATION 171
HYDRAULIC SYSTEM 174
Fuel pump 174
Fuel filter “UFIfilters” 175
Fuel filter “Filtrauto” 176
Fuel pipes 176
High-pressure pump CPH1 177
Pressure control valve 178
Replacing pressure regulator 178
Hydraulic accumulator (rail) 179
ELECTRO-INJECTORS 180
Operation 180
Replacing an electrical injector 180
ELECTRIC/ELECTRONIC COMPONENTS 181
Electronic control unit EDC 16 181
Glow plug electronic control unit 182
Glow plugs 182
SENSORS 182
Engine speed sensor 182
Camshaft timing sensor 182
Air temperature and pressure sensor 183
Fuel temperature sensor 183
Fuel pressure sensor 183
Atmospheric pressure sensor 183
Engine coolant temperature senso 183
Throttle pedal position sensor 183
Clutch pedal position sensor 183
Brake pedal position sensor 183
Vehicle speed sensor 183
Differential pressure sensor – delta p (Dp) 183
Exhaust gas temperature sensor 183
ACTUATORS 184
PWM (PulseWidth Modulation) controls 184
F1C Engine 185
MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE 189
Service procedures to be performed after replacing high-pressure feeding systemand/orexhaust gas post-treatment system components 190
POWER UNIT REMOVAL/REFITTING 191
Removal 191
Refitting 195
Power steering system airbleed 195
Checks and tests 195
REPLACING AIR-CONDITIONING COMPRESSOR DRIVE BELT 196
Disassembly 196
Assembly 196
POWER STEERING PUMP-ALTERNATOR BELT REPLACEMENT 196
Disassembly 196
Assembly 196
REPLACING THE WATER PUMP 196
Removal 196
Refitting 196
REPLACING THE HIGH-PRESSURE PUMP 197
Removal 197
Refitting 197
REPLACING THE POWER STEERING PUMP 198
Removal 198
Refitting 198
REPLACING THE DRIVE SHAFT SEAL RING AND THE FRONT COVER GASKET 198
Removal 198
Refitting 199
REPLACING THE VACUUM PUMPOIL PUMP ASSEMBLY (GPOD) 200
Removal 200
Refitting 200
REPLACING THE DRIVE SHAFT REAR SEAL RING 201
Removal 201
REPLACING ELECTRO-INJECTORS 202
Removal 202
REMOVAL/REFITTING THE CYLINDER HEAD 203
Removal 203
Refitting 205
EGR HEAT EXCHANGER REMOVAL – REFITTING 207
Removal 207
Refitting 208
Checks and tests 208
EGR HEAT EXCHANGER REMOVAL-REFITTING 208
Removal 208
Refitting 209
Checks and tests 209
BURNT GAS EXHAUST SYSTEM 210
REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY COMPONENTS (SYSTEMS EQUIPPED WITH D P F CATALYST) 211
Exhaust silencer removal 211
D P F catalyst removal 211
Refitting 211
Replacing D P F catalyst 212
Replacing differential sensor(delta-p) 212
ENGINE VIEWS 213
EMISSIONS 216
ENGINE IDENTIFICATION CODE 217
CHARACTERISTIC CURVES 223
GENERAL SPECIFICATIONS 225
ASSEMBLY DATA – CLEARANCES 228
TOOLS 233
EXPERIMENTAL TOOLS 239
TIGHTENING TORQUE 246
OVERHAULING ENGINE F1C 249
DISASSEMBLING THE ENGINEAT THE BENCH 249
REPAIRS 260
CYLINDER BLOCK 260
Checks and measurements 260
Checking head mating surface on cylinder block 261
CRANKSHAFT 261
Measuring main journals and crank pins 261
Checking crankshaft 262
Replacing timing control gear 264
ENGINE ASSEMBLY 264
Assembling main bearings 264
Measuring main journal assembly clearance 264
Checking crankshaft end float 265
Assembling rear seal 266
ENGINE FLYWHEEL 267
Replacing bearing supporting gearboxinput shaft 267
CONNECTING ROD – PISTON ASSEMBLY 267
Piston 268
Measuring piston diameter 268
Piston pin 269
Conditions for correct pin-piston coupling 269
Piston rings 269
Connecting rods 270
Bushing 270
Checking connecting rods 270
Checking torsion 271
Checking bending 271
Assembling connecting rod-piston assembly 271
Checking for connecting rod – piston distortion 272
Assembly piston rings 272
Assembly connection rod-piston assembly in the cylinder liner 272
Measuring crankpin assembly clearance 272
Checking piston protrusion 273
CYLINDER HEADS 274
Disassembly 274
Disassembly the camshaft 274
Checking cylinder head seal 275
Checking cylinder head mating surface 275
VALVES 275
Removing deposits, refacing and checkingvalves 275
Checking clearance between valve stem andvalve guide and centring valves 276
VALVE GUIDE 276
Replacing valve guide 276
Boring valve guides 276
VALVE SEATS 277
Recutting and replacing valve seats 277
VALVE SPRINGS 278
ROCKER ARMS – TAPPETS 278
Checks 279
ASSEMBLING CYLINDER HEADS 279
Overhead 280
Overhead removal 280
TIMING SYSTEM 281
Description 281
Camshaft 282
Checks 282
Checking cam lift and pin alignment 282
Assembling overhead 284
AUXILIARY ORGAN CONTROLS 284
TIMING SYSTEM CONTROL 287
Replacement of alternator free wheel 292
LUBRICATION 299
General 299
OIL PUMP/DEPRESSOR UNIT 301
Oil pump 301
Characteristic data 301
Vacuum pump 302
Oil pressure adjusting valve 302
Disassembly 302
Assembly 303
Oil filter 303
Heat exchanger 303
Disassembly 303
Assembly 303
Oil vapour recirculation (Blow-by) 305
Operation 305
COOLING 306
Description 306
Operation 306
Electromagnetic pulley 307
Water pump 307
Thermostat 307
TURBOCHARGING 308
Description 308
Turbocharger type MITSUBISHI TD 4 HL-13T – 6 309
REPAIRS 310
Pressure relief valve 310
Pressure-relief valve check 310
GARRET GT 2260 V variable geometry turbosupercharger 311
General 311
Operation at low engine rpm 311
Operation at high engine rpm 311
Proportional solenoid valve controlling turbocharger actuator 312
Actuator 312
REPAIRS 313
Checking and adjusting the actuator 313
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 314
Operating 314
Main system components 315
E G R valve 315
Modulator solenoid valve 315
Air flow rate meter (flow meter) 315
Throttle valve assembly 316
Heat exchanger 316
EXHAUST SYSTEM REMOVAL-REFITTING 317
General 317
D P F (Diesel Particulate Filter) CATALYST 318
Description 318
SYSTEM TO REDUCE POLLUTANTS AT EXHAUST 319
Operation 319
Forced regeneration 320
Refilling engine oil 320
FUEL SUPPLY 321
HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM (EDC 16) 321
General 321
SYSTEM OPERATION 323
Self-diagnosis — BLINK CODE 323
Immobilizer recognition 323
Checking fuel temperature 323
Checking engine coolant temperature 323
Checking quantity of fuel injected 323
Checking idling adjustment 323
Fuel cut-off in release phase 323
Checking cylinder balancing on idling 323
Checking regular engine rotation (anti-sawing) 323
Checking smokiness at exhaust on acceleration 323
Checking exhaust gas recirculation (E G R ) 323
Checking top speed limit 323
Checking regular rotation on acceleration 323
Checking glow plug control unit 323
Checking activation of air-conditioning system 323
Checking fuel pump 323
Checking diesel warming 324
Checking cylinder position 324
Checking pilot and main injection timing 324
Checking injection pressure closed cycle 324
Fuel supply 324
Correcting flow rate according to water temperature 324
Correcting flow rate to avoid noise, smoke or overloading 324
De-rating 324
Injection timing electronic test 324
Speed governor 324
Engine starting 324
Cold starting 325
Warm starting 325
Run up 325
After run 325
Cut-off 325
Cylinder balancing 325
Synchronization search 325
OPERATION 326
HYDRAULIC SYSTEM 326
Fuel pipes 326
FEED SYSTEM AND FUEL RECIRCULATION 327
HYDRAULIC SYSTEM 329
Fuel pump 329
”Filtrauto” fuel filter 330
”UFIfilters” fuel filter 331
CP3 2 high-pressure pump 332
Pressure regulator 333
Replacing pressure regulator 333
Hydraulic accumulator (rail) 334
ELECTRO-INJECTORS 335
Operation 335
Replacing an electrical injector 335
ELECTRIC/ELECTRONIC COMPONENTS 336
Electronic control unit EDC 16 336
Glow plug electronic control unit 337
Glow plugs 337
SENSORS 337
Engine speed sensor 337
Camshaft timing sensor 337
Air temperature and pressure sensor 338
Fuel temperature sensor 338
Fuel pressure sensor 338
Atmospheric pressure sensor 338
Engine coolant temperature sensor 338
Throttle pedal position sensor 338
Clutch pedal position sensor 338
Brake pedal position sensor 338
Vehicle speed sensor 338
Differential pressure sensor – delta p (Dp) 338
Exhaust gas temperature sensor 338
ACTUATORS 339
PWM (PulseWidth Modulation) controls 339
SECTION 3 – Clutch 341
Clutch 341
DESCRIPTION 343
DIAGNOSTICS 344
CHARACTERISTICS AND DATA 347
TIGHTENING TORQUES 353
TOOLS 353
CLUTCH REMOVAL AND REFITTING 354
Removal 354
CHECKS 354
Refitting 355
THRUST BEARING REMOVALAND REFITTING 355
HYDRAULIC CLUTCH DRIVE 356
HYDRAULIC CLUTCH DRIVE REMOVAL – REFITTING 358
Removal 358
Refitting 358
PEDAL BOARD REMOVAL – REFITTING 360
Removal 360
Refitting 360
PEDAL BOARD 361
CLUTCH WITH AUTOMATIC WEAR RECOVERY – COMBINED WITH 6 AS’300 VD GEARBOX 362
Description 362
Operation 362
REMOVAL AND REFITTING OFCLUTCH WITH DEVICE RECOVERY COMBINED 364
Removal 364
Refitting 365
CHECKS 364
SECTION 4 – Transmission 367
Transmission 367
DIAGNOSTICS 369
TRANSMISSION REMOVAL – REFITTING 373
Removal 373
Refitting 373
Gear control check and adjustment 374
GEAR CONTROL 376
Flexible cable replacement 376
Removal 376
Refitting 377
GEAR SHIFT LEVER SUPPORT 377
Removal 377
Refitting 377
5 S 300 Transmissions 379
GENERAL 381
GEAR SELECTION AND ENGAGEMENT CONTROL 382
SAFETY DEVICES 383
Engagement locking device 383
Reverse gear anti-engagement device 383
SPECIFICATIONS AND DATA 384
TIGHTENING TORQUES 386
Gearbox unit 386
Gearbox control 387
TOOLS 388
OVERHAULING THE TRANSMISSION 394
Gear control box 394
Disassembly 394
Assembly 395
Selection and adjustment tie-rod assembling 396
Disassembling the transmission 397
Disassembling the rear cover bearings 399
Disassembling the transmission bearings 399
Disassembling the main shaft 400
Drive input shaft 402
Disassembling the transmission shaft 402
CHECKS 405
Transmission 405
Hubs – sliding sleeves – forks 405
Bearings 405
Shafts – gears 405
Synchronizing devices 405
Mounting the transmission shaft 406
Mounting the main shaft 406
Rods – forks – selector – driver 409
Disassembly – assembly 409
Mounting the transmission 409
Adjusting the transmission shaft bearing end float 409
6 S 400 O D Transmission 415
GENERAL 417
GEAR SELECTION AND ENGAGEMENT 418
SPECIFICATIONS AND DATA 420
TIGHTENING TORQUES 422
Gearbox control 423
TOOL 424
OVERHAULING THE TRANSMISSION 432
Gear control box 432
Disassembly 432
Assembly 433
Selection and adjustment tie-rod assembling 434
Disassembling the transmission 435
Disassembling the rear cover bearings 438
Disassembling the transmission bearings 439
Disassembling the main shaft 439
Disassembling the drive input shaft 441
Disassembling the transmission shaft 441
CHECKS 445
Transmission 445
Hubs – sliding sleeves – forks 445
Bearings 445
Shafts – gears 445
Synchronizing devices 445
Mounting the transmission shaft 447
Mounting the main shaft 448
Rods – forks – selector – driver 451
Disassembly – assembly 451
Mounting the transmission 451
Adjusting the transmission shaft bearing end float 451
6 S 400 A O D Transmission 457
GENERAL 459
MAIN COMPONENTS LOCATION 460
MAIN SYSTEM FUNCTIONS 461
Startup/start procedure 461
Check procedures 461
Limp Home 462
Buzzer 462
Start up with tow 462
HILL HOLDER (FUNCTION ONLY AVAILABLE TO VEHICLES WITH ESP8 BRAKING SYSTEM) 463
Functional features 463
SYSTEM STRUCTURE 464
System central unit 464
Clutch actuator 465
Gears actuator 465
Accelerator pedal 466
Display unit 466
Gear selector 467
GEAR SELECTION AND ENGAGEMENT 468
Neutral arrangement and/or 3rd/4th gear selection and engagement arrangement 468
1st/3 rd gear selection election and engagementarrangement 468
5th/6th gear selection and engagement arrangement 469
Reverse gear selection and engagement arrangement 469
Safety device 469
SPECIFICATIONS AND DATA 470
TIGHTENING TORQUES 472
TOOLS 473
DIAGNOSIS 474
Diagnosis instruments 474
MODUS – IT 2000 – E A SY CONNECTION 475
GEARBOX REMOVAL/REFITTING 476
Removal 476
Refitting 479
GEARBOX UNIT OVERHAULING 483
CONTROL UNIT 483
Removal 483
Refitting 484
CLUTCH ACTUATOR 485
Removal 485
Refitting 486
GEARBOX ACTUATOR 486
Removal 486
Refitting 487
CHASSIS WIRING GEARBOX 487
Removal 487
Refitting 488
GEARBOX WIRING -GEARBOX 488
Removal 488
Refitting 489
CALIBRATION 490
Power take off 493
SPECIFICATIONS AND DATA 495
TIGHTENING TORQUES 496
ASSEMBLY STANDARDS 497
POWER TAKE OFF ELECTRIC ACTUATOR 498
Description 498
Operation 498
SECTION 5 – Propeller shafts 501
Propeller shafts 501
CHARACTERISTICS AND DATA 503
DIAGNOSTICS 509
TIGHTENING TORQUES 510
TOOLS 510
PROPELLER SHAFT REMOVAL AND REFITTING 511
Removal 511
Refitting 511
CHECKING PROPELLER SHAFTS ON VEHICLE 511
SECTION 6 – Rear axles 513
Rear axles 513
DIAGNOSTICS 515
Rear axle NDA RS 517
DESCRIPTION 519
SPECIFICATIONS AND DATA 520
TIGHTENING TORQUES 522
TOOLS 525
REAR AXLE NDA – RS REMOVAL – REFITTING 529
Removal 529
Refitting 529
OVERHAULING THE REAR AXLEASSEMBLY 531
Air breather disassembly – assembly 531
Wheel hub overhaul 531
Disassembly 531
Assembly 533
REPAIRING THE DIFFERENTIAL 534
Disassembling the differential unit 534
Gear housing removal 535
Dismounting bevel pinion 536
Checking the parts comprising the differential 537
Assembly of gear housing 538
Assembling the bevel pinion assembly 539
Assembly of differential unit 542
Rear axles NDA RG 547
DESCRIPTION 549
SPECIFICATIONS AND DATA 550
TIGHTENING TORQUES 552
TOOLS 555
OVERHAULING THE REAR AXLE ASSEMBLY OVERHAULING THEREAR AXLE ASSEMBLY 560
Air breather disassembly – assembly 560
Wheel hub overhaul 560
Replacing the wheel hub bearing 561
Disassembly 561
Assembly 561
Rear axles 450511 565
DESCRIPTION 567
SPECIFICATIONS AND DATA 568
TIGHTENING TORQUES 570
TOOLS 573
REAR AXLE REMOVAL – REFITTING 577
Refitting 577
Removal 577
OVERHAULING THE REAR AXLE ASSEMBLY 579
Wheel hub overhaul 579
Replacing the wheel hub bearing 580
DIFFERENTIAL REPAIR OPERATIONS 583
Disassembly of differential locking 583
Assembling the differential locking device 583
Differential locking removal 583
Differential locking refitting 583
Adjusting the differential locking device 584
Disassembling the differential unit 584
Disassembly of gear housing 585
Assembly of gear housing 587
Assembling bevel pinion unit 587
Differential unit refitting 591
Rear axle 450517/2 595
DESCRIPTION 597
CHARACTERISTICS AND DATA 598
TIGHTENING TORQUES 600
TOOLS 602
REAR AXLE REMOVAL – REFITTING 607
Removal 607
Refitting 607
OVERHAUL OF REAR AXLE 609
Air breather disassembly – assembly 609
Overhaul of wheel hubs 609
Disassembly 609
Stud replacement 611
DIFFERENTIAL REPAIR OPERATIONS 614
Differential locking 614
Differential unit removal 615
Gearing case removal 615
Differential components check 617
Rear axle casing check 617
Gearing case refitting 617
Differential unit refitting 621
SECTION 7 – Axles 625
Axles 625
DIAGNOSTICS 627
Axle 5817 631
DESCRIPTION 633
SPECIFICATIONS AND DATA 634
TIGHTENING TORQUES 635
TOOLS 636
REMOVING AND REFITTING AXLE 5817 637
Removal 637
Refitting 637
REPAIRS 639
OVERHAULING AXLE 5817 639
Wheel hub removal and refitting 639
Removal 639
Replacing phonic wheel 640
Refitting 640
STUB AXLE REMOVAL-REFITTING 641
Removal 641
Refitting 643
Axle 5818 645
DESCRIPTION 647
SPECIFICATION AND DATA 647
TIGHTENING TORQUES 647
TOOLS 649
OVERHAULING AXLE 5818 650
Replacing phonic wheel 651
Refitting 651
STUB AXLE REMOVAL AND REFITTING 652
Axle 5819 653
DESCRIPTION 655
SPECIFICATION AND DATA 656
TIGHTENING TORQUES 657
TOOLS 658
REPAIR OPERATIONS 659
AXLE 5819 OVERHAUL 659
Stub axle removal and refitting 659
Removal 659
Refitting 659
Axle 5823 661
DESCRIPTION 663
SPECIFICATION AND DATA 664
TIGHTENING TORQUES 665
TOOLS 666
REMOVING AND REFITTING AXLE 5823 667
Removal 667
Refitting 668
AXLE 5823 OVERHAUL 669
Wheel hub removal and refitting 669
Removal 669
Replacing phonic wheel 670
Refitting 670
Wheel geometry 673
DESCRIPTION 675
WHEEL GEOMETRY 677
SPECIFICATIONS AND DATA 677
TIGHTENING TORQUES 677
TOOLS 678
CHECKING CHARACTERISTIC ANGLES 679
Positioning jaws and projectors 679
Electronic balancing of rim eccentricity 680
Wheel alignment 680
Checking toe-in 681
Front wheel deviation test (vehicle wheelbase check) 681
Checking camber 682
Checking king-pin angle and caster angle 682
Checking steering angles 683
Checking rear axle alignmen 683
Checking rear axle alignment 683
Calculating thickness of spacers to be fitted between tie rod mountings and chassis side members (with the exception of vehicles equipped with 5-mm thick chassis or with transverse leaf-spring suspension) 684
SECTION 8 – Suspensions 685
Suspensions 685
Front and rear mechanical suspensions 687
DIAGNOSTICS 689
Front mechanical suspensions 693
DESCRIPTION 695
SPECIFICATIONS AND DATA 696
Front leaf spring 696
Front shock absorbers 698
Front stabilizer bar 698
TOOLS 698
TIGHTENING TORQUES 699
Vehicles 29 L – 35 S 699
TIGHTENING TORQUES 700
Vehicles 35 C 700
TIGHTENING TORQUES 701
Vehicles 29 L – 35 S – 35C 701
REPAIRS 702
Check the clearance of upper swinging armarticulated head 702
Check the clearance of lower swinging armarticulated head 703
OVERHAULING THE SUSPENSION 703
Suspension arms 703
Removal 703
Replacing suspension arm bushings 703
Disassembly 703
Assembly 704
Refitting 704
FRONT SHOCK ABSORBERS 704
Removal 704
Refitting 705
LEAF SPRING 707
Removal 707
Refitting 708
TORSION BAR SUSPENSION (Axle 5819 – vehicles 35C – 40C – 45C – 50C) 709
Description 709
SPECIFICATIONS AND DATA 710
Front shock absorbers 710
Stabilizer bar diameter 710
TOOLS 711
TIGHTENING TORQUES 713
Vehicles 35 C – 40 C – 45 C – 50 C 713
REPAIRS 715
Check the clearance of upper swinging armarticulated head 715
Check the clearance of lower swinging armarticulated head 716
OVERHAULING THE SUSPENSION 717
TIE RODS 717
Removal 717
Replacing swivel heads 717
Refitting 718
TORSION BARS 718
Removal 718
Replacing silentbloc and limit stops 719
Replacing link pins 719
Refitting 720
Adjusting torsion bar pre-load 722
STABILIZER BAR 723
Removal 723
Refitting 723
FRONT SHOCK ABSORBERS 723
Removal 723
Refitting 723
TORSION BAR SUSPENSION (Axle 5823 – vehicles 60C – 65C) 725
Description 725
SPECIFICATIONS AND DATA 726
Front shock absorbers 726
Stabilizer bar 726
TIGHTENING TORQUES 727
TOOLS 729
REPAIR OPERATIONS 730
SUSPENSION OVERHAUL 730
Lower tie rod articulated heads replacement 730
TORSION BARS 730
Removal 730
Rubber bush replacement 731
Removal 731
Refitting 731
Torsion bar preload adjustment 734
Rear mechanical suspensions 735
DESCRIPTION 737
CHARACTERISTICS AND DATA 738
Rear leaf spring 738
Rear shock absorbers 755
TOOLS 756
TIGHTENING TORQUES 757
Vehicles 29 L – 35 S 757
Vehicles 35 C – 40 C – 45 C- 50 C 758
Vehicles 60C – 65C 759
REAR LEAF SPRING 760
Vehicles: 29 L – 35 S 760
Removal 760
Refitting 760
Vehicles: 35 C – 40 C – 45 C – 50 C – 60 C – 65 C 761
Removal 761
Refitting 761
REPAIRS 762
Disassembling the leaf spring 762
Checks 762
Assembling the leaf spring 762
Replacing the bushings 762
REAR SHOCK ABSORBERS 763
Removal 763
Refitting 763
STABILIZER BAR 764
Removal 764
Refitting 764
Rear air suspensions 765
DIAGNOSTIC 767
GENERAL 768
PNEUMATIC SUSPENSIONS -WABCO TYPE (for 29L – 35S vehicles) 768
SPECIFICATIONS AND DATA 769
Air system components 769
Rear leaf spring 770
Rear shock absorbers 770
Stabilizer bar 770
Levelling and height values 770
ELECTRIC SYSTEM WABCO (ECAS) 771
PNEUMATIC SYSTEM WABCO (ECAS) 772
PNEUMATIC SYSTEM ON VEHICLE 773
Vehicles without ABS 773
Vehicles with ABS 774
CHASSIS SELF-LEVELLING, LIFTING AND LOWERING 775
Operation 775
MAIN SYSTEM COMPONENTS 775
PNEUMATIC SUPPLY UNIT 775
Specifications and data 775
ELECTRONIC CONTROL UNIT 775
ECU programming/setting 776
LEVEL SENSOR 776
Level sensor replacement 776
Removal 776
Refitting 776
Level sensor adjustment 776
AIR SPRING 777
Air spring replacement 777
Removal 777
Refitting 777
LOAD SENSING VALVE 777
Load sensing valve replacement 778
Removal 778
Refitting 778
Load sensing valve adjustment on vehicle 778
REAR SUSPENSION OVERHAUL 779
LEAF SPRING 779
Removal 779
Refitting 779
REAR SHOCK ABSORBERS 779
Removal 779
Refitting 779
REAR STABILIZER BAR 779
Removal 779
Refitting 779
PANHARD REACTION BAR 780
Removal 780
Refitting 780
SECTION 9 – Wheel and tyres 781
Wheel and tyres 781
DESCRIPTION 783
Tyre pressure 784
TOOLS 785
FAULT DIAGNOSIS 785
STATIC WHEEL BALANCING 788
TYRE PRESSURE 789
HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE 789
SECTION 10 – Steering gear 791
Steering gear 791
STEERING GEAR 793
General 793
POWER STEERING SPECIFICATIONS AND DATA 794
Steering gear 794
TIGHTENING TORQUES 795
SPECIFIC TOOLS 795
DIAGNOSTICS 796
POWER STEERING 801
Description 801
POWER STEERING TYPE TRW 802
Operation 802
POWER STEERING TYPE ZF 804
Operation 804
CHECKS AND OPERATIONS ON THE VEHICLE 806
Checking maximum pressure 806
Checking hydraulic steering centre (for ”ZF”power steering only) 806
Bleeding the air from the hydraulic system 806
SWIVEL HEADS 806
PROTECTION CASINGS 806
STEERING GEAR CONTROL 806
Vehicles equipped with an Air-Ba 806
SAFETY STANDARDS TO BE OBSERVED DURING REPAIR OR MAINTENANCE OPERATIONS ON VEHICLES EQUIPPED WITHAIR-BAG SYSTEM PROVIDED BY SUPPLIER 807
Preliminary Standards 807
Repairs and inspections required after anaccident 807
Accidents with or without Air-Bag module activation 807
Accidents with Air-Bag module activation 807
Painting 808
Risks for health 808
Overexposure effects 808
Safety Standards to observe when handling Air-Bag modules 808
Air-Bag module scrapping 809
Safety Standards to observe when handling pretensioners 809
Pretensioners scrapping 810
Operations on system components 810
Removing and scrapping activated Air-Bagmodule and pretensioner from vehicle 810
Removing and scrapping non-activated Air-Bag module from a repairable vehicle 810
Air-Bag module deployment Remote activation 811
Activating Air-Bag modules and electronic pretensioners installed on unrecoverable vehicles 811
Upper steering gear shaft removal 813
For vehicles equipped with Air-Bag 813
For all vehicles 813
Refitting 814
Lower steering gear shaft removal 814
Refitting 815
HYDRAULIC POWER STEERING 815
Hydraulic power steering removal 815
Refitting 815
HYDRAULIC POWER STEERING 815
Hydraulic power steering removal 815
Refitting 815
Steering linkage replacement 816
Removal 816
Refitting 816
Rubber bushing replacement procedure 816
POWER STEERING PUMP 817
Power steering pump overhaul procedure 817
SECTION 11 – Hydro-pneumatic system – Brakes 819
Hydro-pneumatic system – Brakes 819
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (MISCELLANEOUS AND GENERATORS) 823
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES) 824
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS) 830
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALIPERS) 831
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALIPERS AND CYLINDERS) 832
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING HEADS) 833
GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES) 835
PIPES AND COUPLINGS 837
General 837
Re-flanging rigid pipes 837
Bending rigid pipes 838
Cutting rigid pipes 838
Replacing flexible hoses with threaded couplings 839
Replacing flexible hoses with quick release couplings 840
BRAKING SYSTEM 842
Outline diagram for vehicles 29L – 35S without ABS 842
Outline diagram for vehicles 29L – 35S with ABS 8 843
Outline diagram for vehicles 29L – 35S with ESP 8 844
Outline diagram for vehicles 35C – without ABS 845
Outline diagram for vehicles 35C with ABS 8 846
Outline diagram for vehicles 35C with ESP 8 847
Outline diagram for vehicles 40C – 45C – 50C – 60C – 65C with ABS 8 848
Outline diagram for vehicles 40C-45-50C-60C-65 with ESP 8 849
Braking system main components layout 850
Location of the main brake system components on vehicles with ABS 852
Location of the main brake system components on vehicles with ESP 854
DESCRIPTION 855
Service brake 855
Emergency brake 855
Parking brake 855
BRAKES 855
Front and Rear disc brakes 855
FAULT DIAGNOSIS 856
Diagnosis Instruments 856
TIGHTENING TORQUES 864
TOOLS 866
SPECIFICATIONS AND DATA – HYDRAULIC SYSTEM 869
SPECIFICATIONS AND DATA – BRAKES 870
CHECKS 872
Functional check of vacuum brake system 872
BRAKING SYSTEM MAIN COMPONENTS 873
Vacuum pump 873
Vacuum servo brake 873
Bleeding air from the hydraulic circuit (vehicles not equipped with ABS) 874
Bleeding air from the hydraulic circuit with deaerator device (vehiclesnot equipped with ABS) 874
Air bleeding from the ABS/ESP system hydraulic circuit 875
ABS 8/ESP 8 system bleeding procedure sequence 876
Mechanically controlled load sensingvalve (vehicles 35C) 877
Regulation of load proportioning valve on vehicle 877
Dual mechanically controlled load sensing valve (vehicles 29L – 35S) 878
Adjusting the load sensing valve 878
STABILITY CONTROL AND ANTI-SKID DEVICES 879
ABS SYSTEM FUNCTIONS 879
Antilock braking system (ABS) 879
Electronic braking distribution device (EBD) 879
Electronic Stability Program (ESP) – Option 879
FUNCTIONS INCLUDED IN THE ESP SYSTEM ONLY 879
Acceleration drive control device (ASR) 879
Engine braking torque control (MSR) 879
Hill holder control (HHC) 879
Hydraulic Brake Assistant (HBA) 879
Electro-hydraulic modulator/control unit for 29L – 35S vehicles ) 880
Electro-hydraulic modulator/control unit for 29L – 35S vehicles ) 881
Rev sensor 882
Phonic wheels 882
ESP SYSTEM SENSORS 882
Yaw sensor with built-in side acceleration sensor 882
Longitudinal acceleration sensor 882
Steering angle sensor 882
BRAKE REPAIR OPERATIONS 883
Front brakes 883
Replacing brake linings 883
Checks 884
Removal/Re-fitting of brake calipers 885
REAR BRAKES 886
Removal/Refitting of brake calipers 886
Checks 887
Removal/Refitting brake calipers 888
OVERHAUL OF BRAKE CALIPERS 888
2×44 – 2×48 – 2×60 Brembo brake calipers 888
1×52 – 1×60 Brembo brake calipers 889
OVERHAUL OF BRAKE DISCS 890
MACHINING AND GRINDING OFDISC BRAKES 890
OVERHAULING PARKING BRAKE 891
WHEEL NUT TIGHTENING SEQUENCE 891
Assembly 893
Adjusting parking brake 893
STEERING ANGLE SENSOR 894
Replacing 894
REPLACING THE ESP COMPONENTS 894
Calibration 894
LONGITUDINAL ACCELERATION SENSOR 895
Removal 895
Refitting 895
Calibration 895
YAW SENSOR 896
Removal 896
Refitting 896
Calibration 896
ELECTROHYDRAULIC MODULATOR/CONTROL UNIT 897
Removal 897
Refitting 897
Programming 897
Calibration 897
Bench overhauling 898
Disassembly 898
Assembly 898
SECTION 12 – Bodywork – Chassis Frame – Cab air-conditioning 899
Bodywork – Chassis Frame – Cab air-conditioning 899
SAFETY STANDARDS TO OBSERVE WHEN WORKING ON VEHICLES EQUIPPED WITH THE AIR-BAG SYSTEM 901
CAB AIR-CONDITIONING 901
General 901
VENTILATION 901
Description 901
AIR-CONDITIONING SYSTEM MAIN COMPONENTS AND FUNCTIONAL DIAGRAM 902
AIR-CONDITIONING AND HEATING 902
Description 902
Air-conditioning 902
Heating 902
MAIN COMPONENTS 903
Compressor 903
Condenser 903
Drier filter 904
Expansion valve 904
Evaporator 904
CONTROL AND SAFETY DEVICES 905
Description 905
Three-level pressure switch 905
Outside air temperature sensor 905
AIR-CONDITIONING UNIT (“M MARELLI” OR “DENSO” TYPE) 906
General 906
Electronic control unit 906
”M MARELLI” TYPE HEATER/AIR-CONDITIONER UNIT 907
Components 907
HEATER UNIT 908
Components 908
PROCEDURE FOR EMPTYING ANDREFILLING THE AIR-CONDITIONING SYSTEMS WITH R134A REFRIGERANT 909
R134A refrigerant recovery and refillingstation (99305146) 909
CONTROL FASCIA 910
SAFETY STANDARDS 912
OPERATION FLOW CHART 913
RECOVERING REFRIGERANT FROM THE VEHICLE SYSTEM 914
CREATING A VACUUM IN THE SYSTEM 916
RESTORING OIL IN THE SYSTEM 918
FILLING THE SYSTEM WITH REFRIGERANT 919
CHECKING THE PRESSURES IN THE SYSTEM 921
OPERATIONS PRIOR TO DISCONNECTING THE STATION FROM THE SYSTEM 921
LEAK FINDER FOR AIR-CONDITIONING SYSTEMS WITH HFC R134A (9905147) 921
SECTION 13 – Scheduled maintenance 923
Scheduled maintenance 923
MAINTENANCE 925
Table of maintenance services 925
F1A ENGINE VEHICLES 926
Inspection and/or maintenance interventions (F1A engine vehicles) 926
Extra plan operations 927
F1C ENGINE VEHICLES 928
Inspection and/or maintenance interventions 928
Extra plan operations 929
DIAGRAM OF CHECK AND/OR MAINTENANCE POINTS 930
MAINTENANCE OPERATIONS 931
SECTION 14 – Electric/Electronic system 937
Electric/Electronic system 937
ABBREVIATIONS AND GRAPHIC SYMBOLS 941
GENERAL WARNINGS 942
TECHNICAL CODES 946
POWER NETWORK 950
POSITIVE NETWORK (CBA) 951
INSTRUMENT PANEL INTERCONNECTION CENTRAL UNITS (CPL) “75002” 953
Fuses / remote control switches identification 955
Internal electrical scheme 956
Junction connectors 957
Junction connector “L” 958
Junction connector “M” 959
Junction connector “R” 960
Junction connector “H” 961
ENGINE OPENING CENTRAL UNIT (CVM) “75001” 962
Fuses / remote control switches identification 963
Internal electrical scheme 965
Junction connectors 966
Junction connectors “A” 967
Junction connectors “C” 968
Junction connectors “B” 968
Junction connectors “D” 969
Junction connectors “E” 969
Junction connectors “F” 969
NEGATIVE NETWORK 970
EARTH POINTS 970
BATTERY (20000) 973
BOSCH KCBI 14V 110A ALTERNATOR 974
EV 12V – 2 3 KW STARTER MOTOR 975
JUNCTION WELDS 976
WIRING HARNESS SECTION 978
Description 978
JUNCTION CONNECTORS 981
Bonnet – instrument panel junction (600/601H) 981
Bonnet – instrument panel junction (600/601B) 982
Bonnet – instrument panel junction (600/601D) 983
Bonnet – instrument panel junction (600/601G) 984
Bonnet – instrument panel junction (600/601A) 985
Bonnet – instrument panel junction (600/601C) 986
INSTRUMENT CLUSTER (58919) 987
Junction connector 988
Display screen 989
STEERING COLUMN SWITCH UNIT (54030) 990
CENTRAL INSTRUMENT PANEL 991
INSTRUMENT PANEL SWITCH ASSEMBLY (53807) 992
OPTIONAL BOX 993
Fuses / remote control switches identification 994
OPT central unit Pin-Out 995
“CAN LINES” SYSTEM DESCRIPTION 996
“C” CAN line 997
“B” CAN line 998
BODY COMPUTER – (86116) 999
Description 1000
Black cab junction connector “LN” 1002
Blue instrument panel junction connector “PF” 1004
Blue bonnet junction connector “AV” 1005
FITTER CONNECTOR (61071) 1007
FITTER CONNECTOR (72068) 1008
ELECTRONIC INJECTION EDC16 1009
Particular features of engines Euro 4 1009
System to reduce pollutants at exhaust 1010
General 1010
E G R (Exhaust Gas Recirculation) SYSTEM 1011
Operation 1011
Main system components 1011
E G R valve 1011
Modulator solenoid valve 1011
Air flow rate meter (flow meter) 1011
D P F (Diesel Particulate Filter) CATALYST 1012
Description 1012
Particulate filter (components location) 1013
Throttle valve assembly 1014
REPLACING THE COMPONENTS 1015
Replacing particulate filter 1015
Replacing flow meter 1016
Replacing rail pressure sensor in hydraulic accumulator 1016
Replacing delta-p sensor 1016
Replacing engine oil 1016
Replacing an injector 1017
Electronic injection control 1018
EDC system components 1022
Bosch EDC16 control unit 1024
Control unit connection to the injection cable on engine side (housing A) 1025
Control unit connection to cab-bonnet cable (housing K) 1027
Accelerator pedal sensor 1029
Brake pedal switches (53501) 1030
Clutch pedal switch (42374) 1030
Preheat plug electronic centre (F1A/F1C engine) 1031
Preheat plugs 1031
R p m / timing sensors (F1C) 1032
Timing sensor (stroke) (F1C) 1033
RPM sensor 1034
Timing sensor 1035
Pressure regulator 1036
Rail (pressure accumulator) F1C 1037
Pressure sensor 1037
Air temperature/pressure sensor 1038
Atmospheric pressure sensor 1039
Engine coolant temperature sensor 1039
Fuel temperature sensor 1039
Injectors 1040
Electromagnetic junction fan 1041
Camshaft sensor (F1A) 48042 1042
Flywheel and rpm sensor 1043
Characteristics of flywheel rpm and timing system sensors 1043
Pressure regulator 1044
Rail (pressure accumulator) F1A 1045
Pressure sensor 1045
Injectors 1046
Air temperature / pressure meter 1047
Electromagnetic junction fan 1048
FUEL FILTER 1049
FUEL PUMP / FUEL LEVEL 1050
ABS 8/ESP 8 1051
The ABS 8 system integrates the following functions 1051
The ESP 8 system, in addition to the EBS 8 system, incorporates the following functions 1051
Four crossed channel system (x) 1052
Electro-hydraulic modulator/control unit 1052
Four parallel channel system (II) 1053
Electro-hydraulic modulator/control unit 1053
ABS 8 control unit PIN OUT (X – crossed channels, II – parallel channels) 1054
ESP 8 control unit PIN OUT (X – crossed channels, II – parallel channels) 1055
PIN OUT of central unit ASR 8 (4 channels -X) 1056
(4 channels -II) 1057
ESP (Electronic Stability Program) operation 1058
Control strategy 1058
Sudden obstacle 1058
Sudden steering 1059
Vehicle running on a slippery road 1059
ASR deactivation strategies 1060
Recovery strategy in case of component failure 1060
Warning light legend 1061
Installing the esp components 1061
ESP system components and calibration 1062
Yaw sensor with built-in side acceleration sensor 1062
Longitudinal acceleration sensor 1063
Longitudinal acceleration sensor calibration 1063
Steering angle sensor 1064
Steering angle sensor calibration 1064
ESP control unit programming 1065
AIR BAG 1066
General 1066
SYSTEM OPERATION 1066
INTERVENTION LOGICS 1068
Preliminary rules 1069
Operations after an accident 1070
Painting work 1070
Health hazards 1070
Effects of over-exposure 1070
Rules of safety in handling air bag modules 1071
Air bag module scrapping 1071
Rules of safety in handling pretensioners 1072
Scrapping pretensioners 1072
Operations on system components 1073
Removing and scrapping an activated air bagmodule and pretensioner from a vehicle 1073
Removing or scrapping an air bagmodule thathas not been deployed from a reparable vehicle 1073
Deployment of an air bag 1074
Deployment of air bag modules and electronic pretensioners still on board of irreparable vehicles 1075
DE-ACTIVATING PASSENGER AIR-BAG 1077
Electronic control unit 1078
Central unit Pin Out 1079
SPIRAL CONTACT 1080
PRETENSIONERS 1081
Operation principle 1081
CURTAIN AIR BAG 1082
COMPONENT REPLACEMENT INTERVENTIONS 1083
Electronic central unit 1083
Drive side air bag module 1084
Passenger side air bag module 1084
Spiral contact 1085
IMMOBILIZER 1086
Operation description 1087
Keys 1087
Body computer 1088
Antenna 1089
Warning lamp 1089
IMMOBILIZER NEW PROCEDURES 1090
6AS 400 A O D VD AUTOMATIC TRANSMISSION 1091
Description of operation 1091
Electronic management 1092
COMPOSITION OF THE SYSTEM 1093
System control unit 1093
Connector control unit PIN-OUT – gearbox side (A) 1094
Connector control unit PIN-OUT – vehicle side (B) 1095
Gearbox actuator 1096
Clutch actuator 1098
Accelerator pedal 1100
Gear selector 1101
REMOTE CONTROL SWITCHES / FUSES ASSEMBLY 1102
PTO 1103
PTO engaging procedure 1104
PTO disengaging procedure 1104
Display screen 1105
DIAGNOSIS (CONNECTOR EOBD) 1107
CIRCUIT CARDS 1109
Card 1: Power network 1111
Card 2: Cab interior components 1112
Card 3: Window winders – Electric mirrors 1113
Card 4: Cab interior components 1114
Card 5: Various loads 1115
Card 6A: Telma decelerator 1116
Card 6B: Differential locking – Heated rear window and windscreen 1117
Card 7A: Air spring suspension 1118
Card 7B: Additional heater – Power take-off 1119
Card 8: Cruise control – Climate control system 1120
Card 9A: Automatic gearbox 1121
Card 9B: ESP 8 1122
Card 10: External illumination 1123
Card 11A: ASR 1124
Card 11B: Camera 1125
Card 12: External illumination 1126
Card 13A: AIR BAG 1127
Card 13B: ABS8 1128
Card 14A: EDC 16 1129
Card 14B: EDC 16 1130
Card 15B: Cab interior components 1131
Card 16: “CAN” lines 1132
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