Iveco Daily Workshop Manual PDF

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DAILY EURO 4 REPAIR MANUAL MECHANICAL ELECTRIC/ELECTRONIC IVECO expert22 для http://rutracker.org

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B.U.TECHNICALPUBLISHING IvecoTechnicalPublications LungoSturaLazio,15 10156Torino(TO)-Italy Producedby: ”Thisdocumentprovidesdata,characteristics,instructionsand methodologytoperformrepairinterventionsonthevehicle anditscomponents. Anyhow, this document is addressed to qualified and specialised personnel. Iveco commercial and assistance networkpersonnelaswellasallIvecoauthorisedpointsof assistancearespecificallyqualifiedandequippedtoperform therepairinterventionsthatareindicatedinthisdocument. Beforeperforminganyintervention,checktohaveavailable thedocumentrelatingtothevehiclemodelonwhichthe interventionisbeingperformedandalsomakesurethatall accidentpreventiondevices,suchas,asaroughguide,goggles, helmet, gloves, shoes, as well as work tooling, lifting and transporttooling,etc.,areavailableandefficient,andfurther make sure that the vehicle is put such a way that an interventioncanbemadeinsafetyconditions. Makinginterventionsstrictlyobservingtheindicationsgiven here, as well as using specific tooling indicated, assures a correctrepairintervention,executiontimingobservanceand operators’safety. Eachrepairinterventionmustbefinalisedtotherecoveryof functionality,efficiencyandsafetyconditionsthatareprovided byIveco. Each intervention, on the vehicle, that is finalised to a modification,alterationorelse,whichisnotauthorisedby Iveco,involvestheexclusionofanyresponsibilityforIveco, and,inparticular,wherethevehicleiscoveredbyaguarantee, eachsuchinterventioninvolvesanimmediatelapseofthe guarantee. ResponsibilityforIvecoinrepairinterventionexecutionis excluded. Ivecoisavailabletoprovideallclarificationsnecessarytomake interventions,aswellastoprovideindicationsincasesand situationsnotincludedinthisdocument. Dataandinformationcontainedinthisdocumentcouldresult nottobeupdatedowingtomodificationsmadebyIvecoat anymomentfortechnicalorcommercialreasons,orbecause of the need to adapt the vehicle tolaw requirementsin differentcountries. Inthecaseofadifferencebetweenwhatcontainedhereand what actually found on the vehicle, please contact Iveco networkbeforemakinganyintervention.” Thedatacontainedinthispublicationmightfailtoreflectthe latestchangeswhichtheManufacturermayintroduceatany time, for technical or sales purposes, or to meet the requirementsoflocallegislation. Copy,evenpartial,oftextanddrawingsisforbidden. PublicationEditedby: IVECOS.p.A. CustomerService LungoSturaLazio,15 10156Torino(TO)-Italy Print 603.93.651 - 1 st Ed.2006

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ManualsforrepairsaresplitintoSections,eachoneofwhichismarkedbyanumeral;thecontentsofthesesectionsareindicated inthegeneraltableofcontents. EachsectionisgenerallydedicatedtoamainUnit(e.g.:engine,gearbox,electricsystem,etc.). Sectionswithmechanicalcontentsincludetechnicaldata,tighteningtorquecollections,toollists,connections—disconnectionsof unitsto/fromthevehicle,overhaulsatthebenchandrelatingtroubleshooting. Ontheelectric/electronicsystemsectiontherearethedescriptionsoftheelectricnetworkandvehicleelectronicsystems,electric schemes,componentselectriccharacteristics,componentscodesand troubleshootingrelatingtothecentralunitsspecificofthe electricsystem. Themanualusespropersymbolsinitsdescriptions;thepurposeofthesesymbolsistoclassifycontainedinformation.Inparticular, therehavebeendefinedasetofsymbolstoclassifywarningsandasetforassistanceoperations. PRELIMINARY REMARKS General danger Itincludesthedangersofabovedescribedsignals. Danger of serious damage for the vehicle Partialorcompletenonobservanceoftheseprescriptionscancauseseriousdamagestothevehicleandsometimes guaranteelapsetoo. Environment protection Itindicatescorrectbehaviourinorderthatvehicleuseisenvironmentallyfriendlyasmuchaspossible. Danger for persons Missingorincompleteobservanceoftheseprescriptionscancauseseriousdangerforpersons’safety. SYMBOLS - WARNINGS Itindicatesanadditionalexplanationforapieceofinformation. ! NOTE Print603.93.651 Base-March2006 I

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Base-March2006 Print603.93.651 II SYMBOLS - ASSISTANCE OPERATIONS Removal Disconnection Intake Refitting Connection Exhaust Removal Disassembly Operation Fittinginplace Assembly ρ Compressionratio Tightentotorque Tolerance Weightdifference α Tightentotorque+anglevalue Rollingtorque Pressorcaulk Rotation Regulation Adjustment Angle Angularvalue Visualinspection Fittingpositioncheck Preload Measurement Valuetofind Check Numberofrevolutions Equipment Temperature Surfaceformachining Machinefinish bar Pressure Interference Strainedassembly Oversized Higherthan … . Maximum,peak Thickness Clearance Undersized Lessthan … . Minimum Lubrication Damp Grease Selection Classes Oversizing Sealant Adhesive Temperature<0 ° C Cold Winter Airbleeding Temperature>0 ° C Hot Summer Replacement Originalspareparts

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Eachtitleorsubtitleconcerningoperationsbeingperformedisprecededbyasix-figurenumbernamedPRODUCTCODE. Thisnumberrepresentsthe PRODUCT CODE referredtobytherepairoperationcontainedinbothREPAIRTIMESand TROUBLECODEdocument. Asaquickreferencethereareshownbelowtheguidelinestoreadthiscode(seeRepairTiming,too). ProductCode: ThefirstandsecondfiguresidentifythePRODUCTwithinmotorvehicle. Example: Product 50 = Vehiclechassis; Product 52 = Axles; Product 53 = Transmission; Product 76 = Electricssystem. UnitCode: ThethirdandfourthfiguresidentifytheUNITwithinthePRODUCT. Example: Product 50 = Vehiclechassis; Unit 01 = Chassis; Unit 02 = Bumpers; Unit 03 = Alternator. Sub-assemblyCode: ThefifthandsixthfiguresexactlyidentifytheSUB-ASSEMBLYandComponentofaUnitwithinaPRODUCT. Example: Product 50 = Vehiclechassis; Unit 01 = Chassis; Sub-assembly40 = Chassiscrossmembers; Sub-assembly13 = Rotor. PRODUCT CODE 5 0 PRODUCT UNIT SUB-ASSEMBLY COMPONENT 0 1 4 0 7 6 0 3 1 3 PRODUCT UNIT SUB-ASSEMBLY COMPONENT PRODUCT UNIT SUB-ASSEMBLY COMPONENT PRODUCT UNIT SUB-ASSEMBLY COMPONENT PRODUCT UNIT SUB-ASSEMBLY COMPONENT PRODUCT UNIT SUB-ASSEMBLY COMPONENT Print603.93.651 Base-March2006 III

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GENERAL WARNINGS Warningsshowncannotberepresentativeofalldangersituationspossiblyoccurring.Therefore,itissuggestedtocontact immediatesuperiorswhereadangersituationoccurswhichisnotdescribed. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenancehandbooks.Checkusestateandsuitabilityoftoolsnotsubjectedtoregularcheck. Themanualhandlingofloadsmustbeassessedinadvancebecauseitalsodepends,besidesweight,onitssizeandon thepath. Handlingbymechanicalmeansmustbewithhoistersproperasforweightaswellasforshapeandvolume.Hoisters, ropesandhooksusedmustcontainclearindicationsonmaximumcarryingcapacityacceptable.Theuseofsaidmeans iscompulsorilypermittedtoauthorisedpersonnelonly.Staydulyclearoftheload,and,anyhow,neverunderit. Indisassemblingoperations,alwaysobserveprovidedprescriptions;preventmechanicalpartsbeingtakenoutfrom accidentallystrikingworkshoppersonnel. Workshopjobsperformedinpairsmustalwaysbeperformedinmaximumsafety;avoidoperationswhichcouldbe dangerousfortheco-operatorbecauseoflackofvisibilityorofhis/hernotcorrectposition. Keeppersonnelnotauthorisedtooperationsclearofworkingarea. Learnoperationandsafetyknowledgenecessaryrelatingtothevehiclepriortoeachinterventiononit.Scrupulously observeallsafetywarningsonthevehicle.Applysuitablesignalsforthevehiclesbeingrepaired.Oncetherepair interventionhasbeencompleted,beforestartingupthevehicle,performallchecksindicatedonparagraph“Controls careofuser”ofUseandMaintenancehandbook. Inlackofvisibilityinoperatingfromthevehicle,chargeapersononthegroundwithassistance.Donotleaveunmanned avehicleinmotionduringrepairinterventions. Keepthevehiclestationarybyproperchocks. Inthecaseofaninterventiononavehicleliftedfromtheground,checkthevehicletobequitesteadyonspecialsupport standsand,inthecaseofliftingbymeansofalift,checkmanual/automaticsafetiestobeactivated. Whenitisnecessarytoperformaninterventiononmethane-fedvehicles,observetheindicationscontainedinsidethe document,aswellasallspecificsafetyregulationsprovided. Onlyremoveradiatorcapwhentheengineiscoldbycautiouslyunscrewingitinordertoletsystemresidualpressure out. Inflammablefuelandallinflammablefluidsandliquidsmustbehandledwithcare,accordingtowhatcontainedonharmful materials12-pointcards.Refuellingmustbeperformedoutdoorswiththeengineoff,avoidinglitcigarettes,freeflames orsparksinordertopreventsuddenfires/bursts.Adequatelystoreinflammable,corrosiveandpollutingfluidsandliquids accordingtowhatprovidedbyregulationsinforce.Compulsorilyavoidtousefoodcontainerstostoreharmfulliquids. Avoidtodrillorborepressurisedcontainers,andthrowclothsimpregnatedwithinflammablesubstancesintosuitable containers. Wornout,damagedorconsumablepartsmustbereplacedbyIvecooriginalspares. Duringworkshopactivity,alwayskeeptheworkplaceclean;timelyclearorcleanfloorsfromaccidentalliquidoroilspots. Electricsocketsandelectricequipmentnecessarytoperformrepairinterventionsmustmeetsafetyrules. Foreveryinterventiononvehiclehydraulic,pneumatic,conditioningandAIR-BAGsystems,scrupulouslyobserve indicationsspecifiedinrelatingmanualsections. ! Base-March2006 Print603.93.651 IV

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GENERAL WARNINGS Cleanunitsorassembliesdetachedfromthevehicleandcarefullychecktheirintegritybeforeoverhaul.Tidyupdetached ordisassembledpartswiththeirsecuringelements(screws,nuts,etc.)intospecialcontainers. Checkfortheintegrityofthepartswhichpreventscrewsfrombeingunscrewed:brokenwashers,dowels,clips,etc. Self-lockingnutswithaninsertmadeofnylonmustalwaysbereplaced. Avoidcontactofrubberpartswithdieseloil,petrolorothernotcompatiblesubstances. Beforewashingunderpressuremechanicalparts,protectelectricconnectors,andcentralunits,ifpresent. Tighteningscrewsandnutsmustalwaysbeaccordingtoprescriptions;IVECOcommercialandassistancenetworkis availabletogiveallclarificationsnecessarytoperformrepairinterventionsnotprovidedinthisdocument. Beforewelding: -Disconnectallelectroniccentralunits,takepowercableoffbatterypositiveterminal(connectittochassisbonding) anddetachconnectors. -Removepaintbyusingpropersolventsorpaintremoversandcleanrelevantsurficeswithsoapandwater. -Awaitabout15minutesbeforewelding. -Equipwithsuitablefireresistantprotectionstoprotecthosesorothercomponentswherefluidsorothermaterials flowwhichmaycatchfireeasilyonwelding. Shouldthevehiclebesubjectedtotemperaturesexceeding80 ° C(dryerovens),disassembledriveelectroniccentral units. Thedisposalofallliquidsandfluidsmustbeperformedwithfullobservanceofspecificrulesinforce. Puton,whererequiredbytheintervention,garmentsandprotectionsprovidedinaccidentpreventionrules;contact withmovingpartscancauseseriousinjuries.Usesuitable,preferablytight-fittedgarments,andavoidtousejewels, scarves,etc. Donotleavetheengineinmotionatworkshoplocationsnotprovidedwithapipetoscavengeexhaustgasoutside. Avoidtobreathefumescomingfromheatingorfrompaintweldingbecausetheycancausedamagestohealth;operate outdoorsorinsuitablyventilatedareas.Putonproperinspiratorifpaintpowderispresent. Avoidcontactwithhotwaterorsteamcomingfromtheengine,radiatorandpipingsbecausetheycouldcauseserious burns.Avoiddirectcontactwithliquidsandfluidspresentinvehiclesystems;whereanaccidentalcontacthasoccurred, referto12-pointcardsforprovisionstomake. Print603.93.651 Base-March2006 V

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GENERAL WARNINGS ON THE ELECTRIC SYSTEM Tostartuptheengine,donotusefastchargers.Startupmustonlybeperformedwitheitherseparatebatteriesorspecial truck. Awrongpolarisationofsupplyvoltageindriveelectroniccentralunits(forinstance,awrongpolarisationofbatteries) cancausethemtobedestroyed. Disconnectthebatteriesfromthesystemduringtheirrechargingwithanexternalapparatus. Onconnecting,onlyscrewupconnector(temperaturesensors,pressuresensorsetc.)nutsatprescribedtightening torque. Beforedisconnectingthejunctionconnectorfromanelectroniccentralunit,isolatethesystem. Donotdirectlysupplyelectroniccentralunitsservocomponentsatnominalvehiclevoltage. Cablesmustbearrangedsuchastoresulttobeparalleltoreferenceplane,i.e.ascloseaspossibletochassis/body structure. Oncetheinterventionontheelectricsystemhasbeencompleted,recoverconnectorsandwiringharnessesaccording tooriginalarrangement. Keymemorisationproceduresareinfluencedbyelectromagneticjamming(mobilephones,etc.).Therefore,duringkey memorisation: 1 Payattentionthatjammingsourcesarenotpresentinthecabornearthekeys. 2. Keysnotinseredinthepanelmustbeatleast1meteraway. Ifaninterventionhastobemadeontheelectric/electronicsystem,disconnectbatteriesfromthesystem;inthiscase, alwaysdisconnect,asafirstone,thechassisbondingcablefrombatteriesnegativeterminal. Beforeconnectingthebatteriestothesystem,makesurethatthesystemiswellisolated. Disconnecttheexternalrechargingapparatusfromthepublicutilitynetworkbeforetakingapparatuspinsoffbattery terminals. Donotcausesparkstobegeneratedincheckingifthecircuitisenergised. Donotuseatestlampincheckingcircuitcontinuity,butonlyusepropercontrolapparatuses. Makesurethattheelectronicdeviceswiringharnesses(length,leadtype,location,strapping,connectiontoscreening braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance interventions. Measurementsindriveelectroniccentralunits,pluggedconnectionsandelectricconnectionstocomponentscanonly bemadeonpropertestinglineswithspecialplugsandplugbushes.Neveruseimpropermeanslikewires,screwdrivers, clipsandthelikeinordertoavoidthedangerofcausingashortcircuit,aswellasofdamagingpluggedconnections,which wouldlatercausecontactproblems. Connectorspresentmustbeseenfromcableside.Connectorsviewscontainedinthemanualarerepresentativeofcable side. ! NOTE Base-March2006 Print603.93.651 VI

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Print603.93.651 Base-March2006 VII Bonding and screening Negativeleadsconnectedtoasystembondedpointmustbebothasshortandpossibleand“star“-connectedtoeachother,trying thentohavetheircenteringtidilyandproperlymade(Figure1,re.M). Further,followingwarningsaretobecompulsorilyobservedforelectroniccomponents: - Electroniccentralunitsmustbeconnectedtosystembondingwhentheyareprovidedwithametallicshell. - Electroniccentralunitsnegativecablesmustbeconnectedbothtoasystembondingpointsuchasthedashboardopening bonding(avoiding“serial“or“chain“connections),andtobatterynegativeterminal. - Analogbonding(sensors),althoughnotconnectedtobatterynegativesystem/terminal bonding,musthaveoptimalisolation. Consequently,particularlyconsideredmustbeparasiticresistancesinlugs:oxidising,clinchingdefects,etc. - Screenedcircuitsbraidingmustonlyelectricallycontacttheendtowardsthecentralunitenteredbythesignal(Figure2). - Ifjunctionconnectorsarepresent,unscreenedsection d ,nearthem,mustbeasshortaspossible(Figure2). - Cablesmustbearrangedsuchastoresulttobeparalleltoreferenceplane,i.e.ascloseaspossibletochassis/bodystructure. 1. NEGATIVECABLES “ STAR “ CONNECTIONTOSYSTEMBONDING M 2. SCREENINGTHROUGHMETALLICBRAIDINGOFACABLETOANELECTRONICCOMPONENT— C. CONNECTOR d. DISTANCE ! 0 88039 Figure 1 Figure 2

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Base-March2006 Print603.93.651 VIII OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Accessories mounting, additionsand modificationson the vehicle are to be performed complyingwith IVECOmounting instructions(specificdocument“Instructionsfortransformationandpreparation”isavailableatAssistanceNetworkworkshops). Itisremindedthat,especiallyabouttheelectricsystem,severalelectricsocketsareprovidedforasseries(oroptional)socketsin ordertosimplifyandnormalisetheelectricalinterventionthatiscareofpreparationpersonnel. Foranyexceptiontomountinginstructions,IVECO’sauthorisationisnecessary. Lackofobservanceofabovedescribedprescriptionsinvolvesguaranteelapse. Itisabsolutelyforbiddentomakemodificationsorconnectionstoelectriccentralunitswiringharnesses;inparticular, thedatainterconnectionlinebetweencentralunits(CANline)istobeconsideredinviolable. CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES Power 1kW = 1.36metricHP 1kW = 1.34HP 1metricHP = 0.736kW 1metricHP = 0.986HP 1HP = 0.746kW 1HP = 1.014metricHP Torque 1Nm = 0.1019kgm 1kgm = 9.81Nm Revolutions per time unit 1rad/s = 1rpmx0.1046 1rpm = 1rad/sx9.5602 Pressure 1bar = 1.02kg/cm 2 1kg/cm 2 = 0.981bar 1bar = 10 5 Pa Whereaccuracyisnotparticularlyneeded: -Nmunitisforthesakeofsimplicityconvertedintokgmaccordingtoratio10:1 1kgm = 10Nm; -barunitisforthesakeofsimplicityconvertedintokg/cm 2 accordingtoratio1:1 1kg/cm 2 = 1bar. Temperature 0 ° C = 32 ° F 1 ° C = (1x1.8+32) ° F

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Print603.93.651 Base-March2006 D AILY E URO 4 Print603.93.651—1 st edition Base—March2006 UPDATE DATA Section Description Page Revision date

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Base-March2006 Print603.93.651

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Print603.93.651 Base-March2006 Section Generalinformation 1 Engine 2 Clutch 3 Gearbox 4 Propellershafts 5 Rearaxles 6 Frontaxle 7 Frontandrearsuspensions 8 Wheelsandtyres 9 Steeringsystem 10 Pneumaticsystem-Brakes 11 Bodyworkandchassisframe 12 Maintenance 13 Electric/ElectronicSystem 14 INDEX OF SECTIONS

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Base-March2006 Print603.93.651

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GENERAL 1 D AILY E URO 4 Print603.93.651 Base-March2006 Print603.43.671 SECTION 1 General Page IDENTIFICATIONDATA 3 .................. -VehicleIdentificationPlate 3 ................ COMPOSITIONOFMODELS 4 .............. ALPHANUMERICALCODINGFOR BUSIDENTIFICATION 6 ................. REPLENISHINGFLUIDS 13 ...................

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2 GENERAL D AILY E URO 4 Base-March2006 Print603.93.651 Print603.43.671

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Vehicle identification plate Plate legend Manufacturer tag For vehicle identification according to the EC directive (on the front crosspiece) Chassis Stamping (at the front on the chassis right-hand side-member) Engine Stamping (on the right side on the engine base) 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 Figure 1 Figure 2 108533 108534 GENERAL 3 D AILY E URO 4 Print 603.93.651 Base - March 2006 IDENTIFICATION DATA

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4 GENERAL D AILY E URO 4 Base-March2006 Print603.93.651 COMPOSITION OF MODELS ASSEMBLIES MODELS 29L10 29L12 29L14 35S10 35S12 35S14 35S18 35C10 35C12 35C14 35C15 35C18 40C10 40C12 40C15 40C18 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: independent with transverse leaf spring (MK3) o o o o o o o o o o o independent with torsion bars ( • ) ( • ) ( • ) ( • ) ( • ) o o o o REAR MECHANICAL Parabolic o o o o o o o Z Z Z Z Z Z Z Z Z MECHANICAL SUSPENSIONS: - single leaf o o o o o o o SUSPENSIONS: - reinforced o o o o o o o Semi-elliptical s s s s s s s s s Semi-elliptic with leaf spring z z z z z z z z z REAR AIR SUSPENSIONS V V V V V V V V V V V V V V V V O.D.=OverDrive ( • )Optionalextra(withmaxloadof1900kg) o Standard • withZF6S400AO.D.gearbox V Alternative Vehicleswithfrontsuspensionwithtransverseleafspring Vehicleswithfrontsuspensionwithtorsionbars z Chassiscabsonly,asanalternative s Standardonchassiscabs,AlternativelyonVans—ChassisCowls andCutAways Z StandardonVans,ChassisCowlsandCutAways—Alternatively onChassisCabs S Singlerearwheels L Lightwithsinglerearwheels C Twinrearwheels

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GENERAL 5 D AILY E URO 4 Print603.93.651 Base-March2006 COMPOSITION OF MODELS ASSEMBLIES MODELS 45C15 45C18 50C15 50C18 60C15 60C18 65C15 65C18 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 with leaf spring z z z z z z z z REAR AIR SUSPENSIONS V V V V V V V V O.D.=OverDrive ( • )Optionalextra(withmaxloadof1900kg) o Standard V Alternative Vehicleswithfrontsuspensionwithtransverseleafspring Vehicleswithfrontsuspensionwithtorsionbars z Chassiscabsonly,asanalternative s Standardonchassiscabs,AlternativelyonVans—ChassisCowls andCutAways Z StandardonVans,ChassisCowlsandCutAways—Alternatively onChassisCabs S Singlerearwheels L Lightwithsinglerearwheels C Twinrearwheels

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6 GENERAL D AILY E URO 4 Base-March2006 Print603.93.651 ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION A LIGHT ROAD VEHICLES A T 25C 29 L B T 30C 35 S C T 35C 35 C D T 40C 40 C E T 50C 50 C 45 C F T 65C 60 C 65 C CUSTOMIZED VEHICLE (V.P.) PROGRAMMING FAMILY MARKET VEHICLE (V.M.) STANDARD VEHICLE (V.C.B.) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 RANGE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CHASSIS CABS AND DERIVATIVES

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GENERAL 7 D AILY E URO 4 Print603.93.651 Base-March2006 H T 25V 29 L K T 30V 35 C J T 35V 35 C L T 40V 40 C M T 50V 50 C 45 C N T 65V 60 C 65 C 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 ENGINE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PROGRAMMING FAMILY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 VANS AND DERIVATIVES

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8 GENERAL D AILY E URO 4 Base-March2006 Print603.93.651 A Mechanicalsuspension:frontwithtransverseleafspring. B Mechanicalsuspension:frontwithtorsionbars. C Mechanicalfrontsuspensionwithtransverseleafspring—rearairsuspension. D Mechanicalfrontsuspensionwithtorsionbars—rearairsuspension. 29 L10 ( • ) - 29 L12 ( • ) - 29 L14 ( • ) 35 S10 ( • ) - 35 S12 ( • ) - 35 S14 ( • ) - 35 S18 ( • ) 1 CHASSIS 35 S10 ( • ) - 35 S12 ( • ) - 35 S14 ( • ) - 35 S18 ( • ) 35 C10 ( • ) - 35 C12 ( • ) - 35 C15 ( • ) - 35 C18 ( • ) 40 C10 ( • ) - 40 C15 ( • ) - 40 C18 ( • ) 1 CHASSIS CAB 40 C10 ( • ) - 40 C15 ( • ) - 40 C18 ( • ) 45 C15 ( • )-50 C15 ( • ) - 50 C18 ( • ) 60 C15 ( • ) 60 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 ( • ) -6 CHASSIS CAB 35 S10 D ( • )-35 S12 D ( • ) - 35 S14 D ( • ) -35 S18 D ( • ) - 35 C10 D ( • ) - 35 C12 D ( • ) -35 C15 D ( • ) 35 C18 D ( • ) - 40 C10 D ( • ) -6 CAB 6 + 1 35 C15 D ( • )-35 C18 D ( • ) - 40 C10 D ( • ) -40 C12 D ( • ) - 45 C15 D ( • ) - 45 C18 D ( • ) 50 C18 D ( • ) 60 C15 D ( • ) 60 C18 D ( • ) 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 ( • ) 0 CHASSIS 35 C12 CC ( • ) - 35 C15 CC ( • )-35 C18 CC ( • ) -40 C12 CC - 40 C15 CC ( • ) - 40 C18 CC ( • ) 0 CHASSIS COWL 40 C12 CC 40 C15 CC () 40 C18 CC () 45 C15 CC - 45 C18 CC ( • ) 50 C15 CC ( • ) - 50 C18 CC ( • ) 50 C15 CC ( • ) - 50 C18 CC ( • ) 60 C18 CC ( • ) - 65 C18 CC ( • ) 35 S12 CCR ( • )-35 S14 CCR ( • ) - 35 S18 CCR ( • ) 35 C12 CCR ( • ) 35 C15 CCR ( • ) 35C18CCR ( • ) R CHASSIS COWL 35 C12 CCR ( • ) - 35 C15 CCR ( • ) - 35C18CCR ( • ) 40 C12 CCR ( • ) - 40 C15 CCR ( • )-40C18CCR ( • ) R COWL SHORT 40 C12 CCR () 40 C15 CCR () 40C18CCR () 45 C15 CCR ( • ) - 45 C18 CCR ( • ) 50 C15 CCR ( • ) - 50 C18 CCR ( • ) 50 C15 CCR ( • ) - 50 C18 CCR ( • ) 60 C18 CCR ( • ) - 65 C18 CCR ( • ) ( • )AlsoavailableintheA(automatictransmission)and/P(pneumaticrearsuspensions)versions. SUSPENSION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 VERSION 1 2 3 4 5 6 7 8 9 10 11 12 13 14

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GENERAL 9 D AILY E URO 4 Print603.93.651 Base-March2006 35 C10 CA ( • ) - 35 C12 CA ( • ) A CUT-AWAY 35 C10 CA ( • ) - 35 C12 CA ( • ) 40 C10 CA ( • ) - 40 C12 CA ( • ) A CUT-AWAY 40 C10 CA () 40 C12 CA () 45 C18 CA ( • ) - 50 C18 CA ( • ) 60 C18 CA () 65 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 ( • ) 4 VAN 35 S18 V ( • ) 35 C10 V ( • ) - 35 C12 V ( • ) - 35 C15 V ( • ) 35 C18 V ( • ) 4 VAN 35 C18 V () 40 C12 V ( • ) - 40 C15 V ( • ) - 40 C18 V ( • ) 45 C15 V ( • ) - 45 C18 V ( • ) 50 C15 V ( • ) - 50 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 ( • ) V SEMI-GLAZE 35 S18 SV ( • ) 35 C10 SV ( • ) - 35 C12 SV ( • ) - 35 C15 SV ( • )-35 C18 SV ( • ) V SEMI GLAZE D VAN 35 C18 SV () 40 C10 SV ( • ) - 40 C12 SV ( • ) - 40 C15 SV ( • ) -40 C18 SV ( • ) -45 C15 SV ( • ) - 45 C18 SV ( • ) 45 C15 SV ( • ) - 45 C18 SV ( • ) 50 C15 SV ( • ) - 50 C18 SV ( • ) VENDOR 35 S12 CV ( • ) - 35 S14 CV ( • ) U VENDOR VERSION 35 S12 CV ( • ) - 35 S14 CV ( • ) 35 C12 CV ( • ) - 40 C12 CV -U VERSION CITY 35 C12 CV () 40 C12 CV 45 C15 CV ( • )-45 C18 CV ( • ) 50 C15 CV () 50 C18 CV () VAN 50 C15 CV ( • ) - 50 C18 CV ( • ) 5 COMBI 29 L14 C ( • ) - 35 S14 C ( • ) 5 COMBI 29 L14 C ( • ) - 35 S14 C ( • ) 8 CAMPER 35 S14 ( • ) - 35 S18 ( • ) 8 CAMPER 35 S14 ( ) 35 S18 ( ) 35 C14 ( • ) - 35 C18 ( • ) 35 C14 () 35 C18 () CHASSIS-COWL 9 COWL SHORT VERSION FOR 35 S14 CCRC ( • ) - 35 S18 CCRC -35 C14 CCRC ( • ) - 35 C18 CCRC VERSION FOR CAMPER VAN 35 C14 CCRC ( ) 35 C18 CCRC ( • )AlsoavailableintheA(automatictransmission)and/P(pneumaticrearsuspensions)versions. VERSION 1 2 3 4 5 6 7 8 9 10 11 12 13 14

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10 GENERAL D AILY E URO 4 Base-March2006 Print603.93.651 1 3000 mm (T25C - T30C - T35C - T40C - T25V - T30V -T35V - T40V - T50V) 2 3000 L mm (T25V - T30V - T35V - T40V - T50V) 3 3300 mm (T25V - T30V - T35V - T40V - T50V) 4 3450 mm (T25C - T30C - T35C - T40C - T50C - T65C) 5 3750 mm (T30C - T35C - T40C - T50C - T65C) 6 3950 L mm (T30V - T35V - T40V - T50V - T65V) 7 4100 mm (T35C - T40C) 8 4350 mm (T50C - T65C) 9 4750 mm (T50C - T65C) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WHEELBASE

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GENERAL 11 D AILY E URO 4 Print603.93.651 Base-March2006 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. OverDrive 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GEARBOX

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12 GENERAL D AILY E URO 4 Base-March2006 Print603.93.651 LEFT-HAND DRIVE (T25C - T30C - T35C - T40C - T50C) 1 LEFT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H 1 = 1545 mm (T25V - T30V - T35V - T40V - T50V) 1 LEFT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H 2 = 1900 mm (T25V - T30V - T35V - T40V - T50V) 2 LEFT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H 3 = 2100 mm (T30V - T35V - T40V - T50V) 3 RIGHT-HAND DRIVE (T25C - T30C - T35C - T40C - T50C) A RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H 1 = 1545 mm (T25V - T30V - T35V - T40V - T50V) A RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H 2 = 1900 mm (T25V - T30V - T35V - T40V - T50V) B RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF LOADING BAY H 3 = 2100 mm (T30V - T35V - T40V - T50V - T65V) C DRIVE — INTERNAL HEIGHT OF LOADING BAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 MANDATORY MARKET OPTIONAL EXTRAS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 OPTIONAL EXTRAS REQUIRED BY THE CUSTOMER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

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GENERAL 13 D AILY E URO 4 Print603.93.651 Base-March2006 REPLENISHING FLUIDS IVECO RECOMMENDED LUBRICANTS PARTS TO BE REPLENISHED Quantity Litres kg Quantityofoilincirculationinthecar-tridgefilterandheatexchanger 1.4 1.23 Totaldryenginecapacity 5.7 5.02 UraniaDaily UraniaLD5 Sumpcapacity: -maxlevel -minlevel 4.3 3 3.78 2.65 UraniaLD5 Quantityofoilincirculationinthecar-tridgefilterandheatexchanger 1 0.88 Totaldryenginecapacity 7.6 6.79 Sumpcapacity: -maxlevel -minlevel 6.6 4.29 5.81 3.78 Max.gradientnegotiablebyvehicleuphill/downhillwithoilatminimumlevel30% ! Gearbox ZF5S300 2 1.8 TutelaTRUCKGEARLITE ZF6S400O.D. 2.2 1.98 ZF6S400AO.D. 2.7 2.43 Frontaxle: 5817 --5818 --5819 --5823 --Rearaxles: TutelaW140/M-DA(SAE80W90) NDAR.S. 1.35 1.21 TutelaW90/M-DA(SAE80W90) NDAR.G. 1.35 1.21 TutelaW140/M-DA(SAE85W140) 450511 1.9 1.65 TutelaW140/M-DA(SAE85W140) 450517/2 3 2.7 TutelaGI/A Powersteering 1.4 1.3 TutelaTRUCKDOTSPECIAL Brakecircuit 1.11 1 ArexonsDP1 Windscreenwasher 5 4.5 Paraflu 11 * Coolingsystem 9 -*=Protectiveanti-freeze(concentration50%,freezingpoint—35 ° C)

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14 GENERAL D AILY E URO 4 Base-March2006 Print603.93.651 International lubricant description FL Group products Engine oil meetsspecifications: ACEAB5withsyntheticbaseSAE5W30 ACEAE3/E5withmineralbaseSAE15W40 Urania Daily Urania LD5 Differential and wheel hub oil meetsspecifications: APIGL-5withmineralbaseSAE85W140 APIGL-5withmineralbaseSAE80W90 Tutela W 140/M - DA (1) Tutela W 90/M - DA (2) Mechanical gearbox oil containing non-EP anti-wear additives MeetsspecificationAPIGL4SAE75W80 Tutela Truck Gearlite Hydrostatic transmission and power steering oil Meetsspecifications:ATF-DEXRONIID Tutela GI/A General-purpose grease lithiumsoapbasedgreaseN.L.G.I.fluidityno.2 Tutela MR 2 Specific grease for wheel hubs and bearings lithiumsoapbasedgreaseN.L.G.I.fluidityno.3 Tutela MR 3 Hydraulic brake and clutch control fluid InconformitywithN.H.T.S.A.standardsNo.116,ISO4925 StandardSAEJ1703,IVECOSTANDARD18-1820 Tutela TRUCK DOT SPECIAL Windscreen washer liquid Mixtureofspirits,waterandsurfactantsCUNANC956-11 Tutela Professional SC 35 Concentrated protective radiator fluid ethyleneglycolbasedcontainingcorrosioninhibitors, inconformitywithIvecoStandard18-1830 Paraflu 11 (3) (1) Hotortemperateclimate (2) Specificforcoldclimes. (3) 100%Paraflutobedilutedwithwaterto50% 35 95 50 10 0 32 14 -10 -15 -25 o C o F -13 5 SAE 40 SAE 30 SAE 20W SAE 10W SAE 15W/40 SAE 5W 30 Figure 3 108535

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F1AENGINE 1 D AILY E URO 4 Base-March2006 Print603.93.651 SECTION 2 5401 Engine Page F1AENGINE 3 ............................ F1CENGINE 157 ............................

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2 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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F1AENGINE 3 D AILY E URO 4 Base-March2006 Print603.93.651 F1A Engine Page MAINOPERATIONSONENGINEMOUNTED ONVEHICLE 7 ......................... -Serviceprocedurestobeperformedafterreplacing high-pressurefeedingsystemand/orexhaustgaspost-treatmentsystemcomponents 8 ............ POWERUNITREMOVAL/REFITTING 9 ........ -Removal 9 ............................. -Refitting 13 .............................. -Checksandtests 13 ....................... -Powersteeringsystemairbleed 13 ........... REPLACINGBELTS 14 ....................... -Powersteeringpump-alternatorbeltreplacement 14 -Disassembly 14 ........................... -Assembly 14 ............................. -Replacingair-conditioningcompressordrivebelt 14 -Disassembly 14 ........................... -Assembly 14 ............................. -Replacingtimingdrivebelt 15 ................ -Disassembly 15 ........................... -Assembling 16 ........................... REPLACINGTHEELECTRICINJECTORS 17 ..... -Removal 18 ............................. -Refitting 18 .............................. CYLINDERHEADREMOVALANDREFITTING 19 -Removal 19 ............................. -Refitting 21 .............................. REPLACINGHIGH-PRESSUREPUMPCPH1 22 ... -Removal 22 ............................. -Refitting 22 .............................. REPLACINGWATERPUMP 22 ............... -Removal 22 ............................. -Refitting 22 .............................. PREHEATINGPLUGREMOVAL/REFITTING 23 ... -Removal 23 ............................. -Refitting 23 .............................. THROTTLEVALVEASSEMBLYREMOVAL-REFITTING 23

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4 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Page -Removal 23 .............................. -Refitting 23 .............................. E.G.R.VALVEREMOVAL/REFITTING 24 ......... -Removal 24 .............................. -Refitting 24 .............................. HEATEXCHANGERREMOVAL/REFITTING 24 ... -Removal 24 .............................. -Refitting 24 .............................. BURNTGASEXHAUSTSYSTEM 25 ............ -Description 25 ............................ OXICAT-OXYDIZERCATALYST 25 .......... -Description 25 ............................ EXHAUSTPIPEASSEMBLYREMOVAL/REFITTING 27 -Removal 27 .............................. -Refitting 27 .............................. REMOVAL/REFITTINGOFEXHAUSTPIPEASSEMBLY COMPONENTS(SYSTEMSEQUIPPEDWITHD.P.F. CATALYST) 28 .......................... -Exhaustsilencerremoval 28 ................. -ReplacingD.P.F.catalyst 29 .................. -Refittingl 28 .............................. -D.P.F.catalystremoval 28 ................... -Replacingdifferentialsensor(delta-p) 29 ........ ENGINEVIEWS 30 .......................... EMISSIONS 33 ............................. ENGINEIDENTIFICATIONCODE 34 ........... CHARACTERISTICSCURVES 35 ............... GENERALSPECIFICATIONS 39 ............... ASSEMBLYDATA—CLEARANCES 40 .......... TOOLS 47 ................................ EXPERIMENTALTOOLS 52 .................. TIGHTENINGTORQUE 63 ................... OVERHAULINGENGINE 68 .................. DISASSEMBLINGTHEENGINEATTHEBENCH 68 REPAIRS 78 ................................ CYLINDERBLOCK 78 ....................... -Checksandmeasurements 78 ................ -Checkingheadmatingsurfaeoncylinderblock 78 CRANKSHAFT 79 .......................... Page -Measuringmainjournalsandcrankpins 79 ...... -Checkingcrankshaft 80 ..................... -Replacingtimingcontrolgear 82 .............. ENGINEASSEMBLY 82 ...................... -Assemblingmainbearings 82 ................. -Measuringmainjournalassemblyclearance 82 ... -Checkingcrankshaftendfloat 83 .............. -Assemblingrearseal 84 ..................... ENGINEFLYWHEEL 85 ...................... -Replacingbearingsupportinggearboxinputshaft 85 CONNECTINGROD—PISTONASSEMBLY 86 ... -Pistons 86 ............................... -Disassembly 86 ........................... -Measuringpistondiameter 87 ................ -Pistonpins 87 ............................ -Conditionsforcorrectpin-pistoncoupling 87 .... -Pistonrings 87 ............................ -Connectingrods 88 ........................ -Bushes 89 ............................... -Checkingconnectingrod 89 ................. -Checkingbending 89 ....................... -Assemblingconnectingrod-pistonassembly 89 ... -Checkingforconnectingrod—pistondistortion 90 -Fittingpistonrings 90 ....................... -Assemblingconnectingrod—pistonassemblies incylinderbarrels 90 ....................... -Measuringcrankpinassemblyclearance 91 ...... -Checkingpistonprotrusion 91 ............... CYLINDERHEADS 92 ....................... -Disassembly 92 ........................... -Removingvalves 92 ........................ -Checkingcylinderheadseal 93 ............... -Checkingcylinderheadmatingsurface 93 ....... VALVES 93 ................................ -Removingdeposits,refacingandcheckingvalves 93 -Checkingclearancebetweenvalvestemandvalve guideandcentringvalves 94 ................. VALVEGUIDE 94 ........................... -Replacingvalveguide 94 ....................

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F1AENGINE 5 D AILY E URO 4 Base-March2006 Print603.93.651 Page -Boringvalveguides 94 ...................... VALVESEATS 95 ........................... -Recuttingandreplacingvalveseats 95 .......... VALVESPRINGS 96 ......................... ROCKERARMS—TAPPETS 96 ................ -Checks 97 ............................... ASSEMBLINGCYLINDERHEADS 97 ........... -Overhead 98 ............................. -Overheadremoval 98 ...................... TIMINGSYSTEM 99 ......................... -Description 99 ............................ -Camshaft 100 ............................. -Checks 100 ............................... -Checkingcamliftandpinalignment 100 ......... -Assemblingoverhead 102 .................... -Assemblingfrontsealring 103 ................. -Refittingcylinderhead 106 ................... -Camshaftdrive 107 ......................... LUBRICATION 115 .......................... -General 115 .............................. OILVACUUMPUMPASSEMBLY(GPOD) 117 ..... -Oilpump 117 ............................. -Characteristicdata 117 ...................... -Vacuumpump 117 ......................... -Oilpressurecontrolvalve 118 ................ -Oilfilter 118 .............................. -Modineheatexchanger 118 .................. -Oilvapourrecirculationsystem 119 ............ -Description 119 ............................ COOLING 121 .............................. -Description 121 ............................ -Operation 121 ............................ -Electromagneticpulley 123 ................... -Waterpump 123 .......................... -Thermostat 123 ........................... TURBOCHARGING 124 ...................... -Description 124 ............................ Page -Turbocharger(KKKK03-2074-CCB5.88type) 125 REPAIRS 126 ................................ -Pressurereliefvalve 126 ..................... -Checkingpressurereliefvalve 126 .............. -GARRETGT17variablegeometry turbosupercharger 127 ...................... -General 127 .............................. -Operationatlowenginerpm 127 .............. -Operationathighenginerpm 127 ............. -Proportionalsolenoidvalvecontrollingturbocharger actuator 128 .............................. -Actuator 128 .............................. REPAIRS 129 ................................ -Checkingandadjustingtheactuator 129 ......... EXHAUSTGASRECIRCULATION(EGR)SYSTEM (EXHAUSTGASRECIRCULATION) 130 ....... -EGRsystemoperation 130 ................... -Mainsystemcomponents 131 ................. -E.G.R.valve 131 ............................ -Modulatorsolenoidvalve 131 ................. -Airflowratemeter(flowmeter) 131 ........... -Heatexchanger 132 ........................ -Throttlevalveassembly 132 .................. EXHAUSTPOLLUTANTREDUCTIONSYSTEMWITH DPFCATALYST(ONREQUEST) 133 ......... -General 133 .............................. D.P.F.(DIESELPARTICULATEFILTER)CATALYST 134 -Description 134 ............................ PARTICULATEFILTERREGENERATIONSYSTEM 135 -Operation 135 ............................ -Forcedregeneration 136 ..................... -Refillingengineoil 136 ....................... FUELSUPPLY 137 ........................... HIGH-PRESSUREELECTRONIC INJECTIONSYSTEM(MS6.3-EDC16) 137 .... -General 137 .............................. SYSTEMOPERATION 139 .................... -Self-diagnosis—BLINKCODE 139 .............

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6 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Page -Immobilizerrecognition 139 .................. -Checkingfueltemperature 139 ................ -Checkingenginecoolanttemperature 139 ....... -Checkingquantityoffuelinjected 139 ........... -Checkingidlingadjustment 139 ................ -Fuelcut-offinreleasephase 139 ............... -Checkingcylinderbalancingonidling 139 ........ -Checkingregularenginerotation(anti-sawing) 139 . -Checkingsmokinessatexhaustonacceleration 139 -Checkingexhaustgasrecirculation(E.G.R.) 139 ... -Checkingtopspeedlimit 139 ................. -Checkingregularrotationonacceleration 139 .... -Checkingglowplugcontrolunit 139 ............ -Checkingactivationofair-conditioningsystem 139 . -Checkingfuelpump 139 ..................... -Checkingdieselwarming 140 ................. -Checkingcylinderposition 140 ................ -Checkingpilotandmaininjectiontiming 140 ..... -Checkinginjectionpressureclosedcycle 140 ..... -Fuelsupply 140 ............................ -Correctingflowrateaccordingtowater temperature 140 ........................... -Correctingflowratetoavoidnoise,smoke oroverloading 140 ......................... -De-rating 140 ............................. -Injectiontimingelectronictest 140 ............. -Speedgovernor 140 ........................ -Enginestarting 140 ......................... -Coldstarting 141 ........................... -Warmstarting 141 ......................... -Runup 141 ............................... -Afterrun 141 ............................. -Cut-off 141 ............................... -Cyliderbalancin 141 ........................ -Synchronisationsearch 141 ................... OPERATION 143 ............................ HYDRAULICSYSTEM 146 ..................... Page -Fuelpump 146 ............................ -Fuelfilter“UFIfilters” 147 .................... -Fuelfilter“Filtrauto” 148 ..................... -Fuelpipes 148 ............................. -High-pressurepumpCPH1 149 ............... -Pressurecontrolvalve 150 ................... -Replacingpressureregulator 150 ............... -Hydraulicaccumulator(rail) 151 ............... ELECTRO-INJECTORS 152 .................... -Operation 152 ............................ -Replacinganelectricalinjector 152 ............. ELECTRIC/ELECTRONICCOMPONENTS 153 ..... -ElectroniccontrolunitEDC16 153 ............ -Glowplugelectroniccontrolunit 154 ........... -Glowplugs 154 ............................ SENSORES 154 ............................. -Enginespeedsensor 154 ..................... -Camshafttimingsensor 154 .................. -Airtemperatureandpressuresensor 155 ........ -Fueltemperaturesensor 155 ................. -Fuelpressuresensor 155 ..................... -Atmosphericpressuresensor 155 .............. -Enginecoolanttemperaturesensor 155 ......... -Throttlepedalpositionsensor 155 ............. -Clutchpedalpositionsensor 155 .............. -Brakepedalpositionsensor 155 ............... -Vehiclespeedsensor 155 .................... -Differentialpressuresensor-deltap( ∆ p ) 155 .... -Exhaustgastemperaturesensor 155 ............ ACTUATORS 156 ........................... -PWM(PulseWidthModulation)controls 156 ....

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MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE Keeptothefollowinginstructionsbeforedoinganyworkontheengineinvolvingcomponentsofthefuelsupplysystem. -Beforedoinganyworkontheengine,performtheengine/vehiclefaultdiagnosiswithspecificIVECOdiagnosis equipmentandprintouttheresults. -ReplacementoftheMS6.3orEDC16controlunitmustbeauthorizedbythe Help Desk. Replacingoperation requiresreprogrammingasdescribedinspecificsection. -Followingcomponentsinfeedsystemcannotbeoverhauledbuthavetobereplaced:pressurereliefvalve,ifpresent, fuelpressuresensor,hydraulicaccumulator,completeCP1Hhighpressurefeedpump,pressurecontrolvalve, electricinjectors. -AllthepartsoftheCommonRailsystemarepackagedbythesupplierinsheetsofoiledpaperandarestoredin cardboardboxes.Theymustthereforebeprotectedagainstmoistureandunpackedjustpriortoassembly. -Thegreatestcaremustbetakenoverthecleanlinessofparts,makingsurethatwhenhandlingorassembling (startingwithstraightforwardfilterandpre-filterreplacement)nodirtofforeignbodiescangetinside.Forthis reason,theplugsprotectingthehydraulicpartsandsensorsmustberemovedjustpriortopositioningintheirseats. -Takecareoverthedirectionofassemblyforallelectricalconnections. -Allthreadedconnectionsmustbetightenedtotheprescribedtorque. -Allthequick-couplingconnectors(ontheenginetheyarefoundonthehigh-pressurepumpandonthedieseldrain manifold)mustbefullyinserted.Todrivethemout,pressonthetabsatthebaseoftheconnectors. Electro-injector Noneofthecouplings/unions/nutsontheinjectorbodymaybehandled.Itisneithernecessarynorpermittedto dismantlethenozzlebodyortheelectromagnet. Ifworkingonthehigh-pressurepipe,thehexagonontheinjectorsidemustbekeptstationarywithawrench. Beforeworkingonpipes,makesuretheinjectorisstationaryinitsseatonthecylinderhead. Whenassembling/disassemblingtheinjectordrain,theretainingspringmustnotberemovedfromitsseatintheinjector: pushingthespringtowardstheengineandapplyingaverticalforceontheconnectorfreestherecirculation.When assembling,resttherecirculationconnectorinitsseatandapplyaverticalforcewhilekeepingtheretainingspring pressedinthedirectionoftheengine.Fittinginhastobeeasy. Replacingoneormoreelectricalinjectorsrequirescentralunitprogrammingasdescribedinspecificsection. CP1H High-pressure pump Ifworkingonthehigh-pressurepipe,thehexagononthepumpsidemustbekeptstationarywithawrench. Beforeworkingonthehigh-pressurepipe,makesurethepumpissecuredinitsseat. High-pressure pipes Eachhigh-pressurepipemustbereplacedafterdisassemblyoperations. Thecouplingsmustbetightenedorloosenedwiththeinjectors,hydraulicaccumulator(rail)andhigh-pressurepump wellsecuredandtakingcaretokeepthehexagononthecomponentsidestationary,spacepermitting. Hydraulic accumulator (rail) and accessories Thepressuresensorcanbeassembledfiveconsecutivetimes;afterthat,itmustbereplaced.Theymustbelubricated withathinlayerofoilbeforebeingmounted.. Replacingthesensorrequirescentralunitprogrammingasdescribedinspecificsection. F1AENGINE 7 D AILY E URO 4 Print603.93.651 Base-March2006

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Service procedures to be performed after replacing high-pressure feeding system and/or exhaust gas post-treatment system components Toensurecorrectoperationoftheengine,theCP1control unit16stores,inthememorynon-labilearea,theinformation relativetotheengineparametersoriginallysetoracquired duringengineoperation. Asaresult,afteranyoftheoperationsbelowiscarriedout: -replacingoneorseveralinjectors, -replacingalltheinjectors, -replacingtheairflowmeter, -replacing the hydraulic accumulator pressure sensor (commonrail), -replacingtheEDCcontrolunit16; -changingtheengineoil, -replacingtheD.P.F.catalyst, -replacingthefilterdifferentialpressure(Dp)sensor, -replacinganysignificantcomponentasregardsemission levels, -performingforcedregeneration, thecontrolunitshallbeprogrammedagainbymeansofthe IVECOMODUS-E.A.SY.-IT2000diagnosisinstrument,and thereplacementprocedurefortheconcernedcomponent shallbeperformed,inaccordancewiththeindicationsofthe diagnosisinstrumentsused. 8 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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540110 POWER UNIT REMOVAL/REFITTING 108554 Figure 1 Removal Placethevehicleonthepitorautolift. Lifttheenginehood(28),undothefasteningscrews(28)and thenremovethehood;removesupportingrod(30). Disconnectnegativecable(11)andpositivecable(4)from battery (10), then remove the latter from the engine compartment. Disconnectelectricconnections(5,7,8and9)andengine cable(6)fromtheEDCcontrolunit,thenreleasetheengine cablefromthestrapssecuringthesametothecab. Unhookcable(31)fromthehoodopeningcontroldevices. Disconnectfrontheadlampelectricconnections(12). Removescrews(19),thentakeoffcover(18). Removefasteningscrews(32),thentakeoffheadlampinserts (13). Donotchangetheassemblypositionofheadlamp insert(13)threadedbush(14,detail D ). NOTE Remove the screws and/or fastening nuts, then remove crosspiece(33). Remove the screws and/or fastening nuts, then remove bumper(17). Removeexpansiontank(3)cap(2). Actasfollows,fromunderthevehicle(seefigure4): -undofasteningscrews(8and10),thenremovelowerside guards(11); -undofasteningscrews(15),thenremovelowercentral guard(12). Applyatube(16)toradiatorpipeunion(detail C ),then unscrew cap (15) and drain the coolant into a suitable container. Ifthevehicleisequippedwithacabair-conditioning unit,proceedasfollows. -Fittheunit99309146pipestoconnections(1) and (24), then blow the gas off the air-conditioning system as described in the respective charter of the ”Bodywork and chassis”section. -Disconnect electric connection (23) from dryingfilterpressureswitch(22). -Disconnect pipes (20) from air-conditioner compressor(21). -Ruts (27), then disconnect pipes (25) from expansionvalveconnector(26). NOTE Seal the air-conditioning unit pipes and their respective mounts, to prevent moisture and impuritiesfrompenetratingintothesystem. NOTE F1AENGINE 9 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 2 Remove nuts (23), then properly place remote-control switch/fuseholder(22)aside. Disconnect pipe (21) from the heat exchanger and the turboblower. Disconnect pipe (13) from the heat exchanger and the throttlevalveassembly. Removefasteningscrews(12),thenremovetheradiator/heat exchangerassemblytogetherwiththecondenser-dryingfilter, pipesandairconveyor(ifany). Removeoilfillingcap(2),thentakesound-proofingcover(1) off. Disconnecttank(5)pressuresensorelectricconnection(3). Removetank(5)fasteningnuts(4),thentakethetankoffthe wall. Disconnectelectricconnection(6)ofthelevelsensorplaced undertank(5). Disconnectorremovethecoolantpipes: - (14),fromthermostat(11); - (15),fromengineoilheatexchanger(10); - (19),frompipe(17); - (18),fromradiator(16); - (20),fromthecylinderhead. Properly obstruct the turboblower air outlet to avoidcasualpenetrationofforeignbodiesintothe turboblowerand,therefore,damagetothelatter. NOTE 108555 10 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 3 Disconnectcabheaterpipe(23)fromE.G.R.exchangeroutlet pipe(22). Disconnect: -vacuumpipe(27)fromtheE.G.R.valve; -pipe(1),fromcoalescencefilter(25); -pipe(21),frompipe(19). Disconnectelectricconnection(15)fromairflowmeter(16). Removeairpipes(14and19),togetherwithairflowmeter (16),fromturboblower(20)andairfilter(13). DisconnecttheelectricconnectionfromVGTsolenoidvalve (12,only136HPengine). DisconnecttheelectricconnectionfromEGRsolenoidvalve (11). Disconnecttheelectricconnections(18)fromalternator(17). Disconnecttheelectricconnectionfromoillevelsensor(26). Disconnectthefuelpipes(3)fromthelow-pressurepipe assembly. Disconnecttheelectricconnection(6)fromair-conditioner compressor(8). Disconnecttheelectricconnection(5)fromstartingmotor (4). Placeacontainerunderthepowersteeringpumptorecover thesystemoil,thendisconnectoilinletanddeliverypipes(9) and(10). Disconnecttheenginegroundcable(7). Applytool99360544(2)totheenginebracketstoremove theenginefromitsowncompartmentandslightlypullthe same Properly obstruct the turboblower air outlet to avoidcasualpenetrationofforeignbodiesintothe turboblower. NOTE 108556 F1AENGINE 11 D AILY E URO 4 Print603.93.651 Base-March2006

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Actfromunderthevehicle: - todisconnectjointedheads(17)oflevershiftcontrol cables(16); - selectioncable(max.pull-outload:250N-max.pull-in load:60N); - engagementcable (max. pull-outload: 100 N -max. pull-inload:80N). Useasuitablescrewdrivertoopenoutflexiblecablefins(18) sothatthepawlsaredisengagedfromthesupport. Undofasteningscrews(22),moveclutchcontrolcylinder(23) togetherwithitsbracketandproperlysecureittothechassis. Removethesealingfromring(1),thenunscrewthesameand disconnectthespeedindicatorcontrolcable. Disconnectelectricconnection(2)(on96/116HPengines)or (4)(on136HPengines)or(26)(onautomatictransmissions) fromthereversinglightswitch. Figure 4 Ifitisnecessarytodetachthegearboxfromtheengine,take outthefixingscrewsandremovethestartermotor. Takeoutthefixingscrewsanddetachthegearboxfromthe engine. Thepowerunitmustberemovedfromtheengine compartment with the greatest care, to avoid damaging the remaining parts on the vehicle, in particularthesteeringboxoilpipes. NOTE As far as automatic transmission is concerned, strictlyadheretotheoperationsdescribedinthe relevantchapterinthe“Gearbox”section. NOTE Disconnectexhaustpipe(9)fromtheturbobloweroutlet pipe. Disconnectvacuumpipe(29)fromVGTactuator(28,only 136HPengine). Putajackunderthegearboxtosupportit. Disconnectthebracketsupportingthegearboxontherear crosspiecebyundoingthefourscrews(5). Unscrewthefixingscrews(6)andremovethecrosspiece(7) supportingthegearboxcompletewiththegearbox/support bracket. Removenuts(14)securingelasticsupports(13)tothechassis. Removebolts(3)securingdriveshaft(4)tothegearbox; remove,ifnecessary,screws(24)securingelasticsupport(25) tothechassis,thenproperlysecurethedriveshafttothe chassis. Takethejackoutfromunderthegearbox. Lifttheengineassemblyandtakeitoutoftheenginebay. In case of vehicles equipped with automatic transmission, disconnect gearbox-chassis cable connector(27)fromthecontrolunit. NOTE 108557 12 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Refitting To refit the engine assembly, carry out the operations described for removal in reverse order, following these instructions: -Beforerefittingthegearboxtotheengine,itisnecessary to remove the pressure plate bearing from the diaphragmspringbyopeningouttheretainingcirclip. Fitthepressureplatebearingonthesleeveofthedrive inputshaftcover,connectingittotheclutchrelease lever. Spread the gearbox input shaft with Molikote molybdenumdisulphidegrease. Asregardsthe5S300-6S400O.D.gearboxunits, proceedasfollows. Engageageartoletthemainshaftturn,rotatingthe propellershaftconnectingflange.Pushthegearboxfully insothatthepressureplatebearingcoupleswiththe diaphragmspringcorrectly. Asregardsthe6S400O.D.gearboxunits,followthe proceduresdescribedinthespecificchapter. -Payspecialattentiontotheoperationsneededtoinstall theengineassemblyintheenginebay. -Checktheconditionsofthecoolantpipesorsleevesand oftheairducts.Replacethemiftheyshowanysignof deterioration. -Checktheflexiblemountingsoftheassemblies:engine andgearbox.Replacethemiftheyshowanysignof deterioration. -Check that the exhaust pipe members have not deterioratedandarenotabouttodeteriorate.Ifthisis so,replacethemalongwiththeflexiblepartsforsecuring them. -Tightenthescrewsornutstotherequiredtorque. -Meticulouslycheckthestateofthevacuumpipe.Itmust shownosignofcracking,cutting,scoringorofbeing crushed.Replaceitifthereisanydoubtatallaboutits soundness.Whenmountingit,makesurethepipedoes notcomeintocontactwithsharpmetalpartsorcorners or with any particularly hot parts. In addition, after assembly,thepipemusthavenobendsorconstrictions, itsradiusofcurvatureshouldbebroadanditmustbe secured to the vacuum pump fitting with a suitable clamp. -makesurethatfuelpipesrapidengagementfittingsare accuratelyclean,andresulttohavebeenfullyinserted and not going to be disconnected after their being connectedtorelatingengagementunions. -Fillthecoolingsystemwithcoolant. -Fillthehydraulicpowersteeringcircuitandbleedtheair asdescribedundertherelevantheading. -Checkthelevelofoilintheengineandgearbox. -rechargeclimatecontrolsystem(ifpresent)asdescribed inchapterrelatingtosection”Bodyandchassis”; -checktheinclinationoflightfromheadlights,ifneeded. -nocoolantleaksfromcoolanthoseandcabinterior heatinghoseconnectionsleeves.Tightenhoseclips,if necessary; -nooilleaksfrombetweencoverandcylinderhead,oil sump and crankcase, oil filter and housing, heat exchangerandcrankcaseorfromlubricationcircuitlines; -no fuel leaks frominjection pumpandinjectorlines. Tightenfittingsifnecessary; -checkthatinjectionpumpcontrollinkageallowstheflow regulation to perform its full travel in both directions. Otherwiseadjustthetravelbyactingonnuts(1-2,Fig. 6); -checkthattheengineshut-offdeviceisworkingproperly; -checkthattheindicatorlightsontheinstrumentpanel and relating to the devices disconnected when the enginewasremovedareworkingproperly. Checkthelevelofoilinthetankandtopitupifnecessary. Liftthevehicleatthefront,startuptheengineandletitidle forsometime. Checkthereisnooilleakagefromthehydrauliccircuitand checkthelevelinthetank. Slowlyturnthesteeringwheelinbothdirectionsofsteering sothattheairinthehydraulicsystemcomesout. Checkthelevelofoilinthetankagainandtopupifnecessary. 501430 Power steering system air bleed Checks and tests Startupengine,leaverunningataspeedslightlyin excessofidlespeedandwaitforcoolanttoheat sufficientlytoopenthermostat.Thencheckthefol-lowing: Whenpositioningtheengineintheenginebay, takespecialcarenottodamagethetoppipeofthe power steering and the soundproof-heatproof claddingoftheenginebay. Oncepositioned,meticulouslycheckthatthetop pipeofthepowersteeringissound. Beforeusingitagain,checkthatthepowersteering oilandcoolantcontainnoimpurities.Iftheydo, filterwithsuitablemeshfilters.Foranytoppingup, refertotheREPLENISHINGFLUIDStableinthe “GENERAL”section. NOTE F1AENGINE 13 D AILY E URO 4 Print603.93.651 Base-March2006

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75248 Figure 5 Disassemblethecompressordrivebelt,ifthereisone,as describedundertherelevantheading. Slackenoffthetensionofthebelt(1)usingaspecificwrench ontheautomatictightener(2)andremovethebelt. 543910 Power steering pump-alternator belt replacement Disassembly Assembly Mountthedrivebelt(1)takingcaretopositionits ribscorrectlyintherespectiveracesofthepulleys. Release the automatic tightener (2). Turn the crankshaftbyoneturntosettlethebelt. Mountthecompressordrivebelt,ifthereisone,and adjustthetensionasdescribedundertherelevant heading. Fitthemiddlesoundproofingguardbackon. 543910 Replacing air-conditioning compressor drive belt Disassembly 90155 Cutelasticbelt(3),asitcannotbereused. Figure 6 Assembly Fittheflexiblebelt(3)equippedwithtool99360191(2) onthepulley(4)andapplythetoolonthepulley(1). Fitthedrivering(5)ontheflexiblebelt(3)andfasten theringonthecompressorsupport. Turn the drive shaft clockwise until the belt fits perfectlyonthepulley(1). 14 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 REPLACING BELTS

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108558 Removetheair-conditionercompressordrivebelt(11)(if thereisone)andthewaterpump/alternatordrivebeltas describedundertherelevantheadings. Removethefan(10)fromtheelectromagneticcoupling(8). Disconnect the electrical connection (9) from the electromagneticcoupling(8). Take out the fixing screws (2) and (3) and remove the mountingtogetherwiththeelectromagneticcoupling(8). Takeoutthescrewsandremovethefixedtightener(4)and theautomatictightener(5). Removescrews(7),thendisassemblepulley(6). Removethewiringfromthetimingcover(12)anddismantle this. Takeoffthecap(2)andremovethesoundproofingcover (20). Disassemblevalvegearcover(12). Disconnectthepipes(19)fromthepipe(18). Disconnecttheelectricconnection(28)fromsensor(27). Takeoutthefixingscrews(26)andremovetheexpansion tank(29);disconnecttheelectricalconnectionforthelevel indicatorfromtheexpansiontankandputthetank(29)aside appropriately. Takeoutthescrews(23)andremovethebracket(22)fixing thesoundproofingcover(20). Removetheplugs(24)fromtheoverheadandtheplug(14) fromtheoilpump—vacuumpumpassemblymounting. Turnthecrankshaftclockwisesoastobeabletoinsertthepins 99360614(25)throughtheholesintheplugs(24)intothe relevant holes of the camshafts and pin 99360615 (15) throughtheholeintheplug(14)intothecrankshaft. Loosenthescrew(17)securingtheautomatictightener(16) andremovethetimingbelt(13). 541257 Replacing timing drive belt Remove,byfollowingthepowerunitdetachmentprocedures, theradiatorassemblytogetherwiththeheatexchangerand thedryingfiltercondenser(ifany),thenplaceitasideproperly. Disassembly Figure 7 F1AENGINE 15 D AILY E URO 4 Print603.93.651 Base-March2006

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85844 Assembling Onlyfortheenginesfeaturingintakevalvedistributingshaftswith taperedshank(fullsection). Inserttool99360608(8)intotheholeofthetoothedpulley(7) and into the corresponding hole of the overhead to prevent changingtheassemblypositionofthetoothedpulley(7)inthe followingoperations. Loosenthescrew(9)fixingthetoothedpulley(7)and,usingtool 99340028,drivethepulley(7)outofthecamshaft. See frame C: holdingthetightenerplate(3)stationarywiththewrench insertedinitshexagon,loosenthefixingscrew(2). Keepingthefixingscrew(2)stationary,turntheplate(3)clockwiseuntilits referencemark ∧ (4)coincideswiththereferencehole(5)ofthefixed portionofthetightener. Intheaboveconditions,tightenthescrew(2)toatorqueof36 ± 4Nm. Rotatetheenginebytwoturnsinitsdirectionofrotationuntilthepointof tool99360615(1)engagementintothedriveshaftisreached.Whenthis pointisexceeded,thedriveshaftshallberotatedbytwomoreturns.Verify, undertheaboveconditions,thatreferencehole(5)isfoundwithinindex(4) as represented in box C ; otherwise, the aforesaid operations shall be repeated. Afterassembly,thebelt(10)tensionmeasuredusingtool99395849must beasfollowsinthefollowingpoints:X,212 ± 12Hz-X 2 ,178 ± 10Hz. Thencompleteassemblybycarryingoutthestepsdescribedfordisassembly inreverseorder. Keepingthescrew(2)stationaryandusingasuitablewrenchonthehexagon oftheplate(3)ofthetightener,turnitanticlockwisetocoverthereference hole(5)locatedonthefixedportionofthetightener(seeframe B ). Intheaboveconditions,tightenthefixingscrew(2)toatorqueof36 ± 4Nm. Tightenscrew(9)tothetorquevaluesbelow: -screw(9)securingpulley(7)tothedistributingshaftwithtaperedshank (fullsection):90Nm; -screw(9)securingpulley(7)tothedistributingshaftwithcylindrical shank(hollowsection):130Nm. Removethetools99360614(6)and99360615(11)forthetiming. Turntheengineinitsdirectionofrotationby8turnstobeabletoputthe tools(6)and(11)backintodothetiming. Intheseconditions,thenotchesofthetimingbelt(10)mustcoincidewith thoseofthepulley(7)andthegear(12). Turntheautomatictightener(1)clockwise,positioningitasshowninframe A . Turnthetimingbelt(10)asshowninthefigureobservingtheprecautions below. Donotbendthetimingbelt.Arrowsindicatingthedirectionofassembly ofthetimingbeltontheengineareshownonthebackofthebelt.The arrowsmustcorrespondtothedirectionofrotationofthebeltandthe notchesmustcoincidewiththoseonthepulley(7)andthegear(12). x=directionofmovementofthetightener y=directionofrotationofthewrench Donotturntheengineintheoppositedirection;if,onturningthe engine,youpassthepointforinsertingthetools(6)and(11),turn theengineclockwisebyanothertwoturns. NOTE NOTE Onlyfortheenginesfeaturingintakevalvedistributingshaftswith taperedshank(fullsection). Ifrequiredtofitthetimingbelt(10)onthepulley(7),removetool 99360608(8)andturnthepulley(7)clockwisebynomorethan halfapulleytooth. NOTE Figure 8 16 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 9 Whenelectricalinjectorsmountedonthevehiclemustbe replaced,meetfollowingwarnings: -whereelectricalinjectorsaredismountedanddonot needtobereplaced,theirmountingpositionhastobe noteddowninordertoremountthemlaterinthesame position;thisisdonetoavoidtoreprogramthecentral unit; -afterreplacingoneormoreinjectors,thecentralunithas tobereprogrammed; -beforemountinganewelectricalinjector,notedown IMAcodeprintedontheinjector,becausethecodeis difficulttoreadaftertheinjectorhasbeenmounted; -wherethecentralunitisreplaced,reprogramthenew centralunitwiththeIMAcodesoftheelectricalinjectors mountedontheengineandcopydowntherectification coefficients(ZFC)ofreplacedcentralunit;whereitisnot possible,theymustberesetandself-learningprocess mustbestartedupagain. Duringenginerunning,EDC16centralunitperformssome checksonelectricalinjectorsminimumflowrate. In certain conditions (overrun: vehicle deceleration with pedal released) an increasing (very small) fuel quantity startingfromzeroisinjectedanditseffectonenginerotation smoothnessisobserved. Injectionstartthresholdisdetectedandstoredbythecentral unit. This self-learning process is carried out on each single cylinder. Therefore,replacinganelectricalinjectorinvolvestheneed ofreprogrammingthecentralunitbyenteringtheIMAcodes of new electrical injectors and resetting the rectification factors(ZFC)ofthecylinderconsidered. Replacingallelectricalinjectorsextendstheneedofresetting to all the rectification coefficients (ZFC) of each single electricalinjector. 105067 Atassistance,codewritteninclearhastobeused(3,Figure9) forcentralunitreplacementandreprogrammingprocedures. InthetablethereisshowntheconversionofOCRcharacters intoArialcharacters. 105066 Figure 10 1.IMAMatrixcode-2.Boschsparepartno.-3.IMAcode inclear-4.Ivecosparepartno.-5.Code-6.Seriesno.-7.Productiondate ElectricalinjectorsarenotassignedanymoretoclassesMin(01) - Med (02) - Max (03); therefore, flow rate deviations from design values are detected, during final check step, by the manufacturer on each single injector and printed with I.M.A. (Injector Menge Abgleichung) [Injector Quantity Offset] code oninjectormagnet. Atengineproductionplant,I.M.A.codeisreadonlinefroman automaticreadingstation,convertedintobarcode,printedon engineidentificationlabelandappliedontheengineitself. Atvehiclesproductionplant,atlineend, E.D.C.16centralunit is programmed automatically reading the engine identification label. ConversiontableofOCR charactersintoARIALcharacters F1AENGINE 17 D AILY E URO 4 Print603.93.651 Base-March2006 755010 REPLACING THE ELECTRIC INJECTORS

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108559 Figure 11 Thoroughly clean the seat of the electro-injectors, takingcare no foreign bodies get into the cylinder barrels. Fit a fresh gasket (12) onto the electro-injector (10) and fit this in the overhead. Complete assembly by carrying out the operations described for disassembly in reverse order, taking the following precautions: -With each disassembly, the fuel pipes must be replaced with fresh ones. -Tighten the nuts, screws and fittings to the prescribed torque. -To tighten the fittings of the fuel pipes, use the wrench in the 99317915 series and the torque wrench 99389829. -After assembly, replenish the coolant as described under the relevant heading. Check assembly of the timing sensor as described under the relevant heading. Partly drain the coolant off from the radiator. Remove the plug (21, Figure 9) and detach the soundproofing cover (20, Figure 9). Disconnect the pipes (19, Figure 9) from the pipe (18, Figure 9). Remove fastening screws (26, Figure 9), then take off expansion tank (29, Figure 9) and disconnect level gauge electric connections (6, figure 7) and sensor (27) electric connections (28, figure 7) from the expansion tank. Disconnect the pipe (20, Figure 12) from the coalescence filter (1, Figure 12). Disconnect the electrical connections (1) from the electro-injectors (10) and (2) from the fuel pressure sensor (8). Press the springs (3) in the direction shown by the arrow and disconnect the fittings of the pipe (4) to recover fuel from the electro-injectors (10). Disconnect the fuel pipes (7) from the electro-injectors (10) and from the hydraulic accumulator (9). Take out the screws (6) and the brackets (5) fixing the electro-injectors (10) to the cylinder head. Using tool 99342153 (11) extract the electro-injectors (10) from the overhead. Removal Refitting 18 F1A ENGINE D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 12 Removal 108560 Take off the camshaft drive belt, as described in the respectivechapter(operation541257). Disconnectcoolantpipes(15)and(14)frompipe(13). Disconnecttheelectricconnectionfrompressuresensor (18). Removethefasteningscrews,thentakeoffexpansiontank (17)bydisconnectingfromthelattertheelectricconnection fromthelevelsensor. Removeoildipstickpipe(12)fromtheinletmanifold. Disconnectoilvapourpipes(20)and(19)fromcoalescence filter(1),thenremovethelatterfromtheoverhead. Disconnectpipe(2)fromtheheatexchangerenginecoolant outletpipe. Takeoffelectricinjectors(4),asdescribedinthe”Replacing theelectricinjectors”chapter(operation775010). Disconnecttheelectricconnectionsfromphasesensor(3), water temperature sensor (8), air pressure/temperature sensor (9), preheating plugs (6), throttle valve assembly actuator(10),fuelpressuresensor(16). Take fuel pipe (7) off hydraulic accumulator (5), high-pressurepumpandinletmanifold. F1AENGINE 19 D AILY E URO 4 Print603.93.651 Base-March2006 540610 CYLINDER HEAD REMOVAL AND REFITTING

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Takeofftheoverheadgasket. Takeoutthetappetsandcarefullyputthemaside. Usingthebushing99355041,takeouttheglowplugs. Takeoutthescrewsfixingthecylinderheadanddetachthis fromthecrankcase. Removethecylinderheadgasket. Figure 13 Loosenclamp(9),thentaketheairconveyoroff. Takeairsuctionsleeve(10)offturboblower(8). Disconnecttheoilpipe(11)fromthecylinderheadandfrom theturbocharger(8). Loosentheclamp(7)anddisconnecttheoilpipe(5)from thecrankcaseunion. Takeoutthescrewsanddisconnecttheexhaustpipe(4) fromtheturbocharger(8). Takeoffthenuts(3)andremovetheturbocharger(8)with itsgasketfromtheexhaustmanifold. Takeoutthescrewsandremovetheoverheadtogetherwith thepins99360614. Close the turbocharger air outlet/inlet appropriately to prevent foreign bodies accidentallygettinginsideanddamagingit. NOTE Thepins99360614appliedsoasnottoalterthe timing after removing the timing belt must be removedfromtheoverheadonlyifthisistobe removed. NOTE 108561 Disconnect the vacuum pipes from E.G.R. valve (2) and turboblower(ifany)actuator(6). 20 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Refitting Refitting requires carrying out the operations for removal in reverse order, while taking the following precautions: Check that the timing tools: -99360614 (6, Figure 13) and 99360608 (8, Figure 13) are inserted in the overhead; -99360615 (11, Figure 13) is inserted in the crankcase as described in “Replacing timing belt.” Check that the mating surfaces of the cylinder head and crankcase are clean. Keep the cylinder head gasket clean. Position the cylinder head gasket with the lettering ”TOP” facing the cylinder head. Figure 14 Diagram of the tightening sequence for the cylinder head fixing screws: -1 st phase: pre-tightening with torque wrench • screws 1-2-3-4-5-6 to a torque of 100 ± 5 Nm; • screws 7-8-9-10 to a torque of 50 ± 2.5 Nm. -2 nd phase: angle closing • screws 1-2-3-4-5-6 90 ° ± 5 ° ; • screws 7-8-9-10 60 ° ± 3 ° . -3 rd phase: angle closing • screws 1-2-3-4-5-6 90 ° ± 5 ° ; • screws 7-8-9-10 60 ° ± 3 ° . A = flywheel side. -Tighten the screws and nuts to the prescribed torque. -The seals and gaskets must not be reused, but replaced with new ones. 75494 Mount the cylinder head. Insert the screws and tighten them, in three successive stages, following the order and method shown in the following figure. To tighten the glow plugs, use the bushing 99355041 and torque wrench 99389819. A It is essential to keep the gasket sealed in itspackage until just before assembly. NOTE The angle closure is done with tool 99395216. NOTE If the engine has run for a period equivalent to = 25,000 km, the toothed timing drive belt must be replaced with a fresh one, no matter what its state of wear. NOTE F1A ENGINE 21 D AILY E URO 4 Print 603.93.651 Base - March 2006

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75271 75272 75273 75569 Figure 16 Figure 15 Figure 17 Figure 18 Lockrotationofthehigh-pressurepumpgear(1)byapplying toolSP.2263(2)asillustratedinthefigure.Removethenut (3)andtakeoutthetool(2). Usingtool99340035(2)appliedas shownin thefigure, extractthegear(1)fromtheshaftofthehigh-pressurepump (3). Takeoutthescrews(1)andremovethehigh-pressurepump (2)fromthewaterpumpmounting(3). Takeoutthescrew(2)andremovethefixedtightener(1). Take out the screws (3) and remove the water pump mounting(4). Removal Refitting Re-attachmentiscarriedoutbyreversingtheorder ofdetachmentoperations.Inparticular,takecareof the following: replace the seal rings, gaskets and high-pressurepipewithnewparts;tightenthenuts, screwsandfittingstothespecifiedtorquevalues. 543210 REPLACING WATER PUMP Removal Refitting Iftheenginehasrunforaperiodequivalentto= 25,000km,thetoothedtimingdrivebeltmustbe replacedwithafreshone,nomatterwhatitsstate ofwear. NOTE Remove the high-pressure pump as described undertherelevantheading. Fittwonewsealsonthewaterpumpandfititback on the crankcase, carrying out the operations described for removal in reverse order and tightening the screwsor nutsto theprescribed torque. Removethetimingdrivebelt,asdescribedintherelevant chapter(operation541257). Disconnectthefollowingitems: - electricconnectionfromthepressuresensor; - fuelpipesfromthehigh-pressurepump. 22 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 771010 REPLACING HIGH-PRESSURE PUMP CPH1

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Figure 19 108562 Removeoilfillingplug(1)andtakeoffsounddeadeningcover (2). Loosenclampanddisconnectairtube(8)fromradiatorand throttlevalveassembly(7). Disconnectelectricalconnection(6)frompressureswitch (5). Removeexpansiontank(4),disconnectelectricalconnection (3)fromthelevelsensorplacedunderthetankandputthe tankononeside. Releaseenginecable(1)fromthefasteningclamps Disconnect electric connections (2) from the electric injectors,thenmovechannel(3)aside. Disconnect electric connection (4) from throttle valve assemblyactuator(6). Removescrews(5)securingthrottlevalveassembly(6)to theinletmanifold. Figure 20 Figure 21 108563 108564 Removenuts(2)securingpipe(3)tothrottlevalveassembly (1). Loosenscrews(4)securingpipe(3)toheatexchanger(5), thentakethrottlevalveassembly(1)offtheinletmanifold. Refitting Forrefitting,reversetheoperationsdescribedfor disconnectionobservingfollowingwarnings: -replacegasketbynewparts; -tightennutsandscrewsatprescribedtorque. Removal PREHEATING PLUGREMOVAL/REFITTING Figure 22 108565 Refitting Forrefitting,reversetheoperationsdescribedfor disconnectionobservingfollowingwarnings: -replacegasketbynewparts; -tightennutsandscrewsatprescribedtorque. Take off the throttle valveassembly,asdescribedinthe respectivechapter. Disconnectelectricconnections(3)frompreheatingplugs (2). UsewrenchSP2275(1)totakeoffpreheatingplugs(2). Removal F1AENGINE 23 D AILY E URO 4 Print603.93.651 Base-March2006 THROTTLE VALVE ASSEMBLY REMOVAL-REFITTING

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Figure 23 108566 Partiallydraintheenginecoolant. Takethefullexhaustpipeofftheengineandthechassis,as describedintherespectivechapter. Loosentheclamps,thendisconnectcoolantpipes(1and3) fromE.G.R.valve(7). Disconnectvacuumpipe(6)fromE.G.R.valve(7). Removefasteningscrews(5-9-10),thenremoveE.G.R.valve (7),togetherwithelbow(11),fromheatexchanger(2),pipe (8)frombracket(4). Actfrominsidetheenginecompartmenttotakeoffthe cylinderheadsound-proofingcover. Disconnect cabheater coolant pipe (2)fromthesimilar E.G.R.valveoutletpipe(1). Removethenut,thentakethepipeoffcoalescencepaper filter(3). Figure 24 Figure 25 108623 108624 Take off the E.G.R. valve,as describedin the respective chapter. Loosenconnectingpipe(6)fasteningnuts(5)inorderto makescrews(7)abletobeaccessed. Removescrews(7),thentakeoffengineliftingbracket(8). Removescrews(9),takepipeunion(2)offthecylinderhead, thentakeoffheatexchanger(1)togetherwithpipes(3and 4)andpipeunion(2). Refitting Forrefitting,reversetheoperationsdescribedfor disconnectionobservingfollowingwarnings: -replacegasketbynewparts; -tightennutsandscrewsatprescribedtorque. -fillexpansiontankwithcoolant. Removal Refitting Forrefitting,reversetheoperationsdescribedfor disconnectionobservingfollowingwarnings: -replacegasketbynewparts; -tightennutsandscrewsatprescribedtorque. -fillexpansiontankwithcoolant. Removal HEAT EXCHANGER REMOVAL/REFITTING Removenut(4)usedforuppersecuringofthrottlevalve assembly (5) connecting pipe (9) to heat exchanger (7). Lowerfasteningnut(6)shallberemovedfromunderthe vehicle. Actfromunderthevehicletoremovetheheatexchanger supportingandengineliftingbracket(8)fasteningscrews. 24 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 5407 E.G.R. VALVE REMOVAL/REFITTING

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Figure 26 BURNT GAS EXHAUST SYSTEM Thefollowingexhaustsystemsareavailableonlight-duty (LD)vehicleswithatotalweightonground(P.T.T.)ofupto 2,840kg: Description -twostandardexhaustsystems: -F1Aengines:single-monolithcatalyst; -F1Cengines:double-monolithcatalyst; -the catalyst may be equipped with an optional continuous-regenerationparticulatefilter(DPF). The standard exhaust system is made up of three components: A.systemlengthwithhose; B.Oxicatcatalyst; C.silencer. Theexhaustsystemismadebytwodifferentmanufacturers: CorTubiandArvinMeritor(ArM).Thecomponentsofboth systemscannotbeinterchangedwitheachother. 507130 OXICAT - OXYDIZER CATALYST Description Theoxidizingcatalyst(1)isapost-treatmentdeviceforex-haustgases.ItisusedtooxidizeCO,HCtransformingthem intocarbondioxide(CO 2 )andsteam(H 2 O). This catalyst also treats saturated and aromatic hydrocarbons formingpartoftheparticulate,suchasthecarbonintheform of soot, metals, water and sulphur compounds that are ex-hausted. Thecylindrical-shapedcatalystconsistsofaceramichoney-combmonolithwhosecellsareplatinum-impregnated,aca-talyzingsubstanceofoxidationreactions.Itstotalvolumetric capacityisequalto600cm 3 withadensityof400cellsper squareinch. Theexhaustgasespassingthroughthecellsheatthecatalyst, convertingthepollutantsintoinertcompounds. ThechemicaloxidationreactionofCO,HCandoftheparti-culate is efficient with temperatures ranging between 200 ° C ÷ 350 ° C. Withtemperatureshigherthan350 ° Citstartsoxidizingthesul-phur contained in the diesel oil, generating sulphur dioxide (SO 2 )andsulphurtrioxide(SO 3 ),whicharethecauseofacid rain. Correctcatalystsizingenableslimitingthetemperature,ob-tainingthegreatestpercentageofconversionofpolluting emissions,whilereducingthefreezingofsulphurcompounds. 108625 F1AENGINE 25 D AILY E URO 4 Print603.93.651 Base-March2006

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108626 Figure 27 The optional exhaust system is made up of three components: A.systemlengthwithhose; B.catalystwithparticulatefilter(DPF); C.silencer ThissystemismanufacturedbyArvinMeritor(ArM). 26 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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108627 For refitting, reverse the operations described for disconnection observing following warnings: -check the conditions of the elastic dowels, taking care to replace the defective ones (if any); -replace gasket by new parts; -tighten nuts and screws at prescribed torque. Refitting Figure 28 Place the vehicle on a pit or auto lift. Disconnect oxygen sensor electric connection (4). Remove fasteners (2), then disconnect exhaust pipe terminal (3) from turboblower flange (1). Properly support the assembly, then use a suitable lever to release supporting hooks (6 and 8) from elastic dowels (5and 7) and take the assembly off the vehicle. Take the assembly components apart, by loosening the retaining clamps. Removal F1A ENGINE 27 D AILY E URO 4 Print 603.93.651 Base - March 2006 EXHAUST PIPE ASSEMBLY REMOVAL/REFITTING

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105073 Placethevehicleonapitorautolift. Carryoutthefollowingoperationsbyactingfromunderthe vehicle: -unscrew nuts (2) securing silencer (3) supporting bracket(1)tothevehiclechassis; -unscrewandremovefasteningscrews(4)offlanges(5) connectingexhaustsilencer(3)andD.P.F.particulate filter(8); -removeexhaustsilencer(3). D.P.F. catalyst removal -unscrew and remove the exhaust gas temperature sensorsatthecatalystinlet (16)andoutlet(17); -unscrewtodisconnectcouplings(6and12)securing rigidpipes(7and11) runningtothepressuresensortoD.P.F.catalyst(8); -properlysecureD.P.F.catalyst(8)tothevehiclechassis; -unscrew nuts (9) securing D.P.F. catalyst (8) filter supportingbracket(10)tothe vehiclechassis; -unscrewandremovefasteningscrews(13)offlanges (15)connectingD.P.F. catalyst(8)filtertotheexhaustgasoutletpipefrom turbine(14); -removeD.P.F.catalyst(8)filter. Exhaust silencer removal Forrefitting,reversetheoperationsdescribedfor disconnectionobservingfollowingwarnings: -check the conditions of the elastic dowels, takingcaretoreplacethedefective ones(ifany); -replacegasketbynewparts; -tightennutsandscrewsatprescribedtorque. Refitting Aftertheoperationhasbeencompleted,andintheevent that either the D.P.F. catalyst or the differential sensor (delta-p)needsreplacing,followtheinstructionsgiveninthe respectivechapters. Figure 29 28 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY COMPONENTS (SYSTEMS EQUIPPED WITH D.P.F. CATALYST)

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507130 Replacing D.P.F. catalyst ReplacingD.P.F.catalystneedsthatallthecountersofbelow indicatedparametersareresetinthecentralunit,as: - particulatequantityinnewfilteriszero,so,ifparticulate quantityisnotreset,filterregenerationwillstartevenifit isnotnecessary; - quantityofaccumulatedashesiszero,so,ifashescounter isnotreset,regenerationfrequencywillbegreaterthan needed,consequentlyincreasingfuelconsumption,and particulatefilterthermalfatigue;and,inextremecases, therewillbeanunnecessaryrequesttorefillengineoil; - post-injectedfuelquantityiszero,so,ifpost-injectedfuel counterisnotreset,theremaybeanearlyrequesttorefill engineoil. The meters used to evaluate the above-mentioned parameterscanberesetbymeansoftheIVECOMODUS-E.A.SY.-IT2000diagnosisinstruments,byprogrammingthe control unit again and performing the DPF catalyst replacementprocedure,inaccordancewiththeinstructions givenbythediagnosisinstruments. WherebothDPFcatalystisreplacedandengineoil isrefilled,resettingpost-injectedfuelcounterisnot necessary. NOTE 540743 Replacing differential sensor (delta-p) Pressuredifferencebetweengaspressureatcatalystmodule inlet and gas pressure at ceramic walls filter outlet is convertedintoavoltagesignal(Vout)bypressuresensor. During engine running, E.D.C. 16 central unit performs checksondifferentialpressuresensordriftandcalculates enginecompensationandrunningvalues,andcorrectsthem. Consequently,afterreplacingthesensor,itisnecessaryto resetrectificationcoefficients. - regenerationstatus:regenerationunnecessary,inprogress, interrupted,resumed; - milescoveredandtimesfromlastcompleteregeneration; - differentialpressure(delta-p)sensordriftself-rectification; - oxidiser catalyst drift; consequently, if catalyst ageing function is not reset, quantities of unnecessary post-injectionsmightbepresent. The meters used to evaluate the above-mentioned parameterscanberesetbymeansoftheIVECOMODUS-E.A.SY.-IT2000diagnosisinstruments,byprogrammingthe control unit again and performing the differential sensor replacementprocedure,inaccordancewiththeinstructions givenbythediagnosisinstruments. F1AENGINE 29 D AILY E URO 4 Print603.93.651 Base-March2006

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108321 Figure 30 30 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 ENGINE VIEWS

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108157 108158 108159 Figure 31 Figure 32 Figure 33 LEFT-HANDSIDEVIEW FRONTVIEW REARVIEW F1AENGINE 31 D AILY E URO 4 Print603.93.651 Base-March2006

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108160 Figure 34 Figure 35 TOPVIEW RIGHT-HANDSIDEVIEW A .Turbochargerwithpressurereliefvalve(Waste-Gate,ENGINES96/116HP) 108161 A 32 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Gas emissions The engines conform to the Euro 4 standards on gas emissions(measurementonenginebenchaccordingtoECE 15+EUDCcycle),withthefollowinglimitsfixedbytheESC andELR1999/96-2001/27standards: levelB: - CO(carbonmonoxide) 0,74 g/km - NOx(nitrogenoxide) 0,39g/km - HC(unburnthydrocarbons)+NOX (nitricoxide) 0,46g/km - Particulate 0,06g/km Testfuel:CECRTF73-T90.5=0.05%. Smokiness Theenginesconformtothelimitsofsmokinessrequiredwith thefollowingexhaustsmokevalues: Maximumpower(BoschBSUopacimeterdegrees) 1.5 Maximumtorque(BoschBSUopacimeterdegrees) 1.5 Noise emissions Maximummeannoiselevel,Lpa,ofthestandardengines measuredaccordingtoISOStd.3745(microphonesat1m fromtheenginesurfaces): Idling (800rpm) 72dBA Atthemaximumtorque 84dBA Fullpower (3800rpm) 93dBA. F1AENGINE 33 D AILY E URO 4 Print603.93.651 Base-March2006 EMISSIONS

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Enginefamily Familydevelopment Engine Emissionlevel UseNo. Supply/injection No.cylinders Enginecycle—cylinderposition 0= 4-stroke, vertical 4=4cylind. 6=6cylind. 8=DI.TCA 1=Truck 2=Bus 4=E.M.mach. &tractors 6=Nautical 9=Military 0481 F= 71kW-( 96CV)3000-3700rpm-244Nm/1800 ÷ 2800rpm 0481 G= 85kW-(116CV)3000-3900rpm-270Nm/1800 ÷ 2800rpm 0481 H=100kW-(136CV)3600-3900rpm-320Nm/1700 ÷ 2900rpm F 1 8 4 0 E A 1 A F * + Typeapprovalpower 34 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 7 ENGINE IDENTIFICATION CODE

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CHARACTERISTICCURVESOFENGINEF1AE0481F 102408 Max OUTPUT 71 kW at 3000 ÷ 3700 rpm Max TORQUE 240 Nm at 1800 ÷ 2800 rpm 96 HP 24.4 kgm Figure 36 rpm F1AENGINE 35 D AILY E URO 4 Print603.93.651 Base-March2006 CHARACTERISTIC CURVES

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102409 CHARACTERISTICCURVESOFENGINEF1AE0481G Max OUTPUT 85 kW at 3000 ÷ 3900 rpm Max TORQUE 270 Nm at 1800 ÷ 2800 rpm 116 HP 27.5 kgm Figure 37 rpm 36 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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102410 CHARACTERISTICCURVESOFENGINEF1AE0481H Max OUTPUT 100 kW at 3600 ÷ 3900 rpm Max TORQUE 320 Nm at 1700 ÷ 2900 rpm 136 HP 31.6 kgm Figure 38 rpm F1AENGINE 37 D AILY E URO 4 Print603.93.651 Base-March2006

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SELF-ADHESIVE LABEL Figure 39 Figure 40 CRANKCASE MARKING 108448 112216 Engine variant Iveco drawing number — 9 digits Engine serial number — 7 digits GAN — 9 characters Electro-injector class 38 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 EXAMPLE A = IVECOtrademark IVECO B = IVECOnameofenginevariant** F1AE0481A*A001 C = Engineserialnumber 1359862 D = 1 st digit,mainjournalno.1(enginefront) E = Mainbearingselectiondiameters 12345 F = Barrelselectiondiameters 1234 G = 1 st digit,cylinderno.1(enginefront) (**)Dataobtainablefrom“XZ”engineorderingnumberinformation

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F1AENGINE 39 D AILY E URO 4 Print603.93.651 Base-March2006 GENERAL SPECIFICATIONS Type F1AE0481 F F1AE0481 G F1AE0481 H Cycle Diesel4strokes Supply Turbochargedwithintercooler Injection Direct Numberofcylinder 4inline ∅ Bore mm 88 Stroke mm 94 + + +.. = Totaldisplacement cm 3 2300 ρ Compressionratio 18 Maximumpower kW (HP) 71 (96) 85 (116) 100 (136) rpm 3900 3900 3900 Maximumtorque kW (HP) 240 (24.4) 270 (27.5) 310 (31.6) rpm 1800 ÷ 3200 1800 ÷ 3150 1800 Slowrunningofengine withnoload rpm 800 Fastidlingspeedof enginewithnoload rpm 4600 PressureatT.D.C. * bar 20 ÷ 26 bar Minimumpermissible pressureatT.D.C. * bar 16 (*) Thepressureismeasuredbysettingtheengineturningwiththeaidofjustthestartermotor,withanoiltemperatureof 40—50 ° C.

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40 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Type F1AE0481 F F1AE0481 G F1AE0481 H A B TIMINGSYSTEM StartbeforeT.D.C. A endafterB.D.C. B 14 ° 27 ° C D StartbeforeT.D.C. D endafterB.D.C. C 54 ° 10 ° X Fortimingcheck mm X mm Operation mm X mm ----SUPPLY HighpressurefuelfeedsystemBOSCHEDC16 ComposedofCP1high-pressurepump,electro-injectors, hydraulicaccumulator(rail),EDCcontrolunit,pressureand temperaturesensors Pumpsetting Withpistonno.1atT.D.C. -X Startofdelivery mm -Electroinjectorstype BOSCHCR122 Electro-injectorstype BOSCHCR12-2 Injectionsequence 1-3-4-2 ba r Injectionpressure bar 1600

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F1AENGINE 41 D AILY E URO 4 Print603.93.651 Base-March2006 Type F1AE0481 F F1AE0481 G F1AE0481 H TURBOCHARGING Withintercooler Turbochargertype KKKK03-2074-CCB5.88 GarrettGT17 Turbochargertype Turbochargershaftradialplay --Turbochargershaftendfloat --Maximumstrokeofpressurereliefvalveopening mm 3.35 ± 0.5 -Pressurecorrespondingtothemaximumstroke bar 1.6 ± 0.005 -Actuatorcalibration: -vacuum:0mmHg valve fullyopen -vacuum:0.2bar valvetravel mm ---2 ÷ 4 -vacuum:0.64bar valvetravel mm -10.5 ÷ 12.5 LUBRICATION forcedbygearpump,pressurereliefvalve,oilfilterwith integralcartridgewithtotalfiltering bar Oilpressurewithenginehot (100 ° C ± 5 ° C): atidlingspeed bar ≥ 0.6 attopspeed bar 4 COOLING bycentrifugalpump,thermostatforadjustment,coolant temperature,fanwithelectromagneticcoupling,radiator, heatexchanger Waterpumpcontrol: bybelt Thermostat: startofopening: N.I. 82 ± 2ºC FLUIDS Capacity: enginesump liters atminimumlevel kg 3 2.65 UraniaDaily UraniaLD5 enginesump litres atmaximumlevel kg 4.3 3.78 quantityofoilforfirst liters quantityofoilforfirst liters filling kg 5.3 5.02

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42 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 ASSEMBLY DATA — CLEARANCES Type F1AE0481 F F1AE0481 G F1AE0481 H CYLINDER ASSEMBLY AND CRANK MEMBERS mm ∅ 1 Cylinderliners: ∅ 1 88.002 ÷ 88.022 Cylinderliners: -L outsidediameter ∅ -∅ 2 length L -Cylinderliners— crankcaseseats (interference) -Outsidediameter ∅ 2 -∅ 3 X Cylinderliners: (protrusionfrombottom ofcrankcase) -insidediameter ∅ 3 -∅ 1 Pistons: suppliedassparestype MAHLEMONDIAL 8 X measurement X 8 87896 87910 ∅ 2 outsidediameter ∅ 1 87.896 ÷ 87.910 31003 31009 ∅ 2 seatforpin ∅ 2 31.003 ÷ 31.009 Piston-cylindersleeve 0.092 ÷ 0.126 Pistondiameter ∅ 1 0.4 X Pistonprotrusion fromcrankcase X 0.3 ÷ 0.6 3 ∅ Pistongudgeonpin ∅ 3 30.990 ÷ 30.996 Pistongudgeonpin—pinseat 0.07 ÷ 0.019

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F1AENGINE 43 D AILY E URO 4 Print603.93.651 Base-March2006 Type F1AE0481 F F1AE0481 G F1AE0481 H CYLINDER ASSEMBLY AND CRANK MEMBERS mm Typeofpiston MAHLEMONDIAL 1 X X1* MAHLEMONDIAL 2200 ÷ 2230 X 1 2 X Pistonringslots X2 2.200 ÷ 2.230 2050 ÷ 2070 X 3 2 X X3 2.050 ÷ 2.070 2540 ÷ 2560 3 X * measuredon ∅ of85mm 2.540 ÷ 2.560 1 S Pistonrings: S1* 2.068 ÷ 2.097 1 2 S S S2 1.970 ÷ 1.990 3 2 S S S3 2.470 ÷ 2.490 3 S *Measuredat2.5mm fromtheouterdiameter Pistonrings—slots 1 0.103 ÷ 0.162 2 0.060 ÷ 0.100 3 0.050 ÷ 0.090 Pistonrings 0.4 X1 2 X Pistonringendopeningin cylinderliner: 3 2 X X X1 0.20 ÷ 0.35 3 X X2 0.60 ÷ 0.80 X3 0.25 ÷ 0.50 1 ∅ Smallendbushingseat Ø1 34.460 ÷ 34.490 ∅ 2 Connectingrodbearingseat* Ø2 62.833 ÷ 62.841 *connecting rod suppliedas sparepart ∅ 4 Smallendbushingdiameter ∅ 3 outside ∅ 4 34.560 ÷ 34.585 S inside ∅ 3 31.010 ÷ 31.020 S Bigendbearingshells Bigendbearingshells suppliedassparepart S -Smallendbushing—seat (interference) 0.07 ÷ 0.125 Pistongudgeonpin—bushing 0.014 ÷ 0.030 Bigendbearingshells 0.254-0.508

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44 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Type F1AE0481 F F1AE0481 G F1AE0481 H CYLINDER ASSEMBLY AND CRANK MEMBERS mm X Measurement X 125 Maximumerror onalignmentof connectingrodaxes = 0.09 1 2 ∅ ∅ Mainjournals ∅ 1 No.1-2-3-4 No.5 71.182 ÷ 71,208 76.182 ÷ 76.208 Crankpins ∅ 2 59.015 ÷ 59.038 S 1 S 2 Mainbearingshells S1* 2.165 ÷ 2.174 S 1 S 2 Bigendbearingshells S2* 1.883 ÷ 1.892 *suppliedasspareparts 3 ∅ Mainbearinghousings ∅ 3 No.1-2-3-4 No.5 75.588 ÷ 75.614 80.588 ÷ 80,614 Bearingshells-mainjournals 0.032 ÷ 0.102 Bearingshells— crankpins 0.035 ÷ 0.083 Mainbearingshells 0.254-0.508 Bigendbearingshells 0.254-.,508 1 X Mainjournal forshoulder X1 31.020 ÷ 31.170 X 2 Mainbearinghousing forshoulder X2 25.790 ÷ 25.840 X3 Halfthrustwashers X3 30.810 ÷ 30.960 Crankshaftshoulder 0.060 ÷ 0.260

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F1AENGINE 45 D AILY E URO 4 Print603.93.651 Base-March2006 Type F1AE0481 F F1AE0481 G F1AE0481 H CYLINDER HEAD — TIMING SYSTEM mm ∅ 1 Guidevalveseats oncylinderhead ∅ 1 9.980 ÷ 10.000 2 ∅ ∅ 2 6.023 ÷ 6.038 ∅ 3 ∅ 2 Valveguide ∅ 3 10.028 ÷ 10.039 Valveguidesandseatsonhead (interference) 0.028 ÷ 0.059 Valveguides 0.05-0.10-0.25 ∅ 4 Valves: ∅ 4 5.975 ÷ 6.000 ∅ 4 α 5.975 ÷ 6.000 44 ° 45’ ± 7.5’ ∅ 4 5.975 ÷ 5.990 α α 5.975 ÷ 5.990 44 ° 45’ ± 7.5’ Valvestemandrelevantguide 0.023 ÷ 0.063 0.033 ÷ 0.063 Seatonheadforvalveseat: ∅ 1 31.390 ÷ 31.415 ∅ 1 ∅ 1 31.390 ÷ 31.415 2 ∅ Outside diameter of valve seats;angleofvalveseatson 2 ∅ seats;angleofvalveseatson cylinderhead: ∅ 2 31495 ÷ 31510 ∅ 2 α 31.495 ÷ 31.510 44.5 ° ± 5’ α α ∅ 2 α 31.495 ÷ 31.510 44.5 ° ± 5’ X X X Recessing X 0.5 ÷ 0.8 0.5 ÷ 0.8

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46 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Type F1AE0481 F F1AE0481 G F1AE0481 H CYLINDER HEAD — TIMING SYSTEM mm Betweenvalve 0.08-0.12 Betweenvalve seatandhead 0.08-0.12 Valveseats -Valvespringheight: freeheight H 54 H H 1 underaloadof: H H 1 H 2 N243 ± 12 H1 45 H 2 N533 ± 24 H2 35 X Injectorprotrusion X 2.77 ÷ 3.23 ∅ Seatsfortappetson cylinderhead normal ∅ 12.016 ÷ 12.034 ∅ Normaldiametertappets 11.988 ÷ 12.000 Betweentappetsandseats 0.016 ÷ 0.046 Camshaftpinseatsin cylinderoverhead 1 ⇒ 7 ∅ ∅ ∅ ∅ 1 ∅ 2 48.987 ÷ 49.013 46987 ÷ 47013 ∅ ∅ ∅ ∅ 2 ∅ 3 46.987 ÷ 47.013 35.987 ÷ 36.013 ∅ 2 Camshaftbearingjournals ∅ 1 ∅ 2 48.925 ÷ 48.950 46925 ÷ 46950 ∅ ∅ 1 3 ∅ 2 ∅ 2 ∅ 3 46.925 ÷ 46.950 35.925 ÷ 35.950 Supportingpinsandseats 0.037 ÷ 0.088 H Usefulcamheight H H 3.811 H 4.230

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F1AENGINE 47 D AILY E URO 4 Print603.93.651 Base-March2006 TOOLS TOOLNO. DESCRIPTION 99305047 Appliancetocheckspringloads 99317915 Setofsixbox-typewrenches(14-17-19mm) 99322205 Rotarytelescopicstandforoverhaulingassemblies (capacity700daN,torque120daN/m) 99340028 Extractorforcamshaftpulley 99340035 High-pressurepumptoothedpulleyextractor 99340059 Tooltoremovecrankshaftfrontgasket

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48 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99340058 Tooltoremovecrankshaftreargasket 99342153 Tooltoextractinjectors 99346254 Keyingdeviceformountingcrankshaftfrontgasket 99346255 Keyingdeviceformountingcrankshaftreargasket 99360076 Tooltoremovecartridgefilters 99360183 Pliersformountingringsonenginepistons

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F1AENGINE 49 D AILY E URO 4 Print603.93.651 Base-March2006 TOOLS TOOLNO. DESCRIPTION 99360191 Guideforflexiblebelt 99360260 Toolforremovingandrefittingenginevalves 99360306 Tooltoretainengineflywheel 99360544 Armforremovingandrefittingengine 99360605 Bandtoinsertstandardandoversizedpistonsintothecylinders 99360608 Toolforpositioningtiminggear

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50 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99360614 Tool(2)forcamshafttiming 99360615 Toolforcrankshafttiming 99361038 Bracketssecuringenginetorotarystand99322205 99367121 Manualpumptomeasurepressureandvacuum 99370415 Comparatorholderbase 99374458 Keyingdeviceformountingoilsealgasketoncamshaftfrontcover

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F1AENGINE 51 D AILY E URO 4 Print603.93.651 Base-March2006 TOOLS TOOLNO. DESCRIPTION 99389819 Torquewrench(0-10Nm)withsquare1/4”connection 99389829 9x12couplingtorquewrench(5-60Nm) 99394038 Millingcuttertoregrindinjectorseat (8140.63engineexcluded) 99395216 Pairofmetersforangulartighteningwithsquare1/2”and3/4” connection 99395363 Completesquaretocheckforconnectingroddistortion 99395603 Comparator(0-5mm)

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52 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99395687 Boremeter(50—178mm) 99395849 Deviceforcheckingbelttension (frequencyfrom10.0to600Hz) 99396037 Centringringforcrankshaftfrontgasketcover EXPERIMENTAL TOOLS Thissectionshowstheworkingdrawingsfortheexperimentaltools(S.P.)usedinoverhaulingtheenginedescribedinthis section,whichmaybemadebytherepairshops.

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F1AENGINE 63 D AILY E URO 4 Print603.93.651 Base-March2006 TIGHTENING TORQUE PART TORQUE PART Nm kgm CylinderheadcentralfixingscrewM14x1.5 firstphase:pre-tightening 100 9.8 secondphase:angle 90º thirdphase:angle 90º CylinderheadsidefixingscrewM14x1.5 firstphase:pre-tightening 50 4.9 secondphase:angle 60º thirdphase:angle 60º HexscrewwithflangeM8x1.25L40fixingoverhead 25 2.5 HexscrewwithflangeM8x1.25L77fixingoverhead 25 2.5 CentralbasefasteningscrewM11x1.25 firstphase:pre-tightening 50 ± 5 5 ± 0.5 secondphase:angle 60º ± 2.5º thirdphase:angle 60º ± 2.5º OuterbasefasteningscrewM8x1,5 26 2.6 Connectingrodcapfixingscrew firstphase:pre-tightening 40 4 secondphase:angle 60 ° HexscrewwithflangeM12x1.25L43fixingengineflywheel firstphase:pre-tightening 30 3 secondphase:angle 90 ° Cylindricalsocketheadscrewfixingphonicwheeltocrankshaft 15 1.5 Nozzleunion 25 2.5 TaperedthreadedsocketplugR3/8”x10oilcircuit 22 2.2 WaterdrainplugM14x1.50L10 25 2.5 UniononcrankcaseforoilreturnfromturbochargerR3/8” 50 5 ScrewM6x1fixingsuctionstrainer 10 1 MalethreadedsocketplugM28x1.5 100 10 HexscrewwithflangeM8x1.5L35fixingframeretainingoilsump 25 2.5 HexscrewwithflangeM6x1L30fixingframeretainingoilsump 10 1 HexscrewwithflangeM6x1L25fixingframeretainingoilsump 10 1 TaperedthreadedsocketplugM6x1x8.5* 2 0.2 MalethreadedplugwithO-ringM22x1.5L16 50 ± 10 5 ± 1 HexscrewwithflangeM6x1L20fixingoilvacuumpumpassembly 10 1 HexscrewwithflangeM6x1L50fixingoilvacuumpumpassembly 10 1 OilfiltercartridgeM22x1.5L7 25 2.5 UnionfixingheatexchangerM22x1.5 80 ± 5 7.8 ± 0.5 HexscrewwithflangeM12x1.25L55fixingtoothedpulleycontrollingtimingsystem 130 13 HexscrewwithflangeM18x1.5L78fixingpulleyoncrankshaft 300 30 HexscrewwithflangeM8x1.25L45fixingpulleyondamper 30 3 HexscrewwithflangeM8x1.25L60fixingautomatictightener 36 3.6 HighpressurepumpgearfasteninghexnutwithflangeM14x1.5 70 6.9 HexscrewwithflangeforcompleteguidepulleyrollerfortimingbeltM8x1.25L45 25 2.5 * ApplyLoctiteonthethread.

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64 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 PART TORQUE PART Nm kgm TaperedthreadedsocketplugR3/8”x10 29 2.9 TaperedthreadedsocketplugR1/8”x8 7 0.7 TaperedthreadedsocketplugR1/4”x9 9 0.9 HexscrewwithflangeM12x1.25L35fixinggearforcamshaftchain 115 11.5 HexscrewwithflangeM6x1L25fixingchaincover 10 1 HexscrewwithflangeM6x1L35automatictightener 10 1 ThreadedplugM14x1.5L10 30 3 BalljointfasteningscrewM6x1x9 10 1 HexscrewwithsplitwasherandflatwasherfixingwaterpumpM8x1.25L28 25 2.5 HexscrewwithsplitwasherandflatwasherfixingwaterpumpM6x1L20 10 1 FlangedscrewM8x1.25fixingwateroutletunion 25 2.5 FlangedscrewM8x1.25fixingpiezometrictubeonintakemanifold 25 2.5 FlangednutM8x1.25fixingpiezometrictubeonbracket 18 1.8 Self-tappingscrewL16fixingbracketoncoalescencefiltercover 6 0.6 FlangedscrewM6x1x16fixingpiezometrictube 10 1 Self-tappingflangedscrewL14fixingpiezometrictubeonfrontcover 2 0,2 CouplingM10x1x10fixingvapouroutlet 12 1.2 HexscrewwithflangeM8x1.25L25fixingthermostat 25 2.5 HexscrewwithflangeM8x1.25L100fixingair-conditionercompressor 25 2.5 HexscrewwithflangeM8x1.25L120fixingair-conditionercompressor 25 2.5 HexscrewwithflangeM8x1.25L50fixingair-conditionercompressormounting 25 2.5 HexscrewfixingbottomofalternatorM10x1.25L40andM10x1.5L50 50 5 HexscrewfixingtopofalternatorM10x1.25L40 --HexscrewwithflangeM10x1,25forcompleteguidepulleyrollerfortimingbeltM10x1.25L50 40 4 AllenheadscrewfixingautomatictightenerM8x1.25L65 25 2.5 HexscrewwithflangeM8x1.25L45fixingpulleyondamper 30 3 ScrewplugwithwasherM12x1.5L20 30 3 VacuumpumpcouplingM10x1onoilvacuumpumpassembly 10 1 FlangedscrewM6x1x27fixingtimingcover 7.5 0.7 HexscrewwithflangeM6x1L27fixingcoalescencefilterassembly 10 1 ScrewM6x1L12fixingsumpblow-byoildrainpipes 10 1 UnionM20x1.5blow-bybreathersocket 35 3.5 HexscrewwithflangeM8x1.25L90fixingintakemanifold 30 3 FlangednutM8x1.25fixingexhaustmanifold 25 2.5 FlangedscrewM6x1fixingoilfillpipe 10 1 FlangedscrewM8x1.25fixingoildipstickpipe 28 2.8 GlowplugM8x1.25 8 ÷ 11 0.8 ÷ 1.1 High-pressure injection system HexscrewwithflangefixinghydraulicaccumulatorM8x1.25L50 28 2.8 ScrewM8x1.25L30fixinghigh-pressurepump 25 2.5 ScrewM8x1.25fixingbracketanchoringfueldeliverypipe 25 2.5 Hexscrewfixingelectro-injectorretainingbracket 28 2.8 Hexscrewwithflangefixinglow-pressurefuelpipesM6x1L30 10 1 * WithLoctite.

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F1AENGINE 65 D AILY E URO 4 Print603.93.651 Base-March2006 PART TORQUE PART Nm kgm PipefittingM12x1.5tosecureelectricinjectorssideandhighpressurepumpsidepiping (weldedhydraulicaccumulator) 25 ± 2 2.5 ± 0.2 PipefittingM14x1.5tosecurehydraulicaccumulatorsidepiping (weldedhydraulicaccumulator) 19 ± 0.2 1.9 ± 0.2 UnionM12x1.5forfixingfuelpipes 25 2.5 FlangedscrewM12x1.5fixingwatertemperaturesensor 30 3 FlangedscrewM6x1fixingairtemperaturesensor 10 1 FlangedscrewM6x1fixingenginespeedsensor 10 1 Socket-headscrewM6x1fixingtimingsensor 10 1 Cylindricalsocket-headscrewM6x1forV-clamp 8 0.8 NutM8x1.25fixingturbocharger 25 2.5 Flangedscrew(M8x1.25)forturboblowergasoutletpipefastening 25 2.5 FittingR1/4“forpipedeliveringoiltoturbocharger 40 4 Nut(M14x1.5)forfasteningtheoildeliverypipetotheturboblower 40 4 Pipeunion(M12x1.5)forfasteningtheoildeliverypipetotheturboblower 35 3.5 FittingM22x1.5foroilreturnpipefromturbocharger 45 4.5 Flangedscrewfixingoilreturnpipefromturbocharger 10 1 HexscrewwithflangeM8x1.25L40fixingpowersteeringpump 25 2.5 TEflangedscrew(M8x1.25)forpowersteeringpumppulleyfastening 25 2.5 HexscrewwithflangeM12x1.25L155fixingelectromagneticcouplingmounting 90 9 HexscrewwithflangeM8x1.25L20fixingmanoeuvringhooks 25 2.5 FlangedscrewsM10x1.25fixingenginemounts 50 5 OillevelsensorM12x1.25 25 2.5 Thermometricswitch/transmitterM16x1.5 25 2.5 OilpressureswitchM14x1.5 40 4 Cylindricalsocket-headscrewM8x1.25fixingE.G.R.valve 25 2.5 FlangedscrewM8x1.25fixingE.G.R.heatexchanger 25 2.5 FlangednutM8x1.25fixingelbow 25 2.5 CompensatorfasteningnutM8x1.25 25 2.5 Oilpressureregulationvalvecap 100 10 Power unit suspension Screw(M8x16)securingtheelasticdoweltothegearboxcross-member 23.5 ± 2.5 2.3 ± 0.2 Nut(M12)securingthegearboxcross-membertothechassis 92 ± 9 9.2 ± 0.9 Nut(M12)securingtheenginesupportstotheelasticdowels 49 ± 4 4.9 ± 0.4 Nut(M12)securingthegearboxbracketontotherearcross-memberelasticdowel 49 ± 4 4.9 ± 0.4 Locknut(M10)withflange,securingtheenginesupportstothechassis 52.5 ± 5.5 5.2 ± 0.5 Screw(M10x30)securingthegearboxsupporttothegearshift 46.5 ± 4.5 4.6 ± 0.4

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Figure 41 LONGITUDINALCROSS-SECTIONOFENGINE 108442 66 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 42 TRANSVERSECROSS-SECTIONOFENGINE 108443 F1AENGINE 67 D AILY E URO 4 Print603.93.651 Base-March2006

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108162 Figure 43 Tobeabletofitthebrackets99361038ontothecrankcase to secure the engine to the stand for overhauling, it is necessarytoremovetheleftandrightenginemounts(3)and disconnecttheoilpipe(2)fromtheturbocharger(1)and fromthecrankcase. Blocktheturbochargerair/exhaustgasinletsand outletstopreventforeignbodiesgettinginside. NOTE Fitthebrackets99361038(9)tothecrankcaseandusethese tosecuretheenginetotherotarystand99322205(6).Drain theoilfromtheenginebyremovingtheplugfromtheoil sump. Takeoffthefan(ifany)fromelectromagneticjoint. Ifthefollowingpartshavenotalreadybeenremoved,doso now: -oilfillingcap(1); -sound-proofingcover(2); -engine cable complete with raceway (13) by disconnectingtheelectricconnectionsofthesamefrom: - electricinjector(3); - preheatingplugs(5) - hydraulicaccumulatorpressuresensor(14); - throttlevalveactuator(11); - inletmanifoldairpressure/temperaturesensor(12); - revssensor(8); - high-pressurepumppressureregulator(10); - phasesensor(4) - thermostatcoolingtemperaturesensor(7). Figure 44 108163 68 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 OVERHAULING ENGINE 540110 DISASSEMBLING THE ENGINE AT THE BENCH

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Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Takeoutthescrews(2)and(3)andremovethemounting (1)togetherwiththeelectromagneticcoupling(4). Cut compressor (2) drive elastic belt (1),as it cannotbe reused. 75248 Usingthespecificwrenchontheautomatictightener(2), slackenthetensionofthebelt(1)andremoveit. 75249 Takeoutthescrew(4)andremovetheautomatictightener (3).Takeoutthescrew(2)andremovethefixedtightener (1).Takeoutthescrews(5)andremovethepulley(6). Takeoutthebolt(1),thebottomscrews(3and4)and removethealternator(2)fromthemounting(5). 75251 Takeoutthescrew(3)andremovethemounting(1)ofthe powersteeringpump(4).Usingasuitablewrench,remove theoillevelsensor(2). 108164 108165 108166 F1AENGINE 69 D AILY E URO 4 Print603.93.651 Base-March2006 ssll

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Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Disconnectthefuelpipes(2)fromtheelectro-injectors(3) andfromthehydraulicaccumulator(1)(rail). 75253 75254 Takeoutthescrews(1)andremovethetimingcover(2). Takeoutthescrew(3)andremovethetightener(4). Takeoutthescrews(1)and(5)andremovethegears(2)and (6).Removethetoothedbelt(7). Loosenclamp(6),thendisconnectpipe(5)frompipeunion (7). Removenut(4),thenremovepipe(3)fromfilter(1). Undoscrews(2),thenremovecoalescencefilter(1). Removescrews(2),thentakebracket(1)off. Removescrews(4),thentakeoilfillingpipeunion(3)off. Pressthesprings(3)inthedirectionshownbythearrowand disconnectthefittingsofthepipe(1)recoveringfuelfromthe electro-injectors(2). 108168 108169 108167 108170 70 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Take out the screws (2) andthe brackets (3) fixingthe electro-injectors(1)tothecylinderoverhead. Usingtool99342153(1)extracttheelectro-injectors(2) fromtheoverhead. Removescrew(1)andnut(3),thenremovepipe(2). Takeoildipstickpipe(4)outoftheenginebase. Loosen clamp (6), then disconnect fuel pipe (5) from high-pressurepump(7). Removescrew(3)securingpipe(2)retainingbracket(4)to theinletmanifold. Disconnect pipe (2) fromhydraulic accumulator (1) and high-pressurepump(7). Take out the screws (1) and remove the hydraulic accumulator(2). Removescrews(4),thendisconnectlow-pressurepipes(5) frombracket(3). Remove coupling (1), then disconnect pipes (5) from high-pressurepump(2). 108171 108172 108174 108175 108173 108176 F1AENGINE 71 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Loosenclamp(7),thendisconnectpipe(6)fromEGRvalve (8). Loosen clamp (4), then disconnect pipe (5) from heat exchanger(3). Removescrews(2and9),thendisconnectheatexchanger (3,withitsrespectivegaskets),togetherwithEGEvalve(8), frompipe(1)andelbow(10). Removenuts(4),thentakepipe(5),togetherwithitsgasket, offthrottlevalveassembly(1). Removescrews(3),thentakethrottlevalveassembly(1), togetherwithitsgasket,offinletmanifold(2). Removescrew(4),thendisassembleairpressure/temperature sensor(3). Removescrews(1),thentakeoffinletmanifold(2)together withitsgasket. UsewrenchSP.2275(1)todisassemblepreheatingplugs(2). Removenut(1),thentakeoffphasesensor(2).Useasuitable wrenchtotakeofftemperaturesensor(3). Removescrews(4),thentakeoffthermostatcase(5). 108177 108179 108178 108180 108181 72 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 68 Figure 69 Figure 70 Figure 71 Figure 72 Removescrew(2),thentakeoffpipeunion(1). Removescrews(3)securingelbow(4)tobracket(5). Removecoupling(5). Disconnectoilpipe(4)fromthecylinderheadcouplingand turboblower(3)coupling. Removenuts(2),thentaketurboblower(3),togetherwith itsgasket,offexhaustmanifold(1). Remove nuts (5) andspacers (4),then take off exhaust manifold(1)togetherwithitsgasket,completewithpipe(2) andelbow(3). Takeoutthescrews(1)andremovetheoverhead(2). Figure 73 75269 Takeoffthegasket(1)andremovethehydraulictappets togetherwiththerockerarms(2). 75270 Takeoutthescrews(1)andremovethecylinderhead(2). Checktheprotrusionofthepistonsasdescribed undertherelevantheadingtocheckthepossibility offacingthecrankcaseifithasdeformed. NOTE 108182 108183 108185 108184 F1AENGINE 73 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Blockrotationofthehigh-pressurepumpgear(1)byapplying toolSP2263(2)asshowninthefigure.Takeoffthenut(3) andremovethetool(2). Takeoutthescrews(1)andremovetheoilpump—vacuum pumpassembly(2). 75271 Usingtool99340035(2),appliedasinthefigure,extractthe gear(1)fromtheshaftofthehigh-pressurepump(3). 75272 75273 Takeoutthescrews(1)andremovethehigh-pressurepump (2)fromthewaterpumpmounting(3). 75274 Take out the screws (1) and remove the water pump assembly(2). 75275 Removetheplug(6)fromtheoilpump—vacuumpump assembly(1). Position the crankshaft so as to be able to insert tool 99360615(5)intoitsholethroughtheholeintheplug(6) andblockrotationofthecrankshaft. Takeoutthescrew(3)withthespacer(4)beneathand removethegear(2). Tool99340059(4)isusedtotakesealring(3)off cover(2)whentheengineisfittedtothevehicle. NOTE 108186 74 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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75279 75278 75281 75282 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 Figure 85 Usingtool99360076(2),removetheoilfilter(1). Takeoutthecoupling(2)andremovetheheatexchanger (1). Takeoutthescrews(2)andremovetheair-conditioner compressor(1)(ifapplicable). Takeoutthescrew(2)andremovethespeedsensor(1). Take out the screws (4) and remove the compressor mounting(3). Takeouttheplug(2)withtheseal(3)andextracttheoil pressurecontrolvalve(1). Undothescrews(2)andremovetheoilsump(1)withthe associatedgasketandframe(3). 108188 108187 F1AENGINE 75 D AILY E URO 4 Print603.93.651 Base-March2006

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75283 75284 75285 75286 Figure 86 Figure 87 Figure 88 Figure 89 Takeoutthescrews(2),(3),(4)and(5)andremovethe suctionstrainer(1)togetherwiththepipe(6). Takeoutthescrews(2)andremovetheconnectingrodcaps (3). Extractthepistons(1)fromthetopofthecrankcase. Blockrotationoftheflywheel(1)withtool99360306(3). Takeoutthescrews(2)andremovetheengineflywheel(1). Takeoutthescrew(5)andremovetheguard(4). Applytool99340058(2)totherearO-ring(1)andextract itfromthecrankcase. Onthesamesideoftheconnectingrodandits associatedcap,indicatethenumberofthecylinder fromwhichtheconnectingrodhasbeenremoved. Keepthebearingshellsintheirrespectivehousings since,iftheyareused,theywillneedtobefittedin thepositionfoundduringremoval. NOTE 76 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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75287 75289 75288 75290 Figure 90 Figure 91 Figure 92 Figure 93 Usinganappropriatewrenchandahex-flutedwrench,unscrew thescrews(1)and(2)andremovethecrankcasebase(3). Withtheaidofahoistandarope,removethecrankshaft(1). Takeoutthecouplings(1)andremovetheoiljets(2). Thecentralhalfring(3)isfittedwiththrusthalf-washers. Notetheassemblypositionofthebottommain bearingshells(2)since,iftheyarereused,theywill need to be fitted in the position found during removal. NOTE Notetheassemblypositionofthetopmainbearing shells(2)since,iftheyarereused,theywillneedto befittedinthepositionfoundduringremoval. NOTE Oncompletingengineremoval,itisnecessaryto clean the removed parts thoroughly andcheck theirintegrity. Thefollowingpagesgivetheinstructionsforthe mainchecksandmeasurementstomakeinorder todeterminewhetherthepartscanbereused. NOTE F1AENGINE 77 D AILY E URO 4 Print603.93.651 Base-March2006

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Themeasurementsmustbemadeforeachsinglecylinderat threedifferentheightsupthelinerandontwoplanesatright anglestoeachother:oneparalleltothelongitudinalaxisof theengine(B)andtheperpendicular(A);thegreatestwear is generally found on this last plane with the first measurement. On finding ovalization, taper or wear, go ahead and bore/grindandfinish the face of the cylinder liners.The refacingofthecylinderlinersshouldbedoneinrelationto thediameterofthepistonssuppliedassparepartsoversized by 0.4 mm of the nominal value and to the prescribed assemblyclearance. 18837 75292 Figure 94 Figure 95 After removing the engine, thoroughly clean the cylinder-crankcase assembly. Use the rings 99365508 to carrythecylinderblock. Carefullycheckthatthecrankcasehasnocracksinit. Check the conditions of processingcaps.Ifthe capsare rustedorifyouhaveeventheslightestdoubtabouttheir sealingefficiency,thecapsshallbereplaced.ApplyLOCTITE 270sealant(IVECONO.93162429)tothecapswhenfitting the latter back into place.. Examine the surfaces of the cylinderliners;theymustshownosignofmeshing,scoring, ovalization,taperorexcessivewear.Theinsidediameterof the cylinder liners is checked,to ascertain the extent of ovalization,taperandwear,usingtheboremeter99395687 (1)fittedwithadialgaugepreviouslyresetontheringgauge ofthediameterofthecylinderlineroronamicrometer. REPAIRS CYLINDER BLOCK Checks and measurements Figure 96 *Surfaceroughnessparameters: Rt = 4 ÷ 10 μ m Rz = 3 ÷ 8 μ m Ra = 0,25 ÷ 0,6 μ m Wt < 1,5 μ m Permissible surface porosity for machined cylinder (see Figure 97) ZONEB1= Area of greatest mechanical stress, segment/linercontact: No.2non-continuousporosities arepermissiblemax.0.5x0.5. ZONEB2= Surfaceinvolvedinsegmentrubbing: No.2non-contiguousporosities arepermissiblemax.1x0.8. 100% 100% 75293 Figure 97 C 1 st measurement 2 nd measurement 3 rd measurement C 78 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Forundersizedcrankpins,letterM. Forundersizedmainjournals,letterB. Forundersizedcrankpinsandmainjournals,letterMB. Seethattheheadmatingsurface,onthecylinderblock,has nodeformation. Thischeckcanbemade,aftertakingoutthegrubscrews(3), with a surface plate spreadwith carbon blackor witha calibratedrule(1)andafeelergauge(2).Afterascertaining theareasofdeformation,levelthebearingsurfacewitha grindingmachine. 75296 Figure 98 Figure 99 75297 Figure 100 The main journalsandcrankpinsmust alwaysbe groundtothesameundersizeclass. Theundersizingperformed,onthemainjournalsor crankpins,mustbemarkedbypunchingontheside ofcrankarmno.1. Undersizeclassesareof: 0.254-0.508mm. TABLEINWHICHTOENTERTHEMEASUREMENTSOFTHECRANKSHAFTMAINJOURNALSANDCRANKPINS 5408 CRANKSHAFT 540810 Measuring main journals and crank pins Checking head mating surface on cylinder block Onfindingsignsofseizure,scoringorexcessiveovalization onmainjournalsandcrankpins,itisnecessarytoregrindthe pins.Beforegrindingthepins(2),measuretheshaftpinswith amicrometer(1)toestablishtowhatdiameteritisnecessary todecreasethepins. 75298 Thecrankcasecanonlybesurfacedaftermaking sure that, on completing the work, the piston protrudesfromthecylinderlinerbynomorethan theprescribedvalue. NOTE Itisadvisabletoenterthemeasurementsinatable. SeeFigure99. NOTE NOTE NOMINAL VALUE NOMINAL VALUE MINIMUM ∅ MAXIMUM ∅ NOMINAL VALUE MINIMUM ∅ MAXIMUM ∅ F1AENGINE 79 D AILY E URO 4 Print603.93.651 Base-March2006

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75299 45066 Figure 101 Figure 102 MAINCRANKSHAFTTOLERANCES SYMMETRYBETWEENMAINJOURNALSANDCRANK-PINS 1.Crankpins 2.MainJournals 3.Normalposition. Checking crankshaft Aftergrinding,keeptothefollowing: -Round off the edges of deburring the holes for lubricationofthemainjournalsandcrankpins. 94 ± 0,125 180 ° ± 15’ The checks on the tolerances indicated in the figuresmustbemadeaftergrindingthecrankshaft pins. NOTE 80 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL SHAPE Circularity ○ SHAPE Cylindricality DIRECTION Parallelism DIRECTION Perpendicularity ⊥ OFPOSITION Concentricityorcoaxiality OSCILLATION Circularoscillation ↗ OSCILLATION Totaloscillation ↗↗ CLASS OF IMPORTANCE ASCRIBED TO THE PRODUCT CHARACTERISTICS SYMBOL CRITICAL E IMPORTANT ⊕ SECONDARY ⊝

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75303 Figure 103 Figure 104 Figure 105 Figure 106 Figure 107 INTERMEDIATE JOURNALS No. 2-4 INTERMEDIATE JOURNAL No. 3 CRANKPINS *Onbothraces,onall360 ° . -Rollingturns:3approach,12effective,3out. -Rollingspeed:56rpm. -Decreaseincrankpinracedepthafterrolling:0.15—0.30 mm*. -Decreaseinmainjournalracedepthafterrolling:0.15— 0.30mm*. *Measuredwithcalibratedrollers ∅ 2.5mm. JOURNAL ON TIMING SYSTEM SIDE JOURNAL ON FLYWHEEL SIDE MAINDATAOFMAINJOURNALSANDCRANKPINS Since,duringthe0.254and0.508mmundersizing onthediameterofthecrankpinsandmainjournals, therolledportionofthesideracesofthepinsmay getinvolved,itisnecessarytoturntheraceskeeping tothedatagiveninthefigureandtodotherolling keepingtothefollowinginstructions Rollingforce: -1 st mainjournal925 ± 25daN. -2 nd —3 rd —4 th —5 th mainjournal1850 ± 50daN. -crankpin1850 ± 50daN. NOTE 108189 108190 108192 108191 honed waviness waviness RACEAREAFORALLMAINJOURNALS (MACHINEDBYTURNING) honed CRANKPINGROOVEAREA (EXTERNALMILLINGPROCESSED) honed incircumferentialdirection inaxialdirection honed incircumferentialdirection waviness inaxialdirection waviness honed Beforerolling Beforerolling Beforerolling Beforerolling F1AENGINE 81 D AILY E URO 4 Print603.93.651 Base-March2006

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75305 75306 75307 90063 Figure 108 Figure 109 Figure 110 Figure 111 Takeoutthescrews(4)andreplacethephonicwheel(3). Thescrews(4)heymustbetightenedtoatorqueof15Nm. Replacing timing control gear Onfindingthetimingcontrolgearteeth(1)damagedor worn,removethemfromthecrankshaft(2)usingasuitable extractor. Thenewgearisfittedontothecrankshaftbyheatingittoa temperatureof200 ° Cfornolongerthan15minutes. Oncompletingassemblyandafterthegearhascooled,it mustwithstandatorqueof150Nmwithoutslipping. ENGINE ASSEMBLY Thefollowingpartsmustbereplacedwithnewonesatthe timeofassembly:retainingrings,sealsandgaskets,screws whosethreadiscoatedwithsealant. Fitontheoilspraynozzles(2)andtightenthecouplings(1) totheprescribedtorque. Themainbearings(1)aresuppliedassparepartsundersized ontheinsidediameterby0.254 ÷ 0.508mm. 540811 Measuring main journal assembly clearance Mountthecrankshaft(1). Checktheclearancebetweenthecrankshaftmainjournals andtheirrespectivebearingsbyproceedingasfollows: -Thoroughlycleanthepins. -Applyacalibratedwireontothemainjournals. Assembling main bearings Thoroughlycleanthetopmainbearingshells(1)andposition theminthecrankcase. Nothavingfounditnecessarytoreplacethemain bearings,theyneedtobefittedbackoninthesame sequenceandpositionfoundupondisassembly. NOTE Donotdoanyaccommodatingonthebearings. NOTE Themiddlehalfring(2)isfittedwiththrustwashers. NOTE 82 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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75288 75309 75310 75311 Figure 112 Figure 113 Figure 114 Thoroughlycleanthebottommainbearingshells(2)and mounttheminthecrankcasebase(1) Mountthecrankcasebase(12). Tightenthescrewsinthesequenceshowninthefigurein threesteps: -Step1:withatorquewrench,toatorqueof50Nm. -Step2:closingtoanangleof60 ° . -Step3:closingtoanangleof60 ° . Theendfloatischeckedbysettingadialgauge(1)witha magneticbaseonthecrankshaft(2)asshowninthefigure. Thenormalassemblyclearanceis0.060—0.310mm. Ifyoufindtheclearance tobe greaterthan asrequired, replace the rear main bearing shells carrying the thrust bearings and repeat the clearance check between the crankshaftpinsandthemainbearingshells. Iftheendfloatofthecrankshaftdoesnotcomewithinthe prescribedvalues,itisnecessarytogrindthecrankshaftand accordinglychangethemainbearingshells. NOTE:Themiddlemainbearing hashalf thrustwashers integratedinit,soitperformsthefunctionofathrustbearing. Itissuppliedasasparepartonlywiththenormalshoulder thickness. α Figure 115 -Removethebottomcrankcase. The clearance between the main bearings and their associatedpinsismeasuredbycomparingthelengthofthe calibratedwire(1),atthepointofgreatestcrushing,withthe graduatedscaleonthecasingcontainingthecalibratedwire. The numbers on the scale indicate the clearance of the couplinginmillimetres,whichmustbe0.032 ÷ 0.102mm. Iftheclearanceisnotasprescribed,replacethebearingsand repeatthecheck. Checking crankshaft end float Usetool99395216(11)fortheangleclosing. NOTE F1AENGINE 83 D AILY E URO 4 Print603.93.651 Base-March2006

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85842 75309 75406 85843 Figure 116 Figure 117 Figure 118 Figure 119 Thoroughly clean the crankcase / crankcase base mating surface. Apply,onbase,sealantLOCTITE510IVECOno.93162432, asindicatedinthescheme.Thesealantmustresulttobe even,notpatchy. Mountthecrankcasebase(12)andtightenthefixingscrews inthreestages,followingthesequenceshowninthefigure: -Step1:withatorquewrench,toatorqueof50Nm. -Step2:closingtoanangleof60 ° . -Step3:closingtoanangleof60 ° . Thentightentheouterscrews(1)toatorqueof36—30Nm. Carefullycleanthesealseat.ApplyLOCTITE510IVECOnr. 2992504ontheseal(1)for30 ° inthepointsshowninthe figure. Lubricatetherearshankofthecrankshaftwithengineoil. Fitpart(2)oftool99346255ontotherearshankofthe crankshaft;secureitwiththescrews(3)andkeythefreshseal (1)ontoit. Positionpart(4)onpart(2);screwdownthenut(5)tofit theseal(1)fullyinsidethecrankcase. α 540460 Assembling rear seal Mountthecrankcasebasewithin10minutesof applyingthesealant. NOTE Usetool99395216(11)fortheangleclosing. NOTE 84 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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75389 Figure 120 Figure 121 Figure 122 540852 Replacing bearing supporting gear-box input shaft Useasuitablebeatertotakeoffengineflywheelbearing(1), takingcarethatthebearingdoesnotsetitselfsidewaysorget stuck,withresultingflywheelhousingdamage. Tofitbackintoplace,putengineflywheelhub(2)ontoa suitablesupport(4)byusingasuitablebeater(3)placedon bearing(1)outerrace,thenfitthebearingintotheengine flywheel. This operation shall be carried out by using a hydraulicpress. Checkclutchdiskrestsurface:ifitshowsdeepscoring,a replacementmustbeperformed. Checkconditionsoftheteethofcrownwheel(1);where excessivecrackingorwearisfound,replaceengineflywheel. Thenominalthicknessoftheengineflywheelis50 ± 0.6mm. NOTE ”LUK”ENGINEFLYWHEELFORENGINESFITTEDTO THEVEHICLESEQUIPPEDWITHMECHANIC TRANSMISSION ”SACHS”ENGINEFLYWHEELFORENGINESFITTED TOTHEVEHICLESEQUIPPEDWITHAUTOMATIC TRANSMISSION 75390 Mountthesheetmetalguard(1)andsecureittothecrankcase tighteningthescrew(2)totheprescribedtorque. Mounttheengineflywheel(3)andscrewdownthescrews(4). 108193 108194 Figure 123 F1AENGINE 85 D AILY E URO 4 Print603.93.651 Base-March2006 540850 ENGINE FLYWHEEL

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75393 75394 Figure 124 Figure 125 Removethepistonrings(1)fromthepiston(2)usingpliers 99360183(3). Takeplunger(1)offtheconnectingrodbyremovingsnap ring(2)andtakingpin(3)out. Figure 126 540840 Pistons Disassembly Figure 127 MAINDATAONPISTONMAHLEMONDIAL,PINSANDSPRINGRINGS ENGINEF1AE0481B(116HP) *Measuredonthediameterof85mm. Fittool99360351(4)ontothecrankcasetoblockrotation oftheengineflywheel(1). Tightenthescrews(3)fixingtheengineflywheel(1)intwo steps: -Step1:withatorquewrench,toatorqueof30Nm. -Step2:closingtoanangleof90 ° . 5408 CONNECTING ROD — PISTON ASSEMBLY α Usetool99395216(2)fortheangleclosing. NOTE 75391 Check the pistons.They must show no signs of seizure, scoring,crackingorexcessivewear;replacethemiftheydo. 107947 86 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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75395 Figure 128 Figure 129 Useamicrometer(2)tomeasureplunger(1)diameter,in ordertodeterminetheassemblingplay.Thediametershall bemeasuredatsuchadistancefromtheplungerbaseas showninthefigure. Theclearancebetweenthepistonandcylinderlinercanalso becheckedusingafeelergauge(1)asillustratedinthefigure. 540841 Piston pins 18857 Figure 130 Measuring the diameter of the piston pin (1) with a micrometer(2). 75397 Figure 131 Conditions for correct pin-piston coupling Lubricatethepin(1)anditsseatonthehubsofthepiston (2)withengineoil.Thepinmustgointothepistonbylightly pressingwiththefingersandmustnotdropoutbygravity. 74947 Thetrapezoidalsplitrings(1 st slot)andtheoilscraperrings (2 nd slot)havethewordTOPetchedinthem;whenfitting themonthepiston,thewordTOPmustbefacingupwards. 540842 Piston rings Figure 132 16552 Figure 133 Checkthethicknessofthepistonrings(2)withamicrometer (1). 1 2 Thepistonsaresuppliedassparepartswiththe standard,normaland0.4mmoversizediameters togetherwithrings,pinandretainingrings. NOTE Measuring piston diameter 108195 F1AENGINE 87 D AILY E URO 4 Print603.93.651 Base-March2006

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74948 41104 Figure 134 Figure 135 Checktheclearancebetweenthetrapezoidalring(2)(1 st slot)andtheassociatedslotonthepistonwithafeelergauge (1),proceedingasfollows:insertthepistonintothecylinder linersothatthering(2)comesapproximatelyhalfwayout ofit. DIAGRAMFORMEASURINGTHECLEARANCEX BETWEENTHEFIRSTPISTONSLOTANDTHE TRAPEZOIDALRING 1.Pistonslot—2.Trapezoidalpistonring— 3.Cylinderliner Usingafeelergauge(1,Figure134),checktheclearance(X) betweenthering(2)andtheslot(1);thisclearancemust havetheprescribedvalue. 75398 Figure 136 Checktheclearancebetweenthepistonrings(2)ofthe2 nd and3 rd slotandtheassociatedseatsonthepiston(3)with afeelergauge(1). 75400 75399 Figure 137 Figure 138 Checktheopeningbetweentheendsofthepistonrings(2) insertedinthecylinderlinerusingafeelergauge(1). MAINDATAOFTHECONNECTINGROD,BUSHING, PISTONPINANDBEARINGSHELLS * Internaldiametertoobtainafterdrivingintothesmall endandgrindingwithareamer. ** Dimensioncannotbemeasuredinthefreestate. *** Thicknessofthebearingshellsuppliedasasparepart. 540830 Connecting rods -with a number indicating the weight class of the connectingrodmountedinproduction. Inaddition,itcouldbestampedwiththenumberofthe cylinderinwhichitisfitted. In the event of replacement it is therefore necessary to numberthenewconnectingrodwiththesamenumberas theonereplaced. Thenumberingmustbedoneontheoppositesidetothe bearingshellretainingslots. Theconnectingrodsaresuppliedassparepartswiththe diameterofthebigend62.842—62.848mmmarkedwiththe letterOandtheweightclassmarkedwiththenumber33. Itisnotpermissibletoremovematerial. Eachconnectingrodhasitscapmarked: -withaletter: O or X indicatingthediameter classofthebigendmountedinproduction; NOTE 88 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 139 Checkthatthebushinthesmallendhasnotcomelooseand showsnosignofseizureorscoring.Ifitdoes,replacethe completeconnectingrod. 540834 Bushes Checking connecting rod 61696 Checkthealignmentoftheaxesoftheconnectingrods(1) withdevice99395363(5),proceedingasfollows: -Fittheconnectingrod(1)onthespindleofthetool 99395363(5)andlockitwiththescrew(4). -Set the spindle (3) on the V-prisms, resting the connectingrod(1)onthestopbar(2). Figure 140 Checkthetorsionoftheconnectingrod(5)bycomparing twopoints( A and B )ofthepin(3)onthehorizontalplane oftheaxisoftheconnectingrod. Positionthemount(1)ofthedialgauge(2)sothatthis pre-loadsbyapprox.0.5mmonthepin(3)atpointAand zero the dial gauge (2). Shift the spindle (4) with the connecting rod (5) and compare any deviation on the oppositesideBofthepin(3):thedifferencebetweenAand Bmustbenogreaterthan0.08mm. Checking torsion 61694 Checking bending Checkthebendingoftheconnectingrod(5)bycomparing twopointsCandDofthepin(3)ontheverticalplaneofthe axisoftheconnectingrod. Positiontheverticalmount(1)ofthedialgauge(2)sothat thisrestsonthepin(3)atpointC. Swingtheconnectingrodbackwardsandforwardsseeking thehighestpositionofthepinandinthisconditionzerothe dialgauge(2). Shiftthespindlewiththeconnectingrod(5)andrepeatthe checkonthehighestpointontheoppositesideDofthepin (3).ThedifferencebetweenpointCandpointDmustbeno greaterthan0.08mm. 61695 Figure 141 Etchedonthetopofthepistonare:thetypeofengine(1), classselection(2)andsupplier(3)aswellasthedirectionof fittingthepistoninthecylinderliner(4).Themark(5)isfor passingthe1 st slotinsertadhesiontest. 75401 Assembling connecting rod-piston assembly Figure 142 F1AENGINE 89 D AILY E URO 4 Print603.93.651 Base-March2006

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75402 Connectthepiston(1)totheconnectingrod(2)together withitscapsothatthepistonassemblyreference,position oftheconnectingrodandofthecapareobservedasshown inthefigure. Positionthepiston(1)ontheconnectingrod,insertthepin (3)andsecureitwiththesplitrings(2). Figure 143 Figure 144 75394 Figure 145 Checking for connecting rod — piston distortion 75403 Afterfittingtheconnectingrod—pistonassemblytogether, checkfordistortionwiththetool99395363(8)asfollows: -Fittheconnectingrod(7)togetherwiththepiston(3) onthespindle(4)oftool99395363(8)andlockitwith thescrew(5). -Resttheconnectingrod(7)onthebar(6). -Positionthemount(1)ofthedialgauge(2)sothatthis ispositionedatpointAofthepistonwithapre-loadof 0.5mmandzerothedialgauge(2). -Shiftthespindle(4)soastopositionthedialgauge(2) atpointBofthepiston(3)andcheckforanydeviation. Figure 146 Fitting piston rings Fitthepistonrings(1)onthepiston(2)usingthepliers 99360183(3). 41097 Figure 147 Assembling connecting rod — piston assemblies in cylinder barrels 75404 Lubricatethepistonswell,includingthepistonringsandthe insideofthecylinderliners. Withtheaidoftheclamp99360605(2),fittheconnecting rod—pistonassembly(1)inthecylinderliners,checkingthat: -Thenumberofeachconnectingrodcorrespondstothe capmatingnumber. The1 st and2 nd slotringsneedtobemountedwith theword”TOP”facingupwards. NOTE 90 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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-Fit the connecting rod caps (2) with the associated bearingshells. -Tightenthescrews(3)intwosteps: - Step1:withatorquewrench,toatorqueof50Nm. - Step2:closingtoanangleof60 ° . Figure 148 -Theopeningsofthepistonringsarestaggered120 ° apart. -Thepistonsareallofthesameweight. -Thesymbolpunchedonthetopofthepistonsfacesthe engineflywheel,ortherecessintheskirtofthepistons tallieswiththeoilspraynozzles. 540831 Measuring crankpin assembly clearance 75405 Tomeasuretheclearance,carryoutthefollowingsteps: -Thoroughly clean parts (1) and(4) andeliminate all tracesofoil. -Placealengthofcalibratedwire(3)onthecrankshaft pins(4). 75408 Figure 149 α -Removethecap(2)anddeterminetheexistingclearance by comparing the width of the calibrated wire (3, Figure148) with the graduated scale on the case (2, Figure148)thatcontainedthecalibratedwire.Onfinding aclearanceotherthanasprescribed,replacethebearing shellsandrepeatthecheck.Onobtainingtheprescribed clearance,lubricatetheconnectingrodbearingshellsand fitthempermanentlybytighteningtheconnectingrodcap fixingscrewsasdescribed. Manuallycheckthattheconnectingrodsslideaxiallyonthe pinsofthecrankshaft. 75409 Figure 150 Checking piston protrusion Aftermountingtheconnectingrod—pistonassemblies,check theprotrusionofthepistons(2)attheT.D.C.inrelationtothe topsurfaceofthecrankcasewithadialgauge(1). 75283 Figure 151 Mountthesuctionstrainer(1)togetherwiththepipe(6). Screwdownthefixingscrews(2-3-4-6)andtightenthemto theprescribedtorque. Notfindingitnecessarytoreplacetheconnecting rodbearings,youneedtofitthembackinexactly the same sequence and position found on disassembly. NOTE Usetool99395216(1)fortheangleclosing. NOTE Theconnectingrodcapfixingscrewsmustalways bereplacedforpermanentassembly. NOTE The difference between the minimum and maximumprotrusionsofthefourpistonsmustbe =0.15mm. Thecylinderheadgasketinthesetofsparegaskets neededforcompleteengineoverhaulissupplied with a single thickness. Clearly, it is supplied separatelytoo. NOTE F1AENGINE 91 D AILY E URO 4 Print603.93.651 Base-March2006

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75410 75413 Figure 152 Figure 153 Figure 154 Figure 155 Fitthegasket(4)andtheframe(3)ontotheoilsump(1). Screwdownthefixingscrews(2)andtightenthemtothe prescribedtorque. Screw down the oil drain plug (5)andtightenit tothe prescribedtorque. Placethecylinderhead(1)onthemountingSP.2271(6). Removethebrackets(5)forliftingtheengine. Intheeventthattemperaturesensor(2)needdisassembling, wrenchSP2262shallbeused. Takeoutthescrews(4)andremovethethermostatcasing (3). Fitpart(4)oftool99360260ontothecylinderhead(5)and secureitwiththescrews(3). Fitpart(2)oftool99360260ontopart(4),screwdownthe nut(1)sothatoncompressingthesprings(8)itispossible toremovethecotters(6).Thentakeouttheplates(7)and thesprings(8). Usingsuitablepliers,removetheoilseal(9). Repeattheseoperationsontheremainingvalves. Turnthecylinderheadover. Theintake(1)andexhaust(2)valveshavethesamediameter mushroom. Thecentralcavity( → )ofthemushroomoftheintakevalve (1)isdistinguishedfromthatoftheexhaustvalve(2). 560610 CYLINDER HEADS Disassembly 541210 Removing valves Removetheintake(1)andexhaust(2)valves. Beforedismountingthevalvesfromcylinderhead, number them,to the purpose ofbeing ableto remounttheminthepositionthatwasfoundon dismountingoperationwheretheyshouldnotbe replaced. A=intakeside—S=exhaustside NOTE 108322 75412 92 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Checking cylinder head seal Checkthehydraulicsealusingasuitabletool. Pumpinwaterheatedtoapprox.90 ° Catapressureof2 ÷ 3bars. Replacethecupplugsiftheyarefoundtoleakatoil,usinga suitabledriftfortheirremoval—assembly. 75451 18625 18882 Figure 156 Figure 157 Figure 158 Figure 159 Thematingsurfaceofthehead(1)withthecylinderblock ischeckedusingarule(2)andafeelergauge(3). Thedeformationfoundontheentirelengthofthecylinder headmustbenogreaterthan0.20mm. Forgreatervalues,regrindthecylinderheadaccordingtothe valuesandinstructionsgiveninthefollowingfigure. ThenominalthicknessAofthecylinderheadis112 ± 0.1mm; themaximumpermissibleremovalofmetalmustnotexceed athicknessof0.2mm. Checking cylinder head mating surface Ifthereisanyleakagefromthecylinderhead,itmustbe replaced. MAINDATAOFINTAKEANDEXHAUSTVALVES Removethecarbondepositsonthevalveswithawirebrush. Checkthatthevalvesshownosignsofseizure,crackingor burning. 540662 VALVES Removing deposits, refacing and checking valves Use micrometer (2) to measure valve (1) stem: it shall correspondtothevalueshowninfigure135.Usegrinding machine 99305018to grind,if necessary,the valveseats (removeaslessmaterialaspossible). Beforemountingtheplugs,applyLOCTITE270 water-reactingsealantontheirsealingsurfaces. NOTE Afterregrinding,checkthevalverecessingandif necessary regrind the valve seats to make the prescribedvalverecessing. NOTE 108196 EXHAUST VALVE INTAKE VALVE F1AENGINE 93 D AILY E URO 4 Print603.93.651 Base-March2006

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75453 75455 75456 75457 Figure 160 Figure 161 Figure 162 Figure 163 Figure 164 Thechecksaremadeusingadialgauge(2)withamagnetic base, positioned as illustrated. The assembly clearance is 0.033—0.063mm. Makingthevalve(1)turn,checkthatthecentringerrorisno greaterthan0.03mm. MAINDATAOFVALVEGUIDES—SEATS Valveguideseatinside ∅ 9.980 ÷ 10.000mm Valveguideoutside ∅ 10.028 ÷ 10.039mm *Measurementtobemadeafterdrivinginthevalveguides. Removethevalveguides(2)withthedriftSP.2312(1). Heatthecylinderheadto80—100 ° Cand,usingthedrift SP.2312(1)providedwithpartSP.2311(2),mountthenew valveguides(3)previouslychilledinliquidnitrogen. Whereaboveindicatedtoolsarenotavailable,mountvalve guides positioning them in cylinder head according to dimensionindicatedinFigure139. Afterdrivinginthevalveguides(2),regrindthemwiththe smootherSP.2310(1). Checking clearance between valve stem and valve guide and centring valves 540667 VALVE GUIDE Replacing valve guide Boring valve guides 108197 94 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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75459 108198 54760 Checkthevalveseats.Onfindinganyslightscoringorburns, regrind them with an appropriate tool according to the anglesgiveninFigure165. Havingtoreplacethem,withthesametoolandtakingcare nottoaffectthecylinderhead,removeasmuchmaterial fromthevalveseatsaspossibleuntil,withapunch,itis possibletoextractthemfromthecylinderhead. Heatthecylinderheadto80 ÷ 100 ° Cand,usingasuitable drift,fitinitthenewvalveseats,previouslychilledinliquid nitrogen. Usingaspecifictool,regrindthevalveseatsaccordingtothe anglesgiveninFigure165. Usingthemillingcutter99394038(1),cleantheinjectorseat ofanydeposits. Mountthevalves,blocktheseatoftheelectro-injectorsand glow plugs; using a suitable tool, check the seal of the valves/seats. Usingadialgauge(1),checkthat,fromtheplaneofthe cylinderhead,thevalverecessing(2)andtheprotrusionof theinjector(3)andoftheglowplughavetheprescribed value: - Valverecessing:0.5 ÷ 0.8mm. - Injectorprotrusion:2.77 ÷ 3.23mm. - Glowplugprotrusion:3.78mm. 540661 VALVE SEATS Recutting and replacing valve seats Figure 165 Figure 166 Figure 167 F1AENGINE 95 D AILY E URO 4 Print603.93.651 Base-March2006

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62386 50676 75461 75942 Figure 168 Figure 169 Figure 170 Figure 171 Beforeassembly,checktheflexibilityofthevalvespringswith the tool 99305047. Compare the load and elastic deformationdatawiththoseofthenewspringsgiveninthe followingfigures. MAINDATATOCHECKINTAKEANDEXHAUST VALVESPRINGS COMPLETEROCKERARMASSEMBLY Therockerarmassemblyiscomposedoftherockerarm(1), hydraulictappet(3),madeintegralwitheachotherbytheclip (2). 540665 VALVE SPRINGS ROCKER ARMS — TAPPETS CROSS-SECTIONOFTHEHYDRAULICTAPPET A=32.44 ± 0.3,endofstroke B=31.30,workingposition C=29.75 ± 0.25,startofstroke 96 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Height Underaloadof mm kg H54 Free H145 P243 ± 12 H235 P1533 ± 24

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75463 75462 75587 Figure 172 Figure 173 Figure 174 Checks Theslidingsurfaceofthetappetsmusthavenoscoring/dents; replacethemiftheydo. Usingamicrometer,measurethediameterofthetappets and,usingaboremeter,measurethediameteroftheseats inthecylinderhead;thedifferenceinthemeasurementswill givetheassemblyclearance. Lubricatethestemofthevalves(1)andinsertthemintothe associatedvalveguides(4)accordingtothepositionmarked duringremoval.UsingtoolSP.2264(2),mounttheoilseals (3)onthevalveguides(4). MAINDATAHYDRAULICTAPPETS—SEATS Positionthesprings(8)andplates(7)onthecylinderhead (5). Fitthepart(4)oftool99360260ontothecylinderhead(5) andsecureitwiththescrews(3). Fitthepart(2)oftool99360260ontopart(4),screwdown thenut(1)sothatbycompressingthesprings(8)itispossible toinserttheretainingcotters(6);thenunscrewthenut(1) checkingthatthecotters(6)havesettledincorrectly. Repeattheseoperationsontheremainingvalves. ASSEMBLING CYLINDER HEADS F1AENGINE 97 D AILY E URO 4 Print603.93.651 Base-March2006

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75465 75466 75467 75468 Figure 175 Figure 176 Figure 177 Figure 178 Figure 179 Fitthethermostatcasing(2)withanewsealandtightenthe fixingscrews(3)totheprescribedtorque. Fittemperaturesensor(1)intoplaceandtightenittothe prescribedtorque. Mountthetemperaturesensors(1and2)and,usingthe wrenchSP.2263(3),tightenthemtotheprescribedtorque. Positiontheoverhead(2)togetherwiththepins99360614 (1)onthemountingSP.2271. Stoprotationthetoothedpulley. Takeoutthescrew(4)withthewasher(5)beneathfastening thetoothedpulley(3). Onlyengineswithintakedistributingshaftcontaperedshank. Usingtheextractor99340028(2)extractthetoothedpulley (1)drivingthecamshaft. Usingfourself-tappingscrews(2),applythetoolSP.2325(3) totheseal(1)andwiththeextractor(5and6)removethe seal(1)fromtheoverhead(4). Removethecirclip(1)andtakeoffthecover(2)together withtheseal(3). 540650 Overhead Overhead removal Thescrews(2)mustbescreweddownsotheyget positionedatthedimensionshowninthefigure. NOTE 108323 98 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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1.Camshaftonintakeside—2.Hydraulictightener— 3.Camshaftonexhaustside—4.MORSEchain— 5.Rockerarms—6.Hydraulicreactingtappet— 7.Valveassembly. Description Thetimingsystemisthetypewithatwincamshaftinthehead andfourvalvespercylinderwithhydraulictappets. Motionistransmittedbythecrankshaft,viaatoothedbelt, tothegearkeyedontotheintakevalvedriveshaft.Thedrive transmissionoftheexhaustvalvedriveshafttakesplacevia a MORSE-type chain kept under tension by a hydraulic tightener. Thetoothedbelt,moreover,drivesthewaterpumpandthe high-pressurepumpCP3andiskeptattherighttensionby anautomatictightenerroller. Thefourvalvesmovebytheactionofthe“free”rockerarms (withnosupportingshaft). Therockerarms,onepervalve,arealwaysincontactwith thecorrespondingcamandarekeptinthispositionbya hydraulicreactingtappet,therebyeliminatingtheneedfor periodicaladjustment. 75469 75471 75470 75472 75473 Figure 180 Figure 181 Figure 182 Figure 183 Figure 184 Takeoutthescrews(1)andremovetherearcover(2) togetherwithitsgasket. Insertasuitablepin(2)inthehole( ⇒ )ofthechaindrive(3). Takeoutthescrews(4)and(6)withtheirwashers(5)for fixinggearstothecamshafts. Takeoutthescrews(7)andremovethechaindrive(3)from theoverhead(1). Turnovertheoverhead(1)and,takingcarenottodamage theseats,extractthecamshafts(2)and(3)fromit. TIMINGSYSTEMDIAGRAM 5412 TIMING SYSTEM F1AENGINE 99 D AILY E URO 4 Print603.93.651 Base-March2006

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75474 75475 75476 Figure 185 Figure 186 Figure 187 Usingamicrometer(1),measurethediameterofthepins(2) of the camshaft and, using a bore meter, measure the diameterofthesupportingseatsintheoverhead. Thedifferencebetweenthesetwomeasurementsgivesthe existingclearance. Thenominalassemblyclearanceis0.037 ÷ 0.088mm. 541210 Camshaft Checks Thesurfacesoftheshaftsupportingpinsandofthecams mustbefinelyhoned;ifthereisanysignofmeshingor scoring,replacetheshaft. 541211 Checking cam lift and pin alignment Settheshaft(1)ontailstocksand,usingadialgaugeonthe middlemounting,checkthatthealignmenterrorisnogreater than0.04mm;replacetheshaftifitis.Inaddition,checkthe camlift:itmustbeasprescribed;replacetheshaftifitisany different. MAINSPECIFICATIONS,FULL-SECTIONDISTRIBUTINGSHAFTSEATSANDPINS 1.Intakevalvecamshaftseats—2.Exhaustvalvecamshaftseats—3.Intakevalvecamshaft—4.Exhaustvalvecamshaft. 100 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 188 MAINSPECIFICATIONS,HOLLOW-SECTIONDISTRIBUTINGSHAFTSEATSANDPINS 1.Intakevalvecamshaftseats—2.Exhaustvalvecamshaftseats—3.Exhaustvalvecamshaft—4.Intakevalvecamshaft. 108199 F1AENGINE 101 D AILY E URO 4 Print603.93.651 Base-March2006

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75471 75478 75477 75479 75469 Figure 189 Figure 190 Figure 191 Figure 192 Figure 193 Lubricatethesupportingpinsoftheshafts(2and3)andfit themintheoverhead(1). Positiontheoverhead(1)andsecureitonthemounting SP.2271(2). Positionthecamshafts(4and5)soastobeabletoinsertthe pins 99360614 (3) into their radial holes through the threadedholesoftheoverhead. Compressthetightenersoastobeabletoinsertasuitable pin(2)intothehole( → )ofthechaindrive(1). Fitthechaindrive(2)onthecamshaftsandsecureittothe overhead(1)tighteningthescrews(8)totheprescribed torque. Screwdownthescrews(4)and(7)withthewashers(5)and (6)andtightenthemasfollows: -Tightenthescrew(7)toatorqueof50Nm. -Closefurtherwithanangleof60 ° . -Takeoutthepin(5). -Tightenthescrew(4)toatorqueof50Nm. -Closefurtherwithanangleof60 ° . Fitontherearcover(2)withanewgasketandtightenthe fixingscrews(1)totheprescribedtorque. α In this operation,take care not to damage the overheadsupportingseats. NOTE Use the goniometer 99395216 for the angle closing. NOTE 102 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Assembling overhead

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75468 75482 75481 75281 75483 Figure 194 Figure 195 Figure 196 Figure 197 Figure 198 Fitanewseal(3)onthecover(2)andfitthisintheoverhead. Fitontheseal(1). Lubricatetheshankofthecamshaft. Usingthekeyingdevice99374458(3),fittheseal(2)inthe overhead(1). Fitthetoothedpulley(1)Onlyfortheintakeshaftwith full-sectionfronttaperedshank,soastoalignthepulleyhole withtheoverheadholeandfittool99360608(4)intothe holesthemselves.Screwdownthescrew(3)togetherwith thewasher(2)withouttighteningfully. Fittheoilpressurecontrolvalve(1)inthecrankcase. Fitontheplug(2)withtheseal(3)andtightenittothe prescribedtorque. Fitthecentringtool99396037(2)ontotheshankofthe crankshaft. Mounttheoilvacuumpumpassembly(1)withanewgasket andtightenthescrews(1-15)accordingtothefollowing procedures: -Tightenthescrewsfromno.1tono.6toatorqueof5 ± 1Nmwhilecheckingthatthetool99360037(2)turns freely. -Tightenthescrewsfromno.7tono.15toatorqueof 10 ± 1Nm. -Tightenthescrewsfromno.1tono.6toatorqueof10 ± 1Nm. -After checking that tool 99360037 (2) turns freely, removeit. 540442 Assembling front seal ring Thetoothedpulley(1,Figure196)fortheintake shaftwithfull-sectiontaperedshankisnotlocked ontheshaftsinceitmustbeabletoturnwhen fittingandtensioningthetimingbelt.Forthesame reason,keepthetools99360608(4,Figure196) and99360614(3,Figure190)fitted. NOTE F1AENGINE 103 D AILY E URO 4 Print603.93.651 Base-March2006

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Lubricatetheshankofthecrankshaft. Screwdownpart(3)oftool99346254inthecrankshaftand placetheseal(2)onthepart(3). Keypart(5)oftool99346254ontopart(3),screwdownthe nut(4)untiltheseal(2)getsintopositionintheseatofthe oilvacuumpumpassembly(1). Takeoutthetool99346254(3,4and5). 75484 75485 75279 75486 Figure 199 Figure 200 Figure 201 Figure 202 Figure 203 Turnthecrankshaftsoastobeabletoinserttool99360615 (5)intotheholeinthecrankofthecrankshaft,throughthe holeintheoilvacuumpumpassembly(1),toblockcrankshaft rotation. Mountthegear(2),screwdownthescrew(3)togetherwith thespacer(4)andtightenittotheprescribedtorque. Mountthespeedsensor(1)withafreshgasketandtighten thefixingscrew(2)totheprescribedtorque(ifapplicable). Fitonthecompressormounting(3)andtightenthefixing screws(4)totheprescribedtorque. Mounttheair-conditionercompressor(1)(ifapplicable)and tightenitsfixing(2)screwstotheprescribedtorque. Mounttheoilpressuretransmitter(3)withafreshgasket. Mounttheheatexchanger(1)withafreshsealandtighten thecoupling(2)totheprescribedtorque. Donotremovethetool99360615(5)asitwillbe neededforfittingthetimingdrivebelt. NOTE 108188 104 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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75489 75488 75490 75271 Figure 204 Figure 205 Figure 206 Figure 207 Figure 208 Lubricatethesealoftheoilfilter(1)withengineoil. Using tool 99360076 (2), tighten the oil filter to the prescribedtorque. Thoroughlycleanthematingsurface(à)ofthewaterpump (1)andpositionfreshseals(2and3)onit. Mountthewaterpump(1)andtightenthefixingscrews(2) totheprescribedtorque. Fitthehigh-pressurepump(2)ontotheflangeofthewater pump(1)andtightenthefixingscrews(3)totheprescribed torque. Fitthedrivinggear(1)ontotheshaftofthehigh-pressure pump and block rotation of this shaft by applying tool SP.2263(2)asillustratedinthefigure.Tightenthenut(3)to theprescribedtorqueandremovethetool(2). 108187 F1AENGINE 105 D AILY E URO 4 Print603.93.651 Base-March2006

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75491 75492 75493 75494 Figure 209 Figure 210 Figure 211 Figure 212 Checkthattool99360619(2)insertedinthehole( → )ofthe oilvacuumpumpassembly(1)blockscrankshaftrotation. Thisconditionisnecessaryforsettingupthetimingsystem andtopreventthevalvesinterferingwiththepistons. Checkthatthematingsurfacesofthecylinderheadand crankcaseareclean. Keepthecylinderheadgasketclean. Position the cylinder head gasket (1) of the thickness determinedundertheheading“checkingpistonprotrusion” withthelettering”TOP”facingthecylinderhead. Mountthecylinderhead(1). Screwdownthefixingscrews(3)andtightenthem,inthree successivestages,followingtheorderandmethodsshownin thefollowingfigure. Diagramofthetighteningsequenceforthecylinderhead fixingscrews: -1 st phase:pre-tighteningwithtorquewrench • screws1-2-3-4-5-6toatorqueof100 ± 5Nm; • screws7-8-9-10toatorqueof50 ± 2.5Nm. -2 nd phase:angleclosing • screws1-2-3-4-5-690 ° ± 5 ° ; • screws7-8-9-1060 ° ± 3 ° . -3 rd phase:angleclosing • screws1-2-3-4-5-690 ° ± 5 ° ; • screws7-8-9-1060 ° ± 3 ° . A =flywheelside. α A Itisessentialtokeepthegasketsealedinitspackage untiljustbeforeassembly. NOTE Theangleclosureisdonewithtool99395216(2). NOTE 106 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Refitting cylinder head

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75495 75497 85844a Figure 213 Figure 214 Figure 215 Figure 216 Thoroughlycleanthehydraulictappets(2),lubricatethemand fittheminthecylinderhead(3),positioningtherockerarms(1) onthevalvescorrectly. Fitonthegasket(5). InsertthetwotoolsSP.2264(4)intotheelectro-injectorseats forsubsequentcentringoftheoverheadonthecylinderhead. Mounttheoverhead(1)togetherwiththetools99360614 (3)forthetimingandtightenthefixingscrews(2)tothe prescribedtorque. TakeoutthetoolsSP.2264(4). Mountthefixedtightener(1)andtightenthefixingscrew(2) totheprescribedtorque. Mounttheautomatictightener(4)withoutfullytightening thefixingscrew(3),max.closingtorque5Nm. Turntheautomatictightener(1)clockwise,positioningitas showninframeA. Turnthetimingbelt(10)asshowninthefigureobservingthe precautionsbelow. Donotbendthetimingbelt.Arrowsindicatingthedirection ofassemblyofthetimingbeltontheengineareshownon thebackofthebelt.Thearrowsmustcorrespondtothe direction of rotation of the belt and the notches must coincidewiththoseonthepulley(7)andthegear(12). X=Directionofmovementofthetightener— Y=Directionofrotationofthekey. 108328 Iftheenginehasrunforaperiodequivalentto ≥ 25,000km,thetoothedbeltmustbereplacedwith afreshone,nomatterwhatitsstateofwear. NOTE Onlyfortheintake valvedistributing shaftwith full-sectiontaperedshank. Ifrequiredtofitthetimingbelt(10)onthepulley (7),removetool99360608(8)andturnthepulley (7)clockwisebynomorethanhalfapulleytooth. NOTE Camshaft drive Oncompletingassembly,adjustthetoothedpulley(7)toput thesectionXofthebeltundertensionandtightenthescrew (9)toatorqueof90Nm Keepingthescrew(2)stationaryandusingasuitablewrench onthehexagonoftheplate(3)of thetightener,turnit anticlockwisetocoverthereferencehole(5)locatedonthe fixedportionofthetightener(seeframeB). Intheaboveconditions,tightenthefixingscrew(2)toa torqueof36 ± 4Nm. Tightenscrew(9)tothetorquevaluesbelow: - screw(9)securingpulley(7)tothedistributingshaftwith full-sectiontaperedshank:90Nm; - screw(9)securingpulley(7)tothedistributingshaftwith hollow-sectioncylindricalshank:130Nm. Removethetools99360614(6)and99360615(11)forthe timing. Turntheengineinitsdirectionofrotationby8turnstobe abletoputthetools(6)and(11)backintodothetiming. Intheseconditions,thenotchesofthetimingbelt(10)must coincidewiththoseofthepulley(7)andthegear(12). F1AENGINE 107 D AILY E URO 4 Print603.93.651 Base-March2006

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75499 75500 75251 Figure 217 Figure 218 Figure 219 Figure 220 Removethetools(6and11,Figure216). Screwtheplug(1)intotheoil-vacuumpumpmounting(2) andtheplugsontheholesoftheoverhead. Mountthetimingcover(1)andtightenthescrews(2)tothe prescribedtorque. Mountthedamperpulley(3)andtightenthescrews(4)to theprescribedtorque. Mounttheoillevelsensor(1). Fitonthepowersteering(2)pumpmounting(4)andtighten thefixingscrews(3)totheprescribedtorque. Positionthealternator(2)onthemounting(5)andsecure itwiththebottomscrews(3and4)andthebolt. Figure 221 Fitonthemounting(1)togetherwiththeelectromagnetic coupling(4)andtightenthefixingscrews(2and3)tothe prescribedtorque. See frame C: Figure216, holding the tightener plate (3) stationarywiththewrenchinsertedinitshexagon,loosenthe fixingscrew(2).Keepingthefixingscrew(2)stationary,turn theplate(3)clockwiseuntilitsreferencemark(4)coincides with the reference hole (5) of the fixed portion of the tightener.Intheaboveconditions,tightenthescrew(2)toa torqueof36 ± 4Nm. Rotatetheenginebytwoturnsinitsdirectionofrotationuntil thepointoftool99360615(1)engagementintothedrive shaftisreached.Whenthispointisexceeded,thedriveshaft shallberotatedbytwomoreturns.Verify,undertheabove conditions,thatreferencehole(5)isfoundwithinindex(4) asrepresentedinbox C ;otherwise,theaforesaidoperations shallberepeated. Afterassembly,thebelt(10)tensionmeasuredusingtool 99395849mustbeasfollowsinthefollowingpoints:X 1 = 212 ± 12Hz-X 1 =178 ± 10Hz. Donotturntheengineintheoppositedirection; if,onturningtheengine,youpassthepointfor insertingthetools(6)and(11),turntheengine clockwisebyanothertwoturns. NOTE 108166 108165 108 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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75248 Figure 222 Figure 223 Figure 224 Figure 225 Usingawrenchontheautomatictightener(2),mountthe drivebelt(1),takingcaretopositionitsribscorrectlyinthe respectiveracesofthepulleys. Screwdownpressuresensor(2)ontohydraulicaccumulator (1)andtightenitto70+5Nm. 75501 Mountthefixedtightener(2)andtightenthefixingscrew(1). Mounttheautomatictightener(3)andtightenthescrew(4) totheprescribedtorque. Fittheflexiblebelt(3)equippedwithtool99360191(2)on thepulley(4)andapplythetoolonthepulley(1). Fitthedrivering(5)ontheflexiblebelt(3)andfastenthering onthecompressorsupport. Turnthedriveshaftclockwiseuntilthebeltfitsperfectlyon thepulley(1). Figure 226 108326 108327 75503 Fitanewseal(3)ontheelectro-injector(1)andmountthis intheoverhead(2). Figure 227 90155 Mountthebrackets(3)fasteningtheelectro-injectors(1) andscrewdownthescrews(2)withoutlockingthem. Mountthehydraulicaccumulator(4)andtightenthefixing screwstotheprescribedtorque. F1AENGINE 109 D AILY E URO 4 Print603.93.651 Base-March2006

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75508 Figure 228 Connectthefuelpipes(2)totheelectro-injectors(1)andto thehydraulicaccumulator(3). Tightenthescrews(4)fixingtheelectro-injectorbracketsto theprescribedtorque. Mounttheglowplugs(1)and,usingthebox-typewrenchSP. 2275(2)andtorquewrench99389819(3),tightenthemto atorqueof8 ÷ 10Nm. Mounttheintakemanifold(1)withanewgasketand,using a torque wrench, tighten the fixing screws (2) to the prescribedtorque. Fit air pressure/temperature sensor (3) into place, then tightenthefasteningscrewtotheprescribedtorque. Usingthewrench(4)ofthe99317915seriesandthetorque wrench99389829(3),tightenthefuelpipefittings(1)and(2) totheprescribedtorque. Figure 229 Figure 230 Whenevertheygetremoved,thefuelpipesmust bereplacedwithnewones. NOTE Figure 231 108329 108330 108331 108332 Figure 232 Fitthrottlevalveassembly(1),togetherwithanewgasket, ontoinletmanifold(3). Screwdownscrews(2),thentightenthemtotheprescribed torque. Fitpipe(5),togetherwithanewgasket,ontothrottlevalve assembly(1). Screwdownfasteningnuts(4)byafewturns,sothatpipe (5)canstillbemoved. 110 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 233 Figure 234 Figure 235 Figure 236 Connectthefuelpipe(4)tothehydraulicaccumulator(7) andtothehigh-pressurepump(5). With wrench (2) of series99317915 anddynamometric wrench 99389829 (1), tighten pipe fittings (3 and 6) at prescribedtorque. Connectfuelpipe(3)tohigh-pressurepump(1)pipeunion. Securethepipebymeansofclamp(2). Fitanewrubbertop(5)ontopipe(4),thensecurethelatter toinletmanifold(8)bymeansofbracket(6)andtighten screw(7)totheprescribedtorque. Fitcoolantpipe(2)intotheenginebase. Screwdownscrew(1),thentightenittotheprescribed torque. Fitoildipstickpipe(4),togetherwithanewsealring,intothe enginebase. Screwdownpipe(2and4)fasteningnut(3)totheinlet manifold,thentightenittotheprescribedtorque. Whenevertheygetremoved,thefuelpipes(4) mustbereplacedwithnewones. NOTE 108176 108333 Connect,withcoupling(1)equippedwithnewgaskets,pipe (5)tohigh-pressurepump(2). Fitlow-pressurepipe(5)ontobracket(3),thentightenscrew (4)totheprescribedtorque. 108173 108334 F1AENGINE 111 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 237 Figure 238 Figure 239 Figure 240 Figure 241 Connectexhaustmanifold(1),togetherwithanewgasket andcompletewithelbow(3)andpipe(2),tothecylinder headagain.Fitspacers(4)intoplace,screwdownnuts(5), thentightenthemtotheprescribedtorque. Connectturboblower(5),togetherwithanewgasket,to exhaustmanifold(1)again.Screwdownnuts(2)thentighten themtotheprescribedtorque. Fitheatexchanger(5),togetherwithEGRvalve(6),backinto place,byproceedingasfollows: -position (by placing a new gasket in between) heat exchanger(5)ontopipe(4),thenscrewdownscrews (3)securingtobracket(2)byafewturns; -positionanewgasketontoelbow(8),thenscrewdown screws(7)securingEGRvalve(6)toelbow(8); -tightennuts(4)andscrews(3and7)totheprescribed torque. 108189 108182 108184 108335 108183 Presstheclips(3)inthedirectionshownbythearrowand connect the fuel recovery pipe fittings (1) to the electro-injectors(2). Beforefittingtheturbochargerontheengine,itis necessary to fill the central body with engine lubricatingoil. NOTE Connectoilpipe(4)toturboblower(5)andtothecoupling on the cylinder head, and tighten the fasteners to the prescribedtorque. Fitpipeunion(1),togetherwithanewsealring,intoplace, thenscrewdownscrew(2)thentightenittotheprescribed torque. Screwdownscrews(3)securingelbow(4)tobracket(5), thentightenthemtotheprescribedtorque. 112 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 ,

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Figure 242 Figure 243 Figure 244 Connectthecoolantpipes(bysecuringthemwiththenew clamps): -(3),toheatexchanger(1)pipeunionandEGRvalve(5); -(2),toheatexchanger(1)andpipeunion(7); -(6),topipeunion(7)andEGRvalve(5); -(4),toheatexchanger(1)pipeunion. Fitoilfillingpipeunion(3),togetherwithanewsealring, screwdownscrews(4),thentightenthemtotheprescribed torque. Fit bracket (1) into place, screw down screws (2),then tightenthemtotheprescribedtorque. Fitcoalescencefilter(1)intoplace,screwdownscrews(2), thentightenthemtotheprescribedtorque. Connectpipe(3)tocoalescencefilter(1),screwdownnut (4),thentightenittotheprescribedtorque. Connectpipe(5)topipeunion(7),thensecureitwithanew clamp(6). 108336 108168 108167 F1AENGINE 113 D AILY E URO 4 Print603.93.651 Base-March2006

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108163 Fitthefollowingitems(ifany)intoplace: -coolingfantoelectromagneticjoint; -enginecablewithducts(13)availablebydisconnecting itfrom: -electricinjectors(3); -preheatingplugs(5); -hydraulicaccumulatorpressuresensor(14); -throttlevalveactuator(11); -inletmanifoldairpressure/temperaturesensor(12); -high-pressurepumppressureregulator(10); -phasesensor(4); -thermostatcoolanttemperaturesensor(9); -throttlevalveactuator(11); -rpmsensor(8); -highpressurepumppressureregulator(10); -temperaturesensor(7); -deadeninghood(2)ifincluded; -plug(1); -theenginewithlubricatingoiloftheprescribedgrade andamount. Fittheswingbartotheengineliftinghooks,thensecurethe swingbartothehoistandtaketheengineoffrotarystand (6).Takeoffbrackets99361038(9). Completeengineassembly. Fitontheleftandrightenginemountings(3)andtightenthe fixingscrewstotheprescribedtorque. Connecttheoilpipe(2)totheturbocharger(1)andtothe crankcaseandtightenthefixingscrewsandthecouplingof theoilpipe(2)totheprescribedtorque. Figure 245 Figure 246 108162 114 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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5450 LUBRICATION General Theengineislubricatedbyforcedcirculationperformedbythe followingparts: -Anoilgearpumpisincorporatedinanassemblythatalso includesthevacuumpump(GPOD). -Apressurecontrolvalveincorporatedinthecrankcase. -AModine-typeheatexchangerwithbuilt-insafetyvalve. -Adoublefiltrationoilfilterwithbuilt-insafetyvalve. Operation (seeFigure247). Engineoilisdrawnupfromthesumpbytheoilpump(3) viathesuctionstrainer(2)anddeliveredunderpressureto theheatexchanger(5)whereitiscooled. Theoilcontinuesthroughtheoilfilter(6)andgoesto lubricatetherelevantpartsthroughductsorpipes. Attheendofthelubricationcycle,theoilreturnstothe sumpbygravity.Theoilfiltercanbeexcludedbythesafety valvebuiltintoitifitgetsclogged.Theheatexchangeris alsoexcludedbyasafetyvalveifitgetsclogged. In addition, the lubrication oil supplies the hydraulic automatictightener(7)ofthecamshaftdrive(8). Totheoilpressuresensor 108337 Oil under pressure Oil in freefall Coolant Breather on pressure control valve Figure 247 F1AENGINE 115 D AILY E URO 4 Print603.93.651 Base-March2006

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DIAGRAMOFGPODASSEMBLYONENGINE 1.Vacuumpump—2.Oilpump—3.Crankshaft— A.Vacuumpumpoilsupplyhole. Clearancebetweenthecrankshaftgearteethandtheoil pumpdrivegear0.003 ÷ 0.2mm. The assembly must not be overhauled; in the event of defectiveoperation,itmustbereplaced. 75517 Figure 248 Figure 249 OIL VACUUM PUMP ASSEMBLY (GPOD) The oil pump(3) is a gear pump driven directly by the crankshaft. 75516 503010 Oil pump Characteristic data transmissionratio 1.15 displacement 16.2 cm 3 pumpingdiameter 49.5 mm numberofteeth 7 height 11 oilpumpminimumspeed 862 rpm oilpumpmax.speed 4485 rpm oilpumpover-revs 5247 rpm oilpumpforcedover-revs 6279 rpm speed 2500 rpm torque 2.1 Nm powerdraw(calc.) 550 W Vacuum pump Thevacuumpump(2,SENZACODICE),withradialblades, isalsoincorporatedintheGPOD(1,Figure249).Itisdriven directlybytheoilpump. transmissionratio 3.25 displacement 86 cm 3 volumetodrain 4.5 litres volumetodrainwithEGR 9 litres chamberdiameter 65 mm rotordiameter 50 mm cam 7.5 mm numberofblades 3 height 34 mm vacuumpumpminimumspeed 994 rpm vacuumpumpmax.speed 5168 rpm vacuumpumpover-revs 6046 rpm vacuumpumpforcedover-revs 7235 rpm theoreticalflowrateatminimum(air) 85.5 l/min actualflowrateatminimum(air)— atatmosphericpressure 46 l/min Theoreticalspeedatmax.speed—(air) 444.4 l/min Actualflowrateatmax.speed—(air) atatmosphericpressure 60 l/min measuredpowerdraw(maximum) speed 2500 rpm torque 2.1 Nm powerdraw(calc.) 550 W F1AENGINE 117 D AILY E URO 4 Print603.93.651 Base-March2006 Oiltemperature:100 ° C—closedrecirculation— max.outletpressure5bars enginespeedrpm (oilpumpspeed—rpm) capacity(l/min) 750(862) 12 3900(4485) 68 Oiltemperature:100 ° C—enginespeed750rpm (pumpspeed994rpm) tank (litres) vacuum (bar) 0.5 0.8 4.5 4.5 12.5 5.6 time(sec) 6.0 16.5 9 9.0 24.0

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CROSS-SECTIONOFOILPRESSURECONTROL VALVEMOUNTEDINCRANKCASE ValveremovedfromcrankcaseL=51.75mm. ValvefittedincrankcaseL=50.75mm. Startofopening4barL=49.5 maximumopening4.6barL=44. 75520 Figure 250 Figure 251 Figure 252 543070 Oil filter 75521 Figure 253 PARTSCOMPRISINGTHEOILPRESSURE CONTROLVALVE 1.Splitring—2.Washer—3.Spring—4.Valve— 5.Valvecasing. 75522 MAINDATAOFTHEOILPRESSURECONTROL VALVESPRING Oilfilterwithsinglefiltrationwithbuilt-inby-passvalve— openingpressure2.5 ± 0.3bar. 543110 Modine heat exchanger 75524 Figure 254 Thoroughlycleantheheatexchanger(1). Alwayschangetheseals(2and4). Built-insafetyvalve(3). Openingpressure 0.82-1.03bar 543475 Oil pressure control valve No.ofheatexchangerelements: - 6(96/116HPengine) - 8(136HPengine). 108539 118 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 255 540480 Oil vapour recirculation system Description Theoilvapoursformedinthesumpwhilethe engineis running,passingthroughtheoverheadcover,arechannelled intotheseparator/condenserfilterknownastheblow-by. Thefilterisstructuredintwosections: -Thefirstonewithalabyrinth,wheremostofthevapours are condensed and return to the sump through an umbrellaoutletvalve. -The second one includes a coalescence filter that condenses the remaining vapours that return to the sumpthroughanotherumbrellavalve. Theportionofvapourthathasnotcondensedissent,viaa MANN-HUMMELvalve,totheintakeductandburntduring normalengineoperation. 75525 OILVAPOURRECIRCULATIONDIAGRAM 1.MANN-HUMMELvalve—2.Umbrellavalves—3.Blow-byfilter—A.Labyrinth—B.Intakeoil vapourrecoveryflow—C.Oilreturnflowintosump—D.Flowofoilvapoursfromthesump— E.Flowofoilvapoursfromtheoverhead—F.Coalescencefilter. Theblow-byfiltercannotbetakenapartandmust thereforebereplacedentirely. NOTE F1AENGINE 119 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 256 5432 COOLING Description Theenginecoolingsystemisthetypewithforcedcirculation inaclosedcircuit.Itcomprisesthefollowingparts: -An expansion tank whose plug has two valves incorporatedinit:anoutletandaninlet,whichgovern thepressureofthesystem. -Acoolantlevelsensoratthebaseoftheexpansiontank. -Only136HP,pressureswitch(3),ofnormallyclosed type(calibratedat0.4bar,absolutepressure1.4bar), located on expansion tank and connected to EDC centralunit,protectsengineagainstoverheatingcaused bycoolingsystemfailure.Wherecoolanttemperature exceeds100 ˚ Candcontemporarilythepressureinside expansiontankanditbecomeslowerthan0.4bar,EDC centralunitreducesengineperformancebychanging fuelflowrate(De-rating)untilenginegoesoff. -Anenginecoolingmoduletodissipatetheheattaken fromtheenginebythecoolantwithaheatexchanger fortheintercooler. -Aheatexchangertocoolthelubricatingoil. -Aheatexchangertocooltheexhaustgases(engines withEGR). -Acentrifugalwaterpumpincorporatedinthecrankcase. -Anelectricfancomprisinganelectromagneticcoupling onwhoseshaftahubturnsidlethatisfittedwithan axially mobile metal plate on which is mountedthe impeller. -A3-waythermostatgoverningthecirculation ofthe coolant. Operation Thewaterpumpdrivenbyapoly-Vbeltbythecrankshaft sendscoolantintothecrankcaseandwithagreaterheadinto thecylinderhead. Whenthecoolanttemperaturereachesandexceedsthe workingtemperature,itcausesthethermostattoopenand thefluidischannelledfromheretotheradiatorandcooled bythefan. Thepressureinthesystemduetothechangeintemperature isgovernedbytheoutlet(2)andinlet(1)valvesincorporated intheexpansiontankfillerplug(detailA). Theoutletvalve(2)hasatwofoldfunction: -tokeepthesystemslightlypressurizedsoastoraisethe boilingpointofthecoolant; -todischargeintotheatmospheretheexcesspressure producedincaseofhighcoolanttemperatures. Thefunctionoftheinletvalve(1)istopermittransferringthe coolantfromtheexpansiontanktotheradiatorwhena lowerpressureiscreatedinthesystemduetothereduction in volume of the coolant as a result of its temperature lowering. Outletvalveopening1 ± 0.1kg/cm 2 . Inletvalveopening0.005—0.02kg/cm 2 . 108200 F1AENGINE 121 D AILY E URO 4 Print603.93.651 Base-March2006

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CROSS-SECTIONOFTHEELECTROMAGNETICJOINT Characteristics Transmissibletorqueat20 ° Cwithclutchrunin 45Nm Voltage 12Volts Powerinput 26W The electric fan control relay is activated or deactivated accordingtothetemperaturesof:theenginecoolant,thefuel superchargingairandthepressureoftheairconditionerfluid (ifpresent). Coolant temperature (ifthesensorisnotdefective) For96/116HPengines: - itactivatesat>96 ° Canddeactivatesat<84 ° C. For136HPengines: - itactivatesat>102 ° Canddeactivatesat<90 ° C. Turbocharging air temperature Itactivatesat>75 ° Canddeactivatesat<65 ° C. Fuel temperatures (ifthecoolanttemperaturesensorisacknowledgedtobe defectivebytheEDCcontrolunit) Itactivatesat>20 ° Canddeactivatesat<10 ° C. With climate control system Withpressureinthesystem itturnson 18.5 ± 0.98bar itturnsoff 14.58 ± 0.98bar 75527 Figure 257 Figure 258 Thewaterpump(3)cannotbeoverhauled.Incaseofcoolant leakingfromthesealordamage,itmustbereplaced.The waterpumpcasing(1)isalsousedasamountingforthe high-pressurepump.Theseals(3and4)mustalwaysbe replaced. 75528 543212 Electromagnetic pulley 543210 Water pump LONGITUDINALCROSS-SECTIONOFTHE WATERPUMP 1.Pumpcasing—2.Pumpdriveshafttogetherwith bearing—3.Seal—4.Impeller. Figure 259 75529 Theby-passthermostat(1)needsnoadjustment. Ifthereisanydoubtaboutitsoperation,replaceit. The thermostat casing is fitted with the thermometric switch/transmitterandwatertemperaturesensor. A.—A1Startofstrokeat78 ° C ± 2 ° C. B. Valve(1)strokeat94 ° C=7mm. B1 Valve(2)stroke94 ° C,6.4mm Thestrokeof7mmlessthan60”. 543250 Thermostat Figure 260 75530 F1AENGINE 123 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 261 TURBOCHARGINGDIAGRAM Description The turbocharging system comprises an air filter, turbochargerandintercooler. Theairfilteristhedrytypecomprisingafilteringcartridgeto beperiodicallyreplaced. Thefunctionoftheturbochargeristousetheenergyofthe engine’sexhaustgastosendpressurizedairtothecylinders. Theintercoolercomprisesaradiatorincludedintheengine coolantradiatoranditsfunctionistolowerthetemperature oftheairleavingtheturbochargertosendittothecylinders. 108201 HOT AIR AT ATMOSPHERIC TEMPERATURE COLD EXHAUST GAS HOT COMPRESSED AIR COLD COMPRESSED AIR EXHAUST GAS 124 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TURBOCHARGING

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75532 Figure 262 A.THROTTLEVALVESHUT Itisbasicallycomposedof: -acentralcasinghousingashaftsupportedbybushingsat whoseoppositeendsarefittedtheturbinewheeland thecompressorrotor; -aturbinecasingandacompressorcasingmountedon theendofthecentralbody; -anoverpressurereliefvalvefittedontheturbinecasing. Itsfunctionistochoketheexhaustgasoutlet(detailB), sendingaportionoftheexhaustgasstraightintothe exhaust pipe when the turbocharging pressure downstreamfromtheturbochargerreachesthesetting. 542410 Turbocharger (KKK K03-2074-CCB 5.88 type) 75533 B.THROTTLEVALVEOPEN Figure 263 F1AENGINE 125 D AILY E URO 4 Print603.93.651 Base-March2006

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88622 Figure 264 Figure 265 88623 Cover the air, exhaust gas and lubricating oil inlets and outlets.Thoroughlycleantheoutsideoftheturbocharger usinganticorrosiveandantioxidantfluid.Disconnectthepipe (2)fromtheunionofthepressurereliefvalve(1)andfiton itthepipeofthedevice99367121(3,Figure265). 542418 Pressure relief valve Checking pressure relief valve Restthetipofthedialgauge(1)withamagneticbaseonthe endofthetierod(2)andzeroit.Usingthedevice99367121 (3),introducecompressedairintothevalvecasing(4)atthe prescribedpressureandmakesurethisvaluestaysconstant throughoutthecheck;replacethevalveifitdoesn’t.Inthe aboveconditions,thetierodmusthavemadetheprescribed travel. Onfindingirregularengineoperationduetothe turbocharging system, it is first expedient to performthechecksontheturbocharger,checkthe efficiencyofthesealsandthefixingofthecouplings, additionallycheckingthereisnoclogginginthe intake sleeves, air filter or radiators. If the turbochargerdamageisduetoalackoflubrication, checkthattheoilcirculationpipesarenotburstor clogged,inwhichcasereplacethemoreliminate thetrouble. NOTE Beforefittingtheturbochargerontheengine,itis necessary to fill the central body with engine lubricatingoil. NOTE 126 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 REPAIRS

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62870 Figure 266 542410 GARRET GT 17 variable geometry turbosupercharger (engine F1A E0481 H - 136 HP) General The variablegeometry turbosuperchargerconsists ofthe following: -centrifugalsupercharger(1); -turbine(2); -setofmobileblades(3); -mobilebladecontrolpneumaticactuator(4),vacuum controlledbyproportionalsolenoidvalvecontrolledby EDC16ECU. Variablegeometryenables: -toincreasethespeedoftheexhaustgasesrunninginto theturbineatlowenginerpm; -todecreasethespeedoftheexhaustgasesrunninginto theturbineathighenginerpm. Toobtainthemax.enginevolumetricefficiencyalsoatlow rpm(withon-loadengine). Operation at low engine rpm 1.TURBINE-2.MOBILEBLADES-3.PNEUMATICACTUATOR-4.REVOLVINGRING Operation at high engine rpm 82871 Figure 267 62872 Figure 268 Whenengineisrunningatlowspeed,theexhaustgases show weak kinetic energy; under these conditions a traditionalturbineshallrotateslowly,thusprovidingalimited boosterpressure. Inthevariablegeometryturbine(1),themobileblades(2)are settomax.closedpositionandthesmallthrough-sections betweenthebladesincreasetheinletgasspeed.Higherinlet speedsinvolvehighertipspeedsoftheturbineandtherefore oftheturbosupercharger. Enginespeedincreaseresultsinagradualincreaseofexhaust gaskineticenergy,andalsointurbine(1)speedandbooster pressureincrease. The ECU, through the actuator control solenoid valve, modulatesthevacuumactingonthediaphragm,soactuator (3)controlsthroughthetierod,thegradualopeningofthe mobileblades(2)untilreachingthemax.openposition. Bladethrough-sectionsresultslargerthusproducingaspeed decreaseinexhaustgasflowthroughtheturbine(1)with speeds equal to or lower than those of the low rpm condition. Turbine(1)speedisthereforeadjustedtoapropervalue enablingsuitableengineoperationathighspeeds. F1AENGINE 127 D AILY E URO 4 Print603.93.651 Base-March2006

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Proportional solenoid valve controlling turbocharger actuator 62876 Figure 269 Thesolenoidvalvemodulatesthelowpressurecontrolling theturbochargeractuator,takenfromtheaircircuitofthe servo brake, according to the information exchanged betweentheelectroniccontrolunitandthesensors:engine speed, throttle pedal position and pressure/temperature fittedontheintakemanifold. Asaresult,theactuatorvariestheopeningofthebladesof theturbochargerthatadjusttheflowofexhaustgases. 62869 TURBOCHARGINGFUNCTIONALDIAGRAM 1.Variablegeometryturbocharger-2.Pneumaticactuator-3.Proportionalsolenoidvalve-4.Airfilter-5.EDC16controlunit-6.Servobrake-7.Vacuumdevice-8.High-pressurepump. Figure 270 Theactuatordiaphragm,connectedtothecontrolrod,is governedbythelowpressureonthetopoftheactuator. Thelowpressuremodulatedbytheproportionalsolenoid valvevariesthemovementofthediaphragmand,asaresult, oftherodgoverningtheturbine’smobileblades. 62875 SECTIONONTHEACTUATOR Figure 271 Actuator 128 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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62873 Figure 272 REPAIRS 542451 Checking and adjusting the actuator Operatethevacuumpumpandcheckwhetherthetierod (3)strokevaluescorrespondtothevacuumvaluesshownin thefollowingtable: Whereadifferentvalueisfound,replaceturbocharger. Duringthecheckthevacuumvalueshallnotfall, otherwisetheactuatorshallbereplaced. NOTE NOT ALLOWED ARE: -any replacement or regulation of the actuator, since the calibration of such component is made in an optimal way for each turbocharger and is guaranteed for the turbocharger; -any operation on nut (5) and ring nut (4), since such operation does not change engine supply characteristics but may impair engine reliability and duration. Ring nut (4) is sealed with antitempering yellow paint. In case of engines under guarantee, each above specified intervention and/or alteration to paint applied on ring nut (4) causes the lapse of the guarantee. NOTE Coverair,exhaustgasandlubricantinletsandoutlets. Clean the turbosupercharger outside accurately using anticorrosiveandantioxidantfluidandchecktheactuator (6). Clamptheturbosuperchargerinavice. Applyvacuometer99367121(1)pipetoactuator(6)hose. Applythemagneticbasegauge(2)toexhaustgasinletflange intheturbine. Setgauge(2)feelerpinontierod(3)endandsetgauge(2) tozero. F1AENGINE 129 D AILY E URO 4 Print603.93.651 Base-March2006 - vacuum0mmHg Fullyopenvalve - vacuum0.2bar Valvestroke2 ÷ 4mm - vacuum0.64bar Valvestroke10.5 ÷ 12.5mm

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During the engine operating phases not requiring gas circulation (e.g. particulate filter regeneration, start-up, enginecold,idlerunning,loaddemands,vehiclerunningat high altitudes), the control unit control signal to the modulatingsolenoidvalvewillbecancelled.Thesolenoid valvewillclosetheconnectionbetweentheservobrake vacuumcircuitandtheE.G.R.one,andwillsimultaneously resumetheatmosphericpressurewithintheE.G.R.circuit. Figure 273 a.Brakeboostervacuumcircuit-b.EGRmodulatedvacuumcircuit.-c.VGTactuatormodulatednegativepressurecircuit 1.Electroniccentralunit-2.Throttlevalveassembly-3.Negativepressuretake-off-4Watertemperaturesensor-5.Engine rpmsensor-6.E.G.R.pneumaticvalve-7.Flowmeter-8.Intakeairfilter-9.EGRmodulatingsolenoidvalve-10.VGTactuatormodulatingsolenoidvalve(ifpresent)-11.Negativepressureadditionaltank(onlyvehicleswith136HP engine)-12.Negativepressurepower-assistedbrake-13.Negativepressuretank. 112219 EGR system operation The E.D.C. electronic control unit E.D.C. processes the informationfromtheatmosphericpressuresensor,water temperature sensor, engine revs sensor and accelerator pedal potentiometer. It drives, according to ways and proceduresproperlyprogrammedwithinitsownmemory, boththemodulatingsolenoidvalveandthethrottlevalveby meansofaPWMsignal. Themodulatingsolenoidvalvewill,everytimeisitdriverby theE.D.C.controlunit16,communicatetheservobrake vacuumcircuitwiththeE.G.R.one.Avacuumvaluewillbe obtainedwithintheEGRcircuit,dependingonthecontrol signal. Such vacuum will act on the E.G.R. pneumatic valve membrane, by withdrawing and lifting the shutter that normallyobstructsthepassageoftheexhaustgastowards theintake. Thus,theexhaustgas,passingthroughtheheatexchanger whereitiscooled,willbeconveyedintothethrottlevalve assemblychamberwhereitwillbemixedwiththeairfrom theintercoolerandmadetoflowoutintotheinletmanifold. IfthevehicleisequippedwiththeD.P.F.catalyst,theEDC controlunit16willsimultaneouslyadapttheflowrateoffuel tobeinjectedintothecylinders,dependingontheamount ofcirculatedexhaustgas. 130 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 EXHAUST GAS RECIRCULATION (EGR) SYSTEM (Exhaust gas recirculation)

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Figure 274 E.G.R.valveismountedonheatexchangerend. Toensurehigherefficiencyandlongerdurabilitytothevalve, thevalveiscooledbyenginecoolantfromheatexchanger. Figure 275 105060 Operation Operationprincipleisbasedonaheatedmembraneputin betweenameasurementchannelthroughwhichinletair enteringtheengineisflowing. Theheatedfilmmembraneiskeptatconstanttemperature (about120 ° C,higherthanincomingairtemperature)by heatingresistance. The air mass which runs through measurement channel tendstotakeoutheatfromthemembrane;therefore, to keepthemembraneatconstanttemperature,thecurrent mustrunthroughtheresistance. Absorbed current is proportional to air mass flowing to engine;thecurrentismeasuredbyaWheatstonebridgeand signalobtainedissenttotheelectroniccentralunit. IfthevehicleisequippedwiththeDPFcatalyst,thecontrol unitprogramwillfeatureafunctioncapableofcorrectingthe flowratemeterdeviationintime.Duringvehicledeceleration with pedal released (overrun), the central unit performs some checks determining a number of flow rate meter reading rectification factors (self-adapting process). Therefore, replacing flow rate meter involves the self-rectifyingprocess. Where the central unit is replaced, flow rate meter rectificationcoefficients(ZFC)storedinoldcentralunithave tobecopieddownandenteredintonewcentralunit.Where itisnotpossible,theymustberesetandself-learningprocess mustbestarted. 772652 Air flow rate meter (flow meter) Recirculatedgasquantityregulationisthroughamushroom valve, pneumatically driven under under-pressure; the under-pressure,throughcalibratedsectionfitting,istaken fromthetubeconnectingthevacuumunittopower-assisted brake. Drivingunder-pressuremodulatedbythesolenoidvalveand overcomingtheforceexertedbycounteractingspring(1), willliftmembrane(2),connectedtocut-offunit(3),which movesupwardsandenablestherecirculationofburntout gassestowardsinletmanifold. Main system components 540744 E.G.R. valve 1.Connector-2.Flowmeterbody -3.Recirculatedoil vapoursairinletgrid-4.Powersupply-5.Earth-6.Inlet airtemperaturesensor-7.Flowrateoutputsignal. Theflowmeterisaheatedfilmtypeflowmeterandisplaced betweenturbochargerandintercooler. Insidetheflowmeter,suckedinairtemperaturesensoris builtin. Modulator solenoid valve is an integrating part in E.G.R. systemandpower-assistedbrakeunder-pressuretubes. ItisaproportionalsolenoidvalvemodulatingE.G.R.valve drivingunder-pressuredependingonPWMsignalgenerated byEDC16centralunit. 108204 540746 Modulator solenoid valve 112333 Theairflowmeterbodybearsanarrowwhich indicatestheairflowand,therefore,thecorrect assemblingofthemeteronthevehicle. NOTE Figure 276 F1AENGINE 131 D AILY E URO 4 Print603.93.651 Base-March2006

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108205 Figure 277 540730 Heat exchanger 105061 108202 1.Throttlevalve-2.Electricalactuator A.Air/exhaustgasmixingchamber Throttlevalve(normallyopen)assembly,mountedoninlet manifold, hasthetask to regulate theflowrateofair, incomingfromtheintercooler,tobemixedtoexhaustgasses recirculated by E.G.R. valve according to programmed percentage. Throttlevalveisdrivenbyanelectricalactuatordrivenbya PWMsignalfromEDC16centralunit. Incaseofthrottlevalvelock,thecentralunitreducesengine performancetopreventtheenginefrombeingdamaged. Whentheengineisswitchedoff,thethrottlevalvewillclose inordertoreduceenginenoiseduringthisphase. Figure 278 Heat exchanger, mounted between turbocharger and throttlevalveassembly,hasthetasktolowerexhaustgas temperatureinordertoreducegasvolume. It consists of a body that incorporates a number of corrugatedpipes.Thecirculatedexhaustgasflowingthrough thepipesarecooledbytheenginecoolantflowinginsidethe body Figure 279 EXHAUSTGASCOOLINGSCHEME A.Airfromintercooler-B.Cooledexhaustgasses-C.Intakeexhaustgasmixture-D.Coolanttoheater-E.Coolant-F.E.G.R.valveexhaustgasses-G.Coolantincomingfromcylinderhead-Coldair Hotexhaustgasses Enginecoolant Cooledexhaustgasses Exhaustgas-airmixture Hotexhaustgasses Enginecoolant Cooledexhaustgasses Airfromintercooler 132 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 540760 Throttle valve assembly

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Figure 280 Tokeeptheexhaustemissionlevelsofpollutantssuchasnitricoxides(NOx),hydrocarbons(HC)andparticulate(PM)within thelimitsestablishedbytheEuro4standard,theengineisequippedwithanEGRsystemcombined,onrequest,totheDPF catalyticsilencerforpost-treatmentoftheaforesaidpollutingsubstances. General 1.E.G.R.valve-2.E.G.R.heatexchanger-3.Airpressure/temperaturesensor-4.Enginerevssensor-5.Vacuumpump coupling-6.Modulatingsolenoidvalve-7.VGTactuatormodulatingsolenoidvalve(136HPengine)-8.Auxiliaryvacuum tankforvehiclesequippedwith136HPengine-9.Airfilter-10.Airflowmeter)-11.VGTactuator-12.Differential pressuresensor(deltap)-13.Incomingexhaustgastemperaturesensor-14.Outgoingexhaustgastemperaturesensor-15.DPFcatalyticsilencer-16.Vacuumtank-17.EDCcontrolunit16-18.Enginecoolanttemperaturesensor-19.Servo brake-20.Throttlevalveassembly. 108363 Exhaustgasses Recirculationcooledexhaustgasses Airfromintercooler Recirculationoilvapours Under-pressuretube F1AENGINE 133 D AILY E URO 4 Print603.93.651 Base-March2006 EXHAUST POLLUTANT REDUCTION SYSTEM WITH DPF CATALYST (ON REQUEST)

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105064 Figure 281 D.P.F. catalyst is made up of an oxidiser catalyst and a particulatefilter. Oxidisercatalyst(3)isanexhaustgaspost-treatmentdevice. Activesubstances,containedinthecatalyst,oxidise,at250 ° C ÷ 450 ° C temperature, carbon oxide (CO) and hydrocarbons(HC),turningthemintocarbondioxide(CO 2 ) andsteam(H 2 O). Catalyst module is made up of a ceramic structure impregnated with platinum, as platinum is a catalysing substanceinoxidationreactions.Exhaustgassesheatthe catalyst,sotriggeringtheconversionofpollutantsintoinert compounds. Particulatefilter(4),connectedtothecatalyst,hasadouble task:retainingparticulateparticles(PM)depositingbetween theporesoftheceramicstructureofwhichthefilterismade up and working as a particulate particles combustion chamberwhenthefilterisbeingclogged. Iffilterinterioriskeptatatemperaturehigherthan530ºC andoxygenpercentage ishigher than8%(oxygenbeing producedbythedecompositionofnitrogenoxideNO 2 ), thensomecombustionreactions,boostedbythecatalystput beforethefilter,burnparticulateparticles(regeneration),so keepingthefilterclean. Conversely,if its temperature is lower,the filter will get clogged,withbadeffectsonthebackpressuretotheexhaust gasgenerated. Inthiscase,toregeneratethefilter,temperatureofexhaust gassesisartificiallyraised(upto630ºC)byfuelpost-injection. A differential pressure sensor (7), connected to D.P.F. catalyst,asitdetectsapressuredifferencebetweeninletand outlet,sendsa(feed-back)signaltothecentralunittowarn aboutparticulatefilterpossibleclogging. Description D.P.F.CATALYSTVIEW 1.Exhaustgasinlet-2.Exhaustgastemperaturesensorconnection-3.Catalystmodule-4.Particulatefilter-5.Exhaustgasoutlet-6.Pipesconnectingpressuresensortocatalyst-7.Differentialpressure( ∆ p)sensor 134 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651 507130 D.P.F. (Diesel Particulate Filter) CATALYST

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105065 Figure 282 ParticulatefilterregenerationismanagedbyengineE.D.C.16 centralunit.Thecentralunit,basedonthetemperatureof exhaustgassesdetectedbysensors(5and4)andparticulate filterclogginggradedetectedbydifferentialpressuresensor (3),whenexhaustvalve(2)isclosingatabout1º ÷ 3ºfrom T.D.C.,causeselectricalinjectors(8)toinjectsmallquantities of fuel into the cylinders. The combustion of this fuel increasesthetemperatureofflowinggasses. Atthesametime,thecentralunitshutsout: -Throttlevalve(11),toprevent,atopeningstart,airfrom entering through inlet valve (9), as air would cool exhaustgasses; -E.G.R.valve(1),topreventrecirculatedoilvapoursand gassesproducedbypost-injectionfrombeingsucked intothecylinders. Exhaustgasses,soheatedenterintothesilencer,where, passing through the catalyst, the pollutants they are composedof(nitrogenoxides)arereducedortransformed intoinertsubstances(carbondioxide-steam),thenpassinto particulatefilterwheretheregenerationprocesstakesplace: exhaust gas high temperature causes the combustion of particulateparticlesaccumulatedinthefilter. Particulate filter regeneration is realised when following conditionsarepresent: - catalystinletexhaustgastemperature>230ºCwiththe helpfrompost-injection; - exhaustgastemperatureinparticulatefilter>530ºCwith presenceoffreeoxygenhavingapercentage>8%; - minimumtimeofpermanenceinaboveconditions>10’. Operation 1.E.G.R.valve-2.Exhaustvalve-3.Differentialpressuresensor-4.Inletexhaustgastemperaturesensor-5.Outletexhaustgastemperaturesensor-6.D.P.F.catalysedsilencer-7.E.D.C.16centralunit-8.Piston-9.Inletvalve-10.Electricalinjector-11.Throttlevalve A.Post-injection-B.Exhaustgassesheatedbypost-injection-C.Catalyst-D.Particulatefilter-E.Purifiedexhaustgasses F1AENGINE 135 D AILY E URO 4 Print603.93.651 Base-March2006 PARTICULATE FILTER REGENERATION SYSTEM

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Forced regeneration Inmanycasesofdoubtsaboutparticulatefiltercleanness actual conditions and/or of impossibility to regenerate it owingtoveryparticularengine/vehiclerunningconditions (persistentidling,veryslowspeedsandveryfrequentstops), asafetyforcedregenerationhastobeperformed. Independentlyofallparametersactivatingtheregeneration, theengineistakentorunwithoutloadtoapointwhere exhaustgasseshaveatemperature(>230ºC)suchasto activate the reaction in the Oxicat in presence of post-injection. Theonlylimittothisoperationisthepresenceinthefilter of a particulate quantity that is in excess, being anyhow calculated by the central unit and set as a condition to regenerationstartup. Duringvehicleuse,thecentralunitcountspost-injectedfuel quantityinordertoactivateandmaintainparticulatefilter regeneration. A small quantity of this fuel, which is injected into the cylinders after combustion has already taken place and remainspartiallyunburnt,leaksoutthroughpistonsspring ringsintooilsump,accumulatingtolubricationoil.Although apartofit,evaporating,willbeburntintheenginethrough recirculation system, its remaining part can degrade oil characteristics,impairingitsfunctionality. Quantityofaccumulatedfuelmayincreaseincaseofcatalyst orengineinefficiency,andvehicleuseinconditionsoflow temperatureand/orsmallamountsofmilescovered. Thecentralunitcountstheamountsofpost-injectionsand consequentlydeterminesthequantityoffuelaccumulatedin engineoil,andwarnsaboutrefillingneeded. If,afterrefillingengineoil,thefunctionisnotreset,thecentral unitwillkeeponcountingfuelaccumulationincreaseeven withnewoil,withconsequentengineoilrefillingwarning. Refilling engine oil 136 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 283 HIGH-PRESSUREELECTRONICINJECTIONSYSTEMCOMPONENTSLAYOUT 1.Timingphasesensor-2.Electricinjectors-3.Preheatingplug-4.Coolanttemperaturesensor-5.Electromagneticfan-6.E.G.R.valvemodulator-7.Enginerevssensor-8.Compressor(ifany)-9.High-pressurepump-10.Connectorforfueltemperaturesensor,heaterandfuelfiltercloggingsensor(onrequest)-11.Pressureregulator-12.Fuelfilter-13.Fueltank-14.Fuelgaugewithbuilt-inelectric fuelpump-15.Controlunitwithatmosphericpressuresensor-16.Battery-17.Acceleratorpedalsensor -18.Clutchpedalsensors-19.Brakepedalsensors-20.Low-pressurefuelpipes-21.Throttlevalve assembly-22.Hydraulicaccumulator(rail)airpressure/temperaturesensor-23.Airpressure/temperaturesensor-24.Hydraulicaccumulator-25.Enginerevscounter-26.Display-27.Tachograph. CommonRailMS6.3isahigh-pressureelectronicinjection systemforfastdieselengineswithdirectinjection. Itsmainfeaturescomprise: - highinjectionpressuresavailable(1600bar); - thesepressurescanbemodulatedbetween250barup to the maximum operating pressure of 1600 bar, irrespectiveofthespeedofrotationandengineload; - capacitytooperateatveryhighspeeds(upto6000 rpm); - injection control precision (injection duration and advance); - lowerconsumption; - loweremissions. Themainfunctionsofthesystemarebasicallyasfollows: - checkingfueltemperature; - checkingenginecoolanttemperature; - checkingamountoffuelinjected; - checkingidlingspeed; - cuttingofffuelinreleasephase; - checkingcylinderbalancingwhenidling; - checkinganti-sawing; - checkingsmokinessatexhaustonacceleration; - checkingexhaustgasrecirculation(E.G.R.); - checkingtopspeedlimit; - checkingglowplugs; - checkingactivationofair-conditioningsystem(ifany); - checkingauxiliaryfuelpump; - checkingpositionofcylinders; - checkingmainandpilotinjectionadvance; - checkingclosedcycleofinjectionpressure; - checkingturbochargingpressure; - self-diagnosis; - connectionwithimmobilizerunit; - checkingmaximumtorquelimitation. Thesystemmakespre-injection(pilotinjection)possible before the TDC with the advantage of decreasing the derivative of the pressure in the combustion chamber, loweringthenoiselevelofcombustion,whichistypicalof directinjectionengines. The control unit checks the amount of fuel injected, adjustingthelinepressureandinjectiontimes. Theinformationthecontrolunitprocessestoregulatethe amountoffueltobeinjectedcomprises: - enginespeed; - coolanttemperature; - turbochargingpressure; - airtemperature; - intakeairquantity; - batteryvoltage; - dieselpressure; - positionofthrottlepedal. HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM (MS 6.3 - EDC 16) General highpressure lowpressure 108203 F1AENGINE 137 D AILY E URO 4 Print603.93.651 Base-March2006 Print603.93.281 FUEL SUPPLY

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SYSTEM OPERATION Self-diagnosis — BLINK CODE Thecontrolunitself-diagnosissystemchecksthesignalsfrom thesensors,comparingthemwiththeadmittedlimits(see relativeheading): Immobilizer recognition Whenthecontrolunitreceivesthesignalofthekeyon”MAR” itcommunicateswiththeimmobilizercontrolunittoenable starting. Checking fuel temperature Withthefueltemperaturegreaterthan75 ° C,detectedbythe sensoronthefuelfilter,thecontrolunitoperatesthepressure regulatortodecreasethelinepressure(injectiontimesarenot changed).Ifthetemperatureexceeds90 ° C,thepoweris reducedto60%. Checking engine coolant temperature Thecontrolunit,dependingonthetemperature: - oftheenginecoolant,turbochargingairandfuel,operates theelectromagneticfan(Baruffaldi)andswitchesonthe coolanttemperaturewarninglight. Checking quantity of fuel injected Accordingtothesignalsfromthesensorsandthemapped values,thecontrolunit: - operatesthepressureregulator; - variesthe”pilot”injectiontimeto2200rpm; - variesthe”main”injectiontime. Checking idling adjustment Thecontrolunitprocessesthesignalsfromthevarioussensors andregulatestheamountoffuelinjected: - itoperatesthepressureregulator; - itvariestheinjectiontimesoftheelectro-injectors. Withincertainthresholdsthespeedtakesaccountofthe batteryvoltage. Fuel cut-off in release phase Inthephaseofreleasingthethrottlepedalthecontrolunit actuatesthefollowinglogicelements: - itcutsoffsupplytotheelectro-injectors; - it partially reactivates supply to the electro-injectors beforereachingidlingspeed; - itoperatesthefuelpressureregulator. Checking cylinder balancing on idling Accordingtothesignalsreceivedfromthesensors,thecontrol unitcontrolstheregularityofthetorqueatidlingspeed: - it varies the amount of fuel injected into the single electro-injectors(injectiontime). Checking regular engine rotation(anti-sawing) Itensuresregularenginerotationataconstantratewhile increasingrevs. The control unit processes the signals received from the sensorsanddeterminestheamountoffueltobeinjectedvia: - thepressureregulator; - theelectro-injectoropeningtime. Checking smokiness at exhaust on acceleration Withheavyacceleration,onthebasisofthesignalsreceived fromtheairintroductionmeterandenginespeedsensor,the controlunitdeterminestheoptimumamountoffueltoinject: - itoperatesthepressureregulator; - itvariestheelectro-injectorinjectiontime. Checking exhaust gas recirculation (E.G.R.) Depending on the engine load and the signal from the acceleratorpedalsensor,thecontrolunitlimitstheamountof airtakenin,actuatingpartialsuctionoftheexhaustgases. Checking top speed limit Dependingonthenumberofrevs,thecontrolunitactuates twoactionstrategies: - at 4250 rpm it cuts off the fuel, decreasing the electro-injectoropeningtime; - over5000rpmitdeactivatestheelectro-injectors. Checking regular rotation on acceleration Regularprogressionisassuredinallconditionsbythecontrol ofthepressureregulatorandtheelectro-injectoropening time. Checking glow plug control unit Theinjectioncontrolunit,inthephaseof: - starting - after-starting timesoperationoftheglowplugsaccordingtotheengine temperature. Checking activation of air-conditioning system Thecontrolunitoperatestheair-conditioningcompressor: - switchingiton/offwhentherelativeswitchispressed; - momentarilyturningitoff(approximately6sec.)ifthe enginecoolantreachesthesettemperature. Checking fuel pump Irrespectiveofthespeed,thecontrolunit: - suppliestheauxiliaryfuelpumpwiththekeyonMAR; - cutsoffauxiliarypumpsupplyiftheengineisnotstarted upwithinafewseconds. F1AENGINE 139 D AILY E URO 4 Print603.93.651 Base-March2006

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Checking diesel warming Ittimesoperationofdieselwarminginrelationtoambient temperature. Checking cylinder position Duringeachturnoftheengine,thecontrolunitrecognizes which cylinder is in the power stroke and operates the injectionsequencefortheappropriatecylinder. Checking pilot and main injection timing Accordingtothesignalsfromthevarioussensors,includingthe absolutepressuresensorbuiltintothecontrolunit,thecontrol unitdeterminestheoptimumpointofinjectionaccordingto internalmapping. Checking injection pressure closed cycle Dependingontheengineload,determinedbyprocessingthe signalsfromthevarioussensors,thecontrolunitoperatesthe regulatortoobtainoptimumlinepressure. Fuel supply Thefuelsupplyiscalculatedinrelationto: - acceleratorpedalposition - enginespeed - quantityofairintroduced. Theoutcomemaybecorrectedinrelationto: - thewatertemperature. Ortoavoid: - noise - smoke - overloading - overheating - turbineover-revving. Thedeliverycanbemodifiedinthecaseof: - actionofexternaldevices(ABS),ABD,EDB - serious trouble decreasing the load or stopping the engine. Afterdeterminingthemassofairintroducedbymeasuringits volume and temperature, the control unit calculates the correspondingmassoffueltoinjectintotherelevantcylinder (mgperdelivery)alsotakingintoaccountthetemperatureof thediesel. Themassoffuelcalculatedinthiswayisfirstconvertedinto volume(mm 3 perdelivery)andthenintodegreesofthrow, ordurationofinjection. Correcting flow rate according to water temperature Acoldenginemeetswithgreaterresistanceduringoperation: frictionishigh,theoilisstillveryviscous,andthevarious clearancesarenotyetoptimized. Inaddition,theinjectedfueltendstocondenseonthemetal surfacesthatarestillcold. Thefuelsupplyforacoldengineisthereforegreaterthanfor awarmone. Correcting flow rate to avoid noise, smoke or overloading Thebehaviourthatcouldleadtothiskindoftroubleiswell known. Thedesignerhasthereforeincludedspecialinstructionsinthe controlunittoavoidit. De-rating Intheeventoftheengineoverheating,injectionismodified, decreasingthedeliverytoavaryingdegree,inproportionto thetemperaturereachedbythecoolant. Injection timing electronic test Theadvance(startofdelivery,expressedindegrees)maybe differentfromoneinjectiontothenext,alsodifferentiated fromonecylindertoanother.Itiscalculated,similarlytothe delivery,inrelationtotheengineload(acceleratorposition, enginespeedandairintroduced). Theadvanceisappropriatelycorrected: - inphasesofacceleration; - accordingtothewatertemperature. Andalsotoobtain: - loweremissions,noiseandoverloading; - bettervehicleacceleration. Anextremelyhighadvanceissetonstarting,dependingonthe watertemperature. Feedbackfromthestartofdeliveryissuppliedbythechange inimpedanceoftheinjectorsolenoidvalve. Speed governor The electronic speed governor has both features of governors: - idlingandtopspeed - allspeeds Itisstableinrangeswhereconventional,mechanicalgovernors areimprecise. Engine starting Duringthefirstfewturnsoftheengine,thetimingandcylinder no.1recognitionsignals(flywheelsensorandcamshaftsensor) aresynchronized. Theacceleratorpedalsignalisignoredonstarting.Starting delivery issetonly accordingto watertemperature, bya specialmap. Whenthecontrolunitdetectssuchspeedandaccelerationof theflywheelastobeabletoconsidertheenginestartedup andnolongerdrivenbythestartermotor,itre-enablesthe acceleratorpedal. 140 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Cut-off This function cuts off fuel delivery when the vehicle is decelerating(acceleratorpedalreleased). Cylinder balancing Individualcylinderbalancingcontributestoincreasingcomfort andhandling. Thisfunctionpermitsindividual,customizedcontroloverthe deliveryoffuelandthestartofdeliveryforeachcylinder,even differentlyfromonecylindertoanother,tocompensatefor thehydraulictolerancesoftheinjector. Thedifferencesinflow(deliveryspecifications)betweenthe variousinjectorscannotbeevaluateddirectlybythecontrol unit.ThisinformationissuppliedbyModusreadingthebar codeofeachinjectoratthetimeofassembly. Synchronization search Ifthereisnosignalfromthecamshaftsensor,thecontrolunit isanyhowabletorecognizethecylindersintowhichthefuel istobeinjected. If this occurs when the engine is already running, the combustion sequence has already been acquired, so the controlunitcontinueswiththesequenceonwhichithas alreadybeensynchronized. Ifthisoccurswhenthemachineisatastandstill,thecontrol unitenergizesasinglesolenoidvalve.Withinatmost2turns ofthecrankshaft,injectionwilltakeplaceinthatcylinder,so thecontrolunitjustneedstogetsynchronizedonthefiring sequenceandtostartuptheengine. Cold starting Ifevenjustoneofthethreetemperaturesensors(water,air ordiesel)recordsatemperaturelowerthan10 ° C,pre-post heatingisactivated. Whenthekeymakescontactthepre-heatingindicatorlight comesonandstaysonforalengthoftimethatvariesin relation to the temperature (while the glow plugs in the cylinderheadheattheair),thenflashes.Itisnowpossibleto startuptheengine. Whenthemotorisrunningthisindicatorlightgoesout,while theglowplugscontinuetobepoweredforacertainlengthof time(variable)forpost-heating. If,withtheindicatorlightflashing,theengineisnotstartedup within 20-25 seconds (inattention time), the operation is cancelledsoasnottorundownthebatteriespointlessly. Thepre-heatingcurveisalsovariableinrelationtothebattery voltage. Warm starting Ifthereferencetemperaturesallexceed10 ° C,whenthekey makescontacttheindicatorlightcomesonforapproximately 2sec.,forashorttest,andthengoesout.Itisnowpossibleto startuptheengine. Run up Whenthekeymakescontact,thecontrolunittransfersthe information stored in memory when the engine was last stoppedintothemainmemory(seeAfterRun)andmakesa diagnosisofthesystem. After run Whenevertheengineisswitchedoffwiththekey,thecontrol unitstayspoweredforafewsecondsbythemainrelay. Thismakesitpossibleforthemicroprocessortotransfersome data from the main memory (volatile) to a non-volatile memory,whichcanbeerasedandwrittenover(EEPROM), soastomakeitavailableatthenextstartup(seeRunUp). Thesedatabasicallyconsistof: - varioussettings(engineidlingadjustment,etc.); - settingsofsomecomponents; - faultmemory. The process lasts a few seconds, typically from 2 to 7 (dependingontheamountofdatatosave),afterwhichthe ECU sends a command to the main relay and makes it disconnectfromthebattery. Itisextremelyimportantforthisprocedurenotto be broken off, for example byswitchingoffthe enginewiththebatterycut-out,orbydisconnecting thebatterycut-outbefore10secondshavepassed sinceswitchingofftheengine. If this happens, the functioning of the system is ensured,butrepeatedinterruptionsmaydamage thecontrolunit. NOTE F1AENGINE 141 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 284 FUELRECIRCULATIONANDSUPPLYSYSTEMDIAGRAM 1.CP1Hhigh-pressurepump-2.Pressureregulator-3.Heatedfuelfilterwithwaterseparator-4.Fueldeliverypipetothefilter-5.Fuelreturnpipetothetank-6.Low-pressurepipeassembly-7. High-pressuredeliverypipetothehydraulicaccumulator-8.Pressuresensor-9.Hydraulicaccumulator-10.Returnpipefromtheelectricinjectorstothelow-pressurepipeassembly-11. High-pressurepipebetweenthehydraulicaccumulatorandtheelectricinjectors-12.Electricinjectors. highpressure lowpressure In this injection system, the pressure regulator, located upstreamfromthehigh-pressurepump,governstheflowof fuel needed in the low-pressure system. Afterwards, the high-pressure pump correctly supplies the hydraulic accumulator. Thissolution,pressurizingsolelythenecessaryfuel,improves theenergyefficiencyandlimitsheatingthefuelinthesystem. Thereliefvalvefittedonthehigh-pressurepumphasthe functionofkeepingthepressure,atthepressureregulator inlet,constantat5bars;irrespectiveoftheefficiencyofthefuel filterandofthesystemupstream.Theactionofthereliefvalve causesanincreaseintheflowoffuelinthehigh-pressurepump coolingcircuit. Thehigh-pressurepumpcontinuallykeepsthefuelatthe workingpressure,irrespectiveofthetimingandthecylinder thatistoreceivetheinjectionandaccumulatesitinaduct commontoalltheelectro-injectors. Attheelectro-injectorinlet,thereisthereforealwaysfuelat theinjectionpressurecalculatedbytheelectroniccontrolunit. Whenthesolenoidvalveofanelectro-injectorisenergizedby the electronic control unit, fuel taken straight from the hydraulicaccumulatorgetsinjectedintotherelevantcylinder. The hydraulic system is made out of a low-pressure fuel recirculationcircuitandahigh-pressurecircuit. Thehigh-pressurecircuitiscomposedofthefollowingpipes: - ;pipeconnectingthehigh-pressurepumpoutlettothe hydraulicaccumulator(rail); - hydraulicaccumulator(rail); - pipesfeedingtheelectricinjectorsfromthehydraulic accumulator. Thelow-pressurecircuitiscomposedofthefollowingpipes: - fuelintakepipefromthetanktothefilter; - pipeassemblymadeupofthefollowing: - feedpipefromthefuelfiltertothehigh-pressurepump; - fuelreturnpipefromthehigh-pressurepumptothetank; - fuelexhaustpipefromtheinjectorstothefuelreturnpipe tothetank. Accordingtothehighperformanceofthishydraulicsystem, forreasonsofsafetyitisnecessaryto: - avoid connecting high-pressure pipe fittings with approximatetightening; - avoid disconnecting the high-pressure pipes with the engine running (NEVER try bleeding, which is both pointlessanddangerous). Theintegrityofthelow-pressurecircuitisalsoessentialforthe systemtoworkproperly;itisthereforenecessarytoavoidall manipulationandmodificationsandactonlyintheeventof leakage. OPERATION Thepipesconnectedtothefuelfiltersupporttothe low-pressure pipe assembly are of the quick-connecttype. Beforefittingthem,makesurethecouplingsandthe associatedfittingsonthemountingareclean. NOTE 108338 F1AENGINE 143 D AILY E URO 4 Print603.93.651 Base-March2006

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109124 Figure 285 FUNCTIONALDIAGRAMOFHYDRAULICSYSTEM 1.High-pressurepump-2.High-pressuredeliverypipe-3.Electricinjectorreturnpipe-4.Electricinjectors-5.Commonrail-6.Fuelpressuresensor-7.Filterwithwaterseparator-8.Fuelelectricpumpnon-returnvalve-9.Injectorreturnline pressure-reliefvalve-10.Tank-11.Fuelelectricpump-12.Fuelelectricpumpintakefilter-13.Fuelelectricpump overpressurevalve-14.Pressure-reliefvalve-15.Proportionalpressure-reliefvalve. Relativepressureswithinthecircuit: a. 4.15bar <p< 5.35bar b. 3.5bar <p< 5.0bar c. p<0.8bar d. 0.3bar <p< 0.8bar F1AENGINE 145 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 286 HYDRAULIC SYSTEM Thehydraulicsystemiscomposedof: - tank - electronicfuelpump; - fuelfilter; - high-pressurefeedpump; - pressureregulator; - manifold(rail); - electricinjectors; - low-pressurefeedpipeassembly; - high-pressurepipes. FUELELECTRICPUMPASSEMBLYSECTION 1.Return-2.Connector-3.Delivery-4.Float-5.Levelsensor(+)-6.Levelsensor(-)-7.Pump(-)-8.Pump(+)-A. Returnline-B.Deliveryline-C.Levelsensor-D.Prefilter-E.Jetpump. 773010 Fuel pump Thefuelelectricpumpisofthevolumetric,low-pressuretype. Itisbuiltintothefuellevelindicatorlocatedinthefueltank Electricconnector(2),locatedintheupperportionoftheassembly,featuresthepinsbothfortheelectricpumpandthelevel sensor. Duringtheinstallation,theassemblyshallnotbestressedwithaxialloadsofmorethan67Nandtorqueofmorethan3Nm. Themaximumfasteningtorqueonthegasketshallbe60Nm. Figure 287 109073 109123 CHARACTERISTICCURVES 146 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 288 542011 Fuel filter “UFIfilters” Fuelfilter(4)ismadeupofafilteringcartridgewithwater separator,insidewhichelectronicunit(6)ishoused. Wateraccumulationcapacityisequalto140cm 3 . Electronicunit(6)includeswaterpresentsensor,(optional) filtercloggingsensorandtemperaturesensor. Water present sensor Water presentsensor detectswater presentin the filter startingfrom110cm 3 volumepresent.Waterpresentsensor providesvaluesof: -lowvoltageinpresenceofwater; -highvoltageinabsenceofwater. Characteristics 12Vnominalvoltage (8Vminimum-16Vmaximum Absorbedcurrent: -lowerthan15mAinrestconditions; -lowerthan150mAinalarmconditions(includingload). Voltageonload: -inrestconditions:higherthan11.8V; -inalarmconditions:lowerthan3.9V. Atkey-onoperation,thesensormakesaself-testissuing2.5 seconddurationsoundsignal. 112723 Normally open contact type. Operationdifferentialpressuredeltap:0.8 bar NTC temperature sensor 30 ˚ C= 26.114ohm ± 9.7% 0 ˚ C= 5.896ohm ± 7.3% +25 ˚ C= 2.057ohm ± 5.6% +60 ˚ C= 596ohm ± 3.8% +100 ˚ C= 186ohm ± .2.0% +110 ˚ C= 144ohm ± 2.4% Temperaturerange:-40 ˚ Cto+130 ˚ C Heater Nominalvoltage 12V Maximum allowed voltage 30V Nominalpower 250W Tightening torques 9. Screwsecuringfilter 1.5+0.5Nm 4. Waterdrainingorairbleedingscrew 1.5+0.5Nm +0,05 -0,5 1.Fuelfiltersupport-2.Dieseloiloutlet-3.Dieseloilinlet-4.Dieseloilfilter-5.Drainscrew-6.Electronicunit-7.Fastener-8.12-wayconnector-9.ScrewsecuringDieseloilfilter:H-G-B,waterpresentsensor;-H-C,cloggingsensor(ifforeseen);-D-E,NTCtemperaturesensor;-F-A,heater. F1AENGINE 147 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 289 Fuel pipes 542011 Fuel filter “Filtrauto” Thefuelfilterconsistsofaninternalfiltering-papercartridge (13)andisequippedwithawaterseparator. Themaximumwaterstoragecapacityofthefilteris150cm 3 . Thewatersensordetectsthepresenceofwaterinthefilter startingfromanexistingvolumeof70cm 3 . Thissensorislocatedinthelowerpartofthefilter. The temperature, water andclogging (if any) sensorsare interfacedwiththeelectroniccircuit(11)locatedinsideinthe upperportionoftheassembly. Whenthedieselfueltemperatureislowerthanalimitvalue, theelectricresistor willcome intooperation byproperly heatingthedieselfuelbeforethelatterisconveyedtothe high-pressurepump. Clogging sensor (if any) features: -differentialworkingpressure:0.7to0.85bar Tightening torques 5. Cover 35 ± 5Nm 12. Air/waterdrainscrew1 ± 0.2Nm NTC and heating features -ratedvoltage 13.5V -max.permittedvoltage 30V -ratedoutput 250Wat185l/h,T=-10 ˚ C -temperaturerange -30to120 ˚ C 112721 1.High-pressurepumpsupplypipequick-couplingfitting— 2.Supplypipequick-couplingfitting—3.— Fuelfilter mounting. 112218 Figure 290 1.Body-2.Gasket-3.Coverbottom-4.Drainscrewgasket-5.Customerreference-6.Dieseloiloutlet-7.Dieseloilinlet-8.Airdrainscrew-9.Suppliercode-10.Airbleedingorwaterdrainingscrew-11.Lowerbottom-12.Innerpipe-13. Filteringpaper-14.Upperbottom-15.Heatingearth-16.NTC1-17.NTC2-18.Cloggingsensor(ifforeseen)-19.Water sensor-20.Heating-21.Feed-22.GND NOTE Duetotheveryhighpressureexistingwithinthishydraulicsystem,thefollowingprecautionsshallbetakenforsafety reasons: -avoidconnectingthehigh-pressurepipefittingsbymeansofmakeshiftfasteners:tightenthemtothespecified torque; -avoiddisconnectingthehigh-pressurepipeswhentheengineisrunning(DONOTmakeanyattemptatdraining: thisisabsolutelyuselessanddangerous Toensurecorrectoperationofthesystem,itisessentialthatthelow-pressurecircuitisintact.Therefore,anymodification orattemptattamperingshallbeavoided,andcorrectiveactionsshallbetakenimmediatelyincaseofleaks. Intheeventthatfuelpipes(1-2-3)aredisconnectedfromsupport(1),makesure,whenreattachingthepipes,thattheir respectivefittingsarefullyclean. Suchprecautionsshallbetakentoavoiddetectivesealing,withresultingfuelleaks. 148 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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109125 Figure 291 Pumpwith3radialpumpingelementscontrolledviaagearby thetimingbelt;itneedsnotiming. Thepumpislubricatedandcooledbythefuel. The high-pressure pump cannot be overhauled; therefore,thefasteningscrewsshallnotberemoved ortamperedwith.Theonlyoperationthatcanbe carriedoutisthereplacementofthedrivegearand pressureregulator. NOTE 1.Low-pressurefeedline-2.Shaftwithcam-3.3-lobeelement-4.Pressureregulator-5.High-pressurelinenon-returnvalve-6.Deliveryline-7.Low/high-pressurelinenon-returnvalve. F1AENGINE 149 D AILY E URO 4 Print603.93.651 Base-March2006 775010 High-pressure pump CPH1

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Figure 292 1.Solenoid—2.Magneticcore—3.Shuttercylinder— 4.Fuelinlet—5.Fueloutlet. Whentheenginecontrolunitgovernsthepressureregulator (viaPWMsignal),thesolenoid(1)isenergizedthat,initsturn, generatesthemovementofthemagneticcore(2).Theshift ofthecorecausestheshuttercylinder(3)tomoveaxially, chokingtheflowoffuel. 75574 75575 1.Solenoid—2.Magneticcore—3.Pre-loadspring— 4.Shuttercylinder. Whenthesolenoid(1)isnotenergized,themagneticcoreis pushedintotherestpositionbythepre-loadspring(3).Inthis condition,theshuttercylinder(4)isinsuchapositionasto offerthefuelthegreatestsectionofpassage. Figure 293 Accuratelycleanhighpressurepump. Takeoffscrews(2)andunthreadpressureregulator(3)from highpressurepump. Figure 294 Figure 295 Accuratelycleantheseat( → )ofpressureregulatorandthe connectionsurface( → )oftheregulator. 88408 Mountnewsealrings(1and2)onpressureregulator(3)and lubricatetheringswithvaseline. 771034 Pressure control valve Thefuelpressureregulatorismountedonthelow-pressure circuitoftheCP3pump.Thepressureregulatormodulates theamountoffuelsenttothehigh-pressurecircuitaccording tothecommandsreceiveddirectlyfromtheenginecontrol unit. The pressure regulator is mainly composed of the followingcomponents: - connector - casing - solenoid - pre-loadspring - shuttercylinder. Whenthereisnosignal,thepressureregulatorisnormally open,thereforewiththepumpprovidingmaximumdelivery. The engine control unit, via the PWM (Pulse Width Modulation)signal,modulatesthechangeinfuelflowratein thehigh-pressurecircuitbypartiallyclosingoropeningthe sectionsofpassageofthefuelinthelow-pressurecircuit. Operation Replacing pressure regulator Forcleaning,donotuseatoolwhichcoulddamage thesurfacesandpayattentionthatimpuritiesare notintroducedintochannels. NOTE Figure 296 108347 108348 150 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 297 Mountpressureregulator(1)onhighpressurepump(2). Screwupscrews(1)andtightenthemat6 ÷ 7Nm(0.6 ÷ 0.7 kgm)torque. Figure 298 Mountingoperationmustbeperformedkeeping the regulator perpendicular to connection plane withoutanglingit,inordernottodamagesealrings (1-2,Figure296). NOTE Wherepressureregulatorisreplacedontheengine mounted on the vehicle, it is needed, after replacement,tocheckthattherearenofuelleaks afteranengineworkingperiod. NOTE 774510 Hydraulic accumulator (rail) Figure 299 The hydraulic accumulator is mounted on aspiration side cylinderhead. Itstaskistodamppressureoscillationscaused: - theoperationofthehigh-pressurepump; - theopeningoftheelectro-injectors. Fuelpressuresensor(2)isfittedonhydraulicaccumulator(1). Smallvalves(throttlevalves)orcontrolbushes(3),with ∅ = 0.85mm,havebeenfittedtothefueldeliverycouplings,which control the fuel pressure waves generated by the high-pressurepump.Theirfunctionistoprotecttheelectric injectorsbyreducingtheirwearintime. Fuelpressuresensor(2)mayaffecttheaccuracyoftheinjector minimumflowratecorrection,sincetheminimumflowrate dependsbothontheinjectiontimeandtheactualpressureof thehydraulicaccumulator. Incaseofreplacement,theEDCcontrolunit16correction coefficients(ZFC)shallbesettozero. Thecorrectioncoefficientscanbesettozerobymeansofthe IVECOMODUS-E.A.SY.-IT2000diagnosisinstruments,by programmingthecontrolunitagainandperformingthesensor replacementprocedure,inaccordancewiththeinstructions givenbythediagnosisinstruments. 108349 108350 108387 F1AENGINE 151 D AILY E URO 4 Print603.93.651 Base-March2006

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Theelectro-injectorshavehigh-pressuresupply(upto1600 bar)andrecirculationatatmosphericpressure,necessaryfor thedieselusedtooperatethepilotvalve. Thetemperatureofthedieselputbackintocirculationbythe electro-injectorcangetveryhigh(approximately120 ° C). Theheadoftheelectro-injectorhasafittingfortheelectrical connector. Theyaremountedonthecylinderheadandoperatedbythe injectioncontrolunit. 75588 Figure 300 775010 ELECTRO-INJECTORS Operation Electro-injectoroperationcanbebrokendownintothree phases: - ”restposition” Coil(4)isde-energised,andshutter(6)isinclosingposition andpreventsfuelfrombeingintroducedintothecylinder,Fc >Fa(Fc:causedbyfuelpressureactingoncontrolarea(7)of rod (1); Fa: caused by line pressure acting on pressure chamber(8). - ”startofinjection” Thecoil(4)isenergizedandcausestheshutter(6)torise. Thefuelofthecontrolvolume(9)flowsofftowardsthereturn manifold(10)causingadropinpressureinthecontrolarea (7). Atthesametime,linepressurethroughfeedduct(12)applies aforceFa>Fcinpressurechamber(8)liftingpeg(2),withfuel beingconsequentlyintroducedintocylinders. - ”endofinjection” Thecoil(4)isde-energizedandmakestheshutter(6)return toitsclosedposition.Thisrecreatessuchabalanceinthe forcesastomakethepin(2)returntoitsclosedpositionand consequentlyendinjection. 1Pressurerod—2Pin—3Nozzle—4Coil—5Pilotvalve— 6Ballshutter—7Controlarea—8.Pressurechamber— 9Controlvolume—10Low-pressurefuelreturn— 11Controlpipe—12Supplypipe—13Electrical connection—14High-pressurefuelinletfitting—15Spring. The electro-injector can be divided into two parts (see Figure301): - actuator/jetcomposedofpressurerod(1),pin(2)and nozzle(3); - controlsolenoidvalvecomposedofcoil(4)andpilot valve(5). Fc Fa 50704 Figure 301 Figure 302 1.IMAMatrixcode-2.Boschsparepartno.-3.IMAcode inclear-4.Ivecosparepartno.-5.Code-6.Seriesno.-7.Productiondate ElectricalinjectorsarenotassignedanymoretoclassesMin (01)-Med(02)-Max(03);therefore,flowratedeviations fromdesignvaluesaredetected,duringfinalcheckstep,bythe manufactureroneachsingleinjectorandprintedwithI.M.A. (InjectorMengeAbgleichung)[InjectorQuantityOffset]code oninjectormagnet. Atengineproductionplant,I.M.A.codeisreadonlinefrom anautomaticreadingstation,convertedintobarcode,printed onengineidentificationlabelandappliedontheengineitself. Atvehiclesproductionplant,atlineend,E.D.C.16centralunit isprogrammedautomaticallyreadingtheengineidentification label. 755010 Replacing an electrical injector 105066 152 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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105067 Atassistance,codewritteninclearhastobeused(3,Figure31) forcentralunitreplacementandreprogrammingprocedures. InthetablethereisshowntheconversionofOCRcharactersinto Arialcharacters. Whenelectricalinjectorsmountedonthevehiclemustbe replaced,meetfollowingwarnings: -whereelectricalinjectorsaredismountedanddonot needtobereplaced,theirmountingpositionhastobe noteddowninordertoremountthemlaterinthesame position;thisisdonetoavoidtoreprogramthecentral unit; -afterreplacingoneormoreinjectors,thecentralunithas tobereprogrammed; -beforemountinganewelectricalinjector,notedownIMA codeprintedontheinjector,becausethecodeisdifficult toreadaftertheinjectorhasbeenmounted; -wherethecentralunitisreplaced,reprogramthenew centralunitwiththeIMAcodesoftheelectricalinjectors mountedontheengineandcopydowntherectification coefficients(ZFC)ofreplacedcentralunit;whereitisnot possible,theymustberesetandself-learningprocess mustbestartedupagain. Duringenginerunning,EDC16centralunitperformssome checksonelectricalinjectorsminimumflowrate. Incertainconditions(overrun:vehicledecelerationwithpedal released)anincreasing(verysmall)fuelquantitystartingfrom zeroisinjectedanditseffectonenginerotationsmoothness isobserved. Injectionstartthresholdisdetectedandstoredbythecentral unit. Thisself-learningprocessiscarriedoutoneachsinglecylinder. Therefore,replacinganelectricalinjectorinvolvestheneedof reprogrammingthecentralunitbyenteringtheIMAcodesof newelectricalinjectorsandresettingtherectificationfactors (ZFC)ofthecylinderconsidered. Replacingallelectricalinjectorsextendstheneedofresetting to all the rectification coefficients (ZFC) of each single electricalinjector. Figure 303 ConversiontableofOCR charactersintoARIALcharacters The control unit is a ”flash EPROM” and so it can be reprogrammedfromoutsidewithoutchangingthehardware. Itprocessesthesignalsfromthesensorsbyapplyingsoftware algorithms and controls the actuators (especially the electro-injectorsandpressureregulator). Thecontrolunitrecords,inthememorynon-labilearea,the information on the engine parameters originally set or acquiredduringengineoperation. Theinjectioncontrolunithastheabsolutepressuresensor builtintofurtherimprovethecontroloftheinjectionsystem. Thecontrolunitismountedontheleft-handsideoftheengine bayandisconnectedtothevehicle’swiringharnessbytwo connectors: — 60-pinconnector A forthecomponentsontheengine — 94-pinconnector K forthecomponentsonthevehicle Inadditiontohandlingtheoperationofthesystemdescribed under the relevant heading, the electronic control unit is interfacedwiththeotherelectronicsystemsonthevehicles such as ABS — EBD cruise control, speed limitingdevice, immobilizer(IVECOCODE),EGRandglowplugs. OnthevehiclesequippedwithD.P.F.catalyst,thecontrolunit alsocontrolsthecatalystregenerationsystem.Inthiscase, afteranyoftheoperationsbelowiscarriedout: - replacingoneorseveralinjectors; - replaceallinjectors; - replaceflowratemeter(flowmeter); - rreplacing the hydraulic accumulator (common rail) pressuresensor; - replaceE.D.C.16centralunit; - refillengineoil; - replaceD.P.F.catalyst; - replacefilterdifferentialpressure( ∆ p)sensor; - replacecomponentsrelevanttoemissions; - necessarilyperformaforcedregeneration; thefollowingoperationsshallbecarriedoutbyusingthe IVECOdiagnosisinstrument::MODUS-E.A.SY.-IT2000; thentheproceduretoreplaceaffectedcomponenthastobe carriedout,followingbelowindicationsprovidedbydiagnosis tools: ELECTRIC/ELECTRONIC COMPONENTS 766161 Electronic control unit EDC 16 Figure 304 k 85711 Thecorrectioncoefficients(ZCF)canbesettozerobymeans of the IVECO: MODUS - E.A.SY. - IT 2000 diagnosis instruments, by programming the control unit again and performingthesensorreplacementprocedureindicatedby thediagnosisinstrumentitself. F1AENGINE 153 D AILY E URO 4 Print603.93.651 Base-March2006 llllk

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SENSORS 764266 Engine speed sensor Itisaninductivetypesensorandispositionedonthephonic wheelmountedonengineshaftfrontend. Itgeneratessignalsobtainedfrommagneticfluxlineswhich closethroughphonicwheelteeth.Teethnumber:58. Theelectroniccontrolunitusesthissignaltomeasurethe speedofrotationoftheengine,itsangularpositionandto operatetheelectronicrevcounter. Ifthissignalfailstherevcounterwillnotwork. 764264 Camshaft timing sensor ItisaHalleffecttypesensorpositionedoncamshaftpulley. Itgeneratessignalsobtainedfromlinesofmagneticfluxthat closethroughanotchinthepulley. Thesignalgeneratedbythissensorisusedbytheelectronic controlunitasaredundantsignaltomeasurethedifferent enginespeeds. Figure 305 761917 Glow plug electronic control unit Theenginecontrolunit,inthephaseof: - starting - after-starting timestheoperationoftheglowplugcontrolunitaccordingto theenginetemperature. Glowplugsdriveisthroughglowplugspre-heatingcentralunit dependingon engine temperature under close controlof enginecontrolcentralunit. The pre-heating control unit contains an “intelligent” contactorthatsendsfeedbacktothecontrolunitthatisthus informedaboutanyfaultwiththepre-heatingcontrolunitor shortingtoearthoftheglowplugs. 75578 761915 Glow plugs Figure 306 75579 CONTROLVALUES Withaconstantsupplyvoltageof11V: - max.currentdrawn 18A - in5sec. 11 ± 1.5A - in30sec. 6 ± 0.9A - temperatureafter7sec. 850 ° C - tighteningtorque 8-10Nm 75514 Figure 307 SectionA-A Thesensorgapis: -1 ± 0.5mm,betweenthecamshaftpulley(2)andtiming sensor(1). -1mm,betweenthephonicwheel(4)andspeedsensor (3). SENSORASSEMBLINGDIAGRAM 154 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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772655 Airtemperatureand pressuresensor Positionedontheintakemanifold,itmeasuresthepressureof theturbochargingairintroducedintotheintakemanifold. Thisvalue,togetherwiththatoftheairtemperaturesensor, makesitpossiblefortheelectroniccontrolunittocalculatethe exactquantityofairintroducedintothecylinderssoasto operate the injectors adjusting the fuel delivery, limiting harmfulemissions,improvingconsumptionandperformance. The sensor contains an electronic temperature correction circuittooptimizethepressuremeasurementinrelationtothe temperatureoftheintakeair. 772656 Fuel temperature sensor Integratedinthefuelfilter,itmeasuresthefueltemperature andtransmitsittotheelectroniccontrolunit. Whenthefueltemperatureistoohigh(ambienttemperature condition,engineatfullloadandtankinreserve),correct lubricationofthehigh-pressurepumpisnolongerassured.On thebasisofthevaluesreceived,thecontrolunitdeterminesthe densityandvolumeofthefuel,correctingthedeliverylimiting engineperformance. 774511 Fuel pressure sensor Thisismountedinthemiddleofthehydraulicaccumulator (rail)andithasthetaskofprovidingfeedbackfortheinjection controlunitto: - adjustinjectionpressure - adjustthedurationofinjection. 772641 Clutch pedal position sensor Mountedonthepedalboard,itprovidesthecontrolunitwith apositivesignalwhentheclutchisengaged(pedalreleased). Everytimetheclutchisdisengagedtochangegear,thecontrol unit fails to receive this signal and deactivates the Cruise Controlfunction. 772642 Brake pedal position sensor Therearetwoofthesesensorsmountedonthepedalboard. Withthebrakepedalreleased,theyprovidethecontrolunit withapositivesignalthatisusedtodetectbrakeoperationso astodeactivatetheCruiseControlfunctionandstopdelivery offuel. Inaddition,asensorswitchesonthebrakelights. 764261 Vehicle speed sensor Thissensor,mountedonthegearboxbythedriveoutput shaft,transmitsthevehiclespeedsignal,throughtheelectronic tachograph,tothecontrolunit. 540743 Differential pressure sensor - delta p (Dp) Thissensordetectsthedifferencebetweenthepressure(Dp) oftheincomingexhaustgasandthepressureofthegasflowing outoftheD.P.F.catalyst. Themeasuredvalueindicatestheextentofparticulate(PM) particleaccumulationorcloggingintheD.P.F.filter. This value will, through a proper signal (feed-back), be processed by the EDC control unit 16, which will cause post-injectionsoastoincreasetheexhaustgastemperature (630 ˚ -650 ˚ C) and also cause the particulate particles accumulatedintheD.P.F.filtertobeburned. 766161 Atmospheric pressure sensor Thisisintegratedintheelectroniccontrolunit.Itprovidesa criterionofcorrectionforthemeasurementoftheairflow rateandtocalculatethereferenceairflowratetocheckthe EGR. 764254 Engine coolant temperature sensor Thisprovidesthecontrolunitwithanindexofthethermal statusoftheengineinordertodeterminecorrectionsforthe fueldelivery,injectionpressure,EGRinjectionadvancewhen startingcold(ifmounted)andwarm-up. 505910 Throttle pedal position sensor Theacceleratorpedalpositionsensorprovidesthecontrol unit with a voltage value in proportion to the angle of operationofthepedaldeterminingfueldelivery. Incaseofreplacement,thecontrolunitshallbe programmed again by means of the IVECO MODUS-E.A.SY.-IT2000diagnosisinstrument,by performingthereplacementprocedureindicated bythediagnosisinstrumentitself. NOTE Incaseofreplacement,thecontrolunitshallbe programmed again by means of the IVECO MODUS-E.A.SY.-IT2000diagnosisinstrument,by performingthereplacementprocedureindicated bythediagnosisinstrumentitself. NOTE Exhaust gas temperature sensor TheD.P.F.catalystincludestwotemperaturesensorslocated attheD.P.F.catalystinletandoutlet,respectively. Thetemperaturevaluesareprocessedbythecontrolunitto determinepost-combustion,inordertoincreasetheexhaust gastemperatureneededtoburntheparticulateparticles. F1AENGINE 155 D AILY E URO 4 Print603.93.651 Base-March2006

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ACTUATORS The injection system comprisesthreeclassesofactuators interlockedwiththeelectroniccontrolunit: -electro-injectors(seerelevantheading); -regulators(seerelevantheadings)requiringPWMcontrol (PulseWidthModulation): • forpressure • EGR(seerespectivechapter) • turbochargerwithvariablegeometry(ifmounted); -actuatorswithcontinuousON/OFFsignalto: • engageelectromagneticcouplingforradiatorcooling fan; • turnon/offair-conditionercompressor(ifmounted); • CruiseControl; • starterheatercontrol; • fuelfilterheating; • electricsupplypump. PWM (Pulse Width Modulation) controls A PWM control has an active and an inactive state that alternatewithinaconstantsetlengthoftime.Duringtheactive state the actuator control circuit is closed, which is thus powered with the control voltage; whereas, during the inactivestatethecircuitisopen. The duration of the two states may be varied with the conditionthatthesumofthetwotimesisequaltothelength ofthemodulationdelivery. Thedurationoftheactivestatedeterminestheduty-cycle, whichisnormallyexpressedasapercentageofthetotaltime. Therefore,ifthedurationofthetwoactiveandpassivestates arethesame,theduty-cycleisequalto50%. Forreasonsofdiagnostics,theduty-cycleislimitedbetween 1% and 99%; the control resolution is equal to 0.005% (1/20000ofthetime). The time length has been chosen taking account of the dynamicactuatorresponsespecifications. Toolowacarrierfrequencycouldcauseoscillationsinthe actuator,whiletoohighafrequencywoulddecreasecontrol resolution. TheE.G.R.andvariablegeometryturbocharger(ifmounted) arecontrolledthroughavacuummodulatingvalve. Allthepowercontrolsaremadewithrelayslocated inthecab. NOTE 156 F1AENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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F1CENGINE 157 D AILY E URO 4 Print603.93.651 Base-March2006 F1C engine Page MAINOPERATIONSONENGINEMOUNTEDON VEHICLE 161 ............................. -Serviceprocedurestobeperformedafterreplacing high-pressurefeedingsystemand/orexhaustgas post-treatmentsystemcomponents 162 ......... POWERUNITREMOVAL/REFITTING 163 ........ -Removal 163 .............................. -Refitting 167 .............................. -Checksandtests 167 ....................... -Powersteeringsystemairbleed 167 ............ REPLACINGAIR-CONDITIONINGCOMPRESSOR DRIVEBELT 168 .......................... -Disassembly 168 ........................... -Assembly 168 ............................. POWERSTEERINGPUMP-ALTERNATORBELT REPLACEMENT 168 ....................... -Disassembly 168 ........................... -Assembly 168 ............................. REPLACINGTHEWATERPUMP 168 ............ -Removal 168 .............................. -Refitting 168 .............................. REPLACINGTHEHIGH-PRESSUREPUMP 169 .... -Removal 169 .............................. -Refitting 169 .............................. REPLACINGTHEPOWERSTEERINGPUMP 170 .. -Removal 170 .............................. -Refitting 170 .............................. REPLACINGTHEDRIVESHAFTSEALRINGAND THEFRONTCOVERGASKET 170 ............ -Removal 170 .............................. -Refitting 171 .............................. REPLACINGTHEVACUUMPUMPOILPUMP ASSEMBLY(GPOD) 172 .................... -Removal 172 .............................. -Refitting 172 .............................. REPLACINGTHEDRIVESHAFTREARSEALRING 173 -Removal 173 .............................. -Refitting 173 .............................. REPLACINGELECTRO-INJECTORS 174 .......... -Removal 174 ..............................

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158 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Page -Refitting 174 .............................. REMOVAL/REFITTINGTHECYLINDERHEAD 175 . -Removal 175 .............................. -Refitting 177 .............................. EGRHEATEXCHANGERREMOVAL-REFITTING 179 -Removal 179 .............................. -Refitting 180 .............................. -Checksandtests 180 ....................... EGRHEATEXCHANGERREMOVAL-REFITTING 180 -Removal 180 .............................. -Refitting 181 .............................. -Checksandtests 181 ....................... BURNTGASEXHAUSTSYSTEM 182 ............ REMOVAL/REFITTINGOFEXHAUSTPIPEASSEMBLY COMPONENTS(SYSTEMSEQUIPPEDWITHD.P.F. CATALYST) 183 .......................... -Exhaustsilencerremoval 183 ................. -D.P.F.catalystremoval 183 ................... -Refitting 183 .............................. -ReplacingD.P.F.catalyst 184 .................. -Replacingdifferentialsensor(delta-p) 184 ........ ENGINEVIEWS 185 .......................... EMISSIONS 188 ............................. ENGINEIDENTIFICATIONCODE 189 ........... CHARACTERISTICCURVES 195 ................ GENERALSPECIFICATIONS 197 ............... ASSEMBLYDATA—CLEARANCES 200 .......... TOOLS 205 ................................ EXPERIMENTALTOOLS 211 .................. TIGHTENINGTORQUE 218 ................... OVERHAULINGENGINEF1C 221 .............. DISASSEMBLINGTHEENGINEATTHEBENCH 221 REPAIRS 232 ................................ CYLINDERBLOCK 232 ....................... -Checksandmeasurements 232 ................ -Checkingheadmatingsurfaceoncylinderblock 233 CRANKSHAFT 233 .......................... Page -Measuringmainjournalsandcrankpins 233 ...... -Checkingcrankshaft 234 ..................... -Replacingtimingcontrolgear 236 .............. ENGINEASSEMBLY 236 ...................... -Assemblingmainbearings 236 ................. -Measuringmainjournalassemblyclearance 236 ... -Checkingcrankshaftendfloat 237 .............. -Assemblingrearseal 238 ..................... ENGINEFLYWHEEL 239 ...................... -Replacingbearingsupportinggearboxinputshaft 239 CONNECTINGROD—PISTONASSEMBLY 239 ... -Piston 240 ................................ -Measuringpistondiameter 240 ................ -Pistonpin 241 ............................. -Conditionsforcorrectpin-pistoncoupling 241 .... -Pistonrings 241 ............................ -Connectingrods 242 ........................ -Bushing 242 ............................... -Checkingconnectingrods 242 ................ -Checkingtorsion 243 ....................... -Checkingbending 243 ....................... -Assemblingconnectingrod-pistonassembly 243 ... -Checkingforconnectingrod—pistondistortion 244 -Assemblypistonrings 244 .................... -Assemblyconnectionrod-pistonassemblyinthe cylinderliner 244 ........................... -Measuringcrankpinassemblyclearance 244 ...... -Checkingpistonprotrusion 245 ............... CYLINDERHEADS 246 ....................... -Disassembly 246 ........................... -Disassemblythecamshaft 246 ................ -Checkingcylinderheadseal 247 ............... -Checkingcylinderheadmatingsurface 247 ....... VALVES 247 ................................ -Removingdeposits,refacingandcheckingvalves 247 -Checkingclearancebetweenvalvestemandvalve guideandcentringvalves 248 ................. VALVEGUIDE 248 ........................... -Replacingvalveguide 248 ....................

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F1CENGINE 159 D AILY E URO 4 Print603.93.651 Base-March2006 Page -Boringvalveguides 248 ...................... VALVESEATS 249 ........................... -Recuttingandreplacingvalveseats 249 .......... VALVESPRINGS 250 ......................... ROCKERARMS—TAPPETS 250 ................ -Checks 251 ............................... ASSEMBLINGCYLINDERHEADS 251 ........... -Overhead 252 ............................. -Overheadremoval 252 ...................... TIMINGSYSTEM 253 ......................... -Description 253 ............................ -Camshaft 254 ............................. -Checks 254 ............................... -Checkingcamliftandpinalignment 254 ......... -Assemblingoverhead 256 .................... AUXILIARYORGANCONTROLS 256 ........... -Cynderheadrefitting 258 .................... TIMINGSYSTEMCONTROL 259 ............... -Replacementofalternatorfreewheel 264 ....... LUBRICATION 271 .......................... -General 271 .............................. OILPUMP/DEPRESSORUNIT 273 .............. -Oilpump 273 ............................. -Characteristicdata 273 ...................... -Vacuumpump 274 ......................... -Oilpressureadjustingvalve 274 ............... -Disassembly 274 ........................... -Assembly 275 ............................. -Oilfilter 275 .............................. -Heatexchanger 275 ........................ -Disassembly 275 ........................... -Assembly 275 ............................. -Oilvapourrecirculation(Blow-by) 277 .......... -Operation 277 ............................ COOLING 278 .............................. -Description 278 ............................ -Operation 278 ............................ -Electromagneticpulley 279 ................... Page -Waterpump 279 .......................... -Thermostat 279 ........................... TURBOCHARGING 280 ...................... -Description 280 ............................ -TurbochargertypeMITSUBISHITD4HL-13T-6 281 REPAIRS 282 ................................ -Pressurereliefvalve 282 ..................... -Pressure-reliefvalvecheck 282 ................ -GARRETGT2260Vvariable geometryturbosupercharger 283 .............. -General 283 .............................. -Operationatlowenginerpm 283 .............. -Operationathighenginerpm 283 ............. -Proportionalsolenoidvalvecontrollingturbocharger actuator 284 .............................. -Actuator 284 .............................. REPAIRS 285 ................................ -Checkingandadjustingtheactuator 285 ......... EXHAUSTGASRECIRCULATION(EGR)SYSTEM 286 -Operating 286 ............................. -Mainsystemcomponents 287 ................. -E.G.R.valve 287 ............................ -Modulatorsolenoidvalve 287 ................. -Airflowratemeter(flowmeter) 287 ........... -Throttlevalveassembly 288 .................. -Heatexchanger 288 ........................ EXHAUSTSYSTEMREMOVAL-REFITTING 289 .... -General 289 .............................. D.P.F.(DIESELPARTICULATEFILTER)CATALYST 290 -Description 290 ............................ SYSTEMTOREDUCEPOLLUTANTSATEXHAUST 291 -Operation 291 ............................ -Forcedregeneration 292 ..................... -Refillingengineoil 292 ....................... FUELSUPPLY 293 ........................... HIGH-PRESSUREELECTRONICINJECTIONSYSTEM (MS6.3-EDC16) 293 ..................... -General 293 ..............................

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160 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Page SYSTEMOPERATION 295 .................... -Self-diagnosis—BLINKCODE 295 ............. -Immobilizerrecognition 295 .................. -Checkingfueltemperature 295 ................ -Checkingenginecoolanttemperature 295 ....... -Checkingquantityoffuelinjected 295 ........... -Checkingidlingadjustment 295 ................ -Fuelcut-offinreleasephase 295 ............... -Checkingcylinderbalancingonidling 295 ........ -Checkingregularenginerotation(anti-sawing) 295 . -Checkingsmokinessatexhaustonacceleration 295 -Checkingexhaustgasrecirculation(E.G.R.) 295 ... -Checkingtopspeedlimit 295 ................. -Checkingregularrotationonacceleration 295 .... -Checkingglowplugcontrolunit 295 ............ -Checkingactivationofair-conditioningsystem 295 . -Checkingfuelpump 295 ..................... -Checkingdieselwarming 296 ................. -Checkingcylinderposition 296 ................ -Checkingpilotandmaininjectiontiming 296 ..... -Checkinginjectionpressureclosedcycle 296 ..... -Fuelsupply 296 ............................ -Correctingflowrateaccordingtowatertemperature 296 -Correctingflowratetoavoidnoise,smokeor overloading 296 ............................ -De-rating 296 ............................. -Injectiontimingelectronictest 296 ............. -Speedgovernor 296 ........................ -Enginestarting 296 ......................... -Coldstarting 297 ........................... -Warmstarting 297 ......................... -Runup 297 ............................... -Afterrun 297 ............................. -Cut-off 297 ............................... -Cylinderbalancing 297 ...................... -Synchronizationsearch 297 ................... OPERATION 298 ............................ Page HYDRAULICSYSTEM 298 ..................... -Fuelpipes 298 ............................. FEEDSYSTEMANDFUELRECIRCULATION 299 .. HYDRAULICSYSTEM 301 ..................... -Fuelpump 301 ............................ -”Filtrauto”fuelfilter 302 ..................... -”UFIfilters”fuelfilter 303 ..................... -CP3.2high-pressurepump 304 ................ -Pressureregulator 305 ...................... -Replacingpressureregulator 305 ............... -Hydraulicaccumulator(rail) 306 ............... ELECTRO-INJECTORS 307 .................... -Operation 307 ............................ -Replacinganelectricalinjector 307 ............. ELECTRIC/ELECTRONICCOMPONENTS 308 ..... -ElectroniccontrolunitEDC16 308 ............ -Glowplugelectroniccontrolunit 309 ........... -Glowplugs 309 ............................ SENSORS 309 .............................. -Enginespeedsensor 309 ..................... -Camshafttimingsensor 309 .................. -Airtemperatureandpressuresensor 310 ........ -Fueltemperaturesensor 310 ................. -Fuelpressuresensor 310 ..................... -Atmosphericpressuresensor 310 .............. -Enginecoolanttemperaturesensor 310 ......... -Throttlepedalpositionsensor 310 ............. -Clutchpedalpositionsensor 310 .............. -Brakepedalpositionsensor 310 ............... -Vehiclespeedsensor 310 .................... -Differentialpressuresensor-deltap(Dp) 310 .... -Exhaustgastemperaturesensor 310 ............ ACTUATORS 311 ........................... -PWM(PulseWidthModulation)controls 311 ....

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MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE Keeptothefollowinginstructionsbeforedoinganyworkontheengineinvolvingcomponentsofthefuelsupplysystem. -Beforedoinganyworkontheengine,performtheengine/vehiclefaultdiagnosiswithspecificIVECOdiagnosis equipmentandprintouttheresults. -ReplacementoftheMS6.3orEDC16controlunitmustbeauthorizedbythe Help Desk. Replacingoperation requiresreprogrammingasdescribedinspecificsection. -Followingcomponentsinfeedsystemcannotbeoverhauledbuthavetobereplaced:pressurereliefvalve,ifpresent, fuelpressuresensor,hydraulicaccumulator,completeCP3highpressurefeedpump,pressurecontrolvalve,electric injectors. -AllthepartsoftheCommonRailsystemarepackagedbythesupplierinsheetsofoiledpaperandarestoredin cardboardboxes.Theymustthereforebeprotectedagainstmoistureandunpackedjustpriortoassembly. -Thegreatestcaremustbetakenoverthecleanlinessofparts,makingsurethatwhenhandlingorassembling (startingwithstraightforwardfilterandpre-filterreplacement)nodirtofforeignbodiescangetinside.Forthis reason,theplugsprotectingthehydraulicpartsandsensorsmustberemovedjustpriortopositioningintheirseats. -Takecareoverthedirectionofassemblyforallelectricalconnections. -Allthreadedconnectionsmustbetightenedtotheprescribedtorque. -Allthequick-couplingconnectors(ontheenginetheyarefoundonthehigh-pressurepumpandonthedieseldrain manifold)mustbefullyinserted.Todrivethemout,pressonthetabsatthebaseoftheconnectors. Electro-injector Noneofthecouplings/unions/nutsontheinjectorbodymaybehandled.Itisneithernecessarynorpermittedto dismantlethenozzlebodyortheelectromagnet. Ifworkingonthehigh-pressurepipe,thehexagonontheinjectorsidemustbekeptstationarywithawrench. Beforeworkingonpipes,makesuretheinjectorisstationaryinitsseatonthecylinderhead. Whenassembling/disassemblingtheinjectordrain,theretainingspringmustnotberemovedfromitsseatintheinjector: pushingthespringtowardstheengineandapplyingaverticalforceontheconnectorfreestherecirculation.When assembling,resttherecirculationconnectorinitsseatandapplyaverticalforcewhilekeepingtheretainingspring pressedinthedirectionoftheengine.Fittinginhastobeeasy. Replacingoneormoreelectricalinjectorsrequirescentralunitprogrammingasdescribedinspecificsection. CP3 High-pressure pump Ifworkingonthehigh-pressurepipe,thehexagononthepumpsidemustbekeptstationarywithawrench. Beforeworkingonthehigh-pressurepipe,makesurethepumpissecuredinitsseat. High-pressure pipes Eachhigh-pressurepipemustbereplacedafterdisassemblyoperations. Thecouplingsmustbetightenedorloosenedwiththeinjectors,hydraulicaccumulator(rail)andhigh-pressurepump wellsecuredandtakingcaretokeepthehexagononthecomponentsidestationary,spacepermitting. Hydraulic accumulator (rail) and accessories Thepressuresensorcanbeassembledfiveconsecutivetimes;afterthat,itmustbereplaced.Theymustbelubricated withathinlayerofoilbeforebeingmounted..Replacingthesensorrequirescentralunitprogrammingasdescribedin specificsection. F1CENGINE 161 D AILY E URO 4 Print603.93.651 Base-March2006

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Service procedures to be performed after replacing high-pressure feeding system and/or exhaust gas post-treatment system components Forenginecorrectoperation,E.D.C.16centralunitstores, intomemorynonvolatilearea,informationrelatingtoengine parametersoriginallysetoracquiredduringoperation. Consequently,wheneveracomponentofhighpressurefeed systemand/orofthepost-treatingsystemforbelowlisted exhaustgasses,thecentralunithastobereprogrammedby IVECOdiagnosistool:MODUS-E.A.SY.-IT2000;thenthe proceduretoreplaceaffectedcomponenthastobecarried out,followingbelowindicationsprovidedbydiagnosistools: - replaceinjector; - replaceallinjectors; - replaceflowratemeter(flowmeter); - replacehydraulicaccumulator(commonrail); - replaceE.D.C.16centralunit; - refillengineoil; - replaceD.P.F.catalyst; - replacefilterdifferentialpressure( ∆ p)sensor; - replacecomponentsrelevanttoemissions; - necessarilyperformaforcedregeneration; - replacecentralunit. 162 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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540110 POWER UNIT REMOVAL/REFITTING 108628 Removal Placethevehicleonthepitorautolift. Lifttheenginehood(26),undothefasteningscrews(27)and thenremovethehood;removesupportingrod(28). Disconnectnegativecable(4)andpositivecable(11)from battery (10), then remove the latter from the engine compartment. Disconnectelectricconnections(5,7,8and9)andengine cable(6)fromtheEDCcontrolunit,thenreleasetheengine cablefromthestrapssecuringthesametothecab. Unhookcable(1)fromthehoodopeningcontroldevices. Disconnectfrontheadlampelectricconnections(12). Removescrews(19),thentakeoffcover(18). Removefasteningscrews(32),thentakeoffheadlampinserts (13). Donotchangetheassemblypositionofheadlamp insert(13)threadedbush(14,detailD). NOTE Remove the screws and/or fastening nuts, then remove crosspiece(33). Remove the screws and/or fastening nuts, then remove bumper(17). Removeexpansiontank(3)cap(2). Actasfollows,fromunderthevehicle(seefigure4): -undofasteningscrews(12and13),thenremovelower sideguards(14); -undofasteningscrews(16),thenremovelowercentral guard(26). Applyatube(16)toradiatorpipeunion(detailC),then unscrew cap (15) and drain the coolant into a suitable container. Ifthevehicleisequippedwithacabair-conditioning unit,proceedasfollows: -fittheunit99309146pipestoconnections(23), thenblowthegasofftheair-conditioningunitas described in the respective charter of the ”Bodyworkandchassis”section; -disconnectelectric connection(29) fromthe dryingfilterpressureswitch; -disconnect pipes (20) from air-conditioner compressor(21); -removenuts(25),thendisconnectpipes(22) fromexpansionvalveconnection(24). NOTE Seal the air-conditioning unit pipes and their respective mounts, to prevent moisture and impuritiesfrompenetratingintothesystem. NOTE Figure 1 F1CENGINE 163 D AILY E URO 4 Print603.93.651 Base-March2006

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Remove nuts (4), then place remote-control switch/fuse holder(3)aside. Disconnect pipe (18) from the heat exchanger and the turboblower. Disconnect pipe (34) from the heat exchanger and the throttlevalveassembly. Disconnectorremovethecoolantpipes: - (15),fromthethermostat; - (16),fromtheengineoilheatexchanger; - (19),frompipe(18); - (20),fromradiator(17). Properly obstruct the turboblower air outlet to avoidcasualpenetrationofforeignbodiesintothe turboblowerand,therefore,damagetothelatter. NOTE 108629 Properly obstruct the turboblower air outlet to avoidcasualpenetrationofforeignbodiesintothe turboblowerand,therefore,damagetothelatter. NOTE Figure 2 Removescrews(13)securingradiator(17)tothesupports. Disconnectelectricconnection(12). Releaseremote-controlswitchsupportingbracket(14)from theleftside. Removeradiator/heatexchangerassembly(17)togetherwith thecondenser-dryingfilterandpipes(ifany). Removeoilfillingcap(1)andremovesound-proofingcover (5). Loosenthestraps,thendisconnectcoolantventpipes(2) fromexpansiontank(8). Disconnecttank(8)pressuresensor(7)electricconnection. Removetank(8)fasteningnuts(10),thenremovethetank fromthewall. Disconnectelectricconnection(9)ofthelevelsensorplaced undertank(8). Loosenthestraps,thendisconnectcoolantpipe(6)located belowtank(8). Disconnectelectricconnection(11)fromthethrottlevalve assemblyactuator. Disconnectexpansiontank(8)pipe(28)andcabheaterpipe (29)fromwaterpumppipe(25). Loosenthestraps,thendisconnectcoolantventpipes(33) fromEGRvalve(31)and(27)fromthecylinderhead. Loosen the strap, then disconnect coolant pipe (32) and vacuumpipe(30)fromEGRvalve(31). Loosenthestrap,thendisconnectpipe(26)fromairpipe(22). Disconnectelectricconnection(24)fromairflowmeter(23). Loosenthestraps,thendisconnectairpipe(22)complete withairflowmeter(23)fromtheturboblowerandairfilter (21). 164 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Disconnect vacuum pipe (2) from variable geometry turbobloweractuator(1)(ifany). Cut the straps securing the cables to the engine, then disconnecttheelectricconnectionsfromtheVGTsolenoid valve(13,ifany),alternator(15),oillevelsensor(16). Removethescrewandtakegroundcable(9)off. Removethenuts,thentakecablesoffstartingmotor(7). Disconnectservobrakevacuumpipe(8)frompipeunion (12). Disconnectdeliverypipe(5)andreturnpipe(6)fromthe low-pressurefuelpipes. Placeacontainerunderthepowersteeringpumptorecover thesystemoil,thendetachoilreturnanddeliverypipes(11 and10). Loosenthefasteningstrap,thenremovepowersteeringtank (4)fromthesupport. Applytool99360543(3)ontotheenginebracketstotakethe engineoffitscompartmentandsecureittothehoist. 108630 Figure 3 F1CENGINE 165 D AILY E URO 4 Print603.93.651 Base-March2006

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Actfromunderthevehicletodisconnectjointedheads(17) from: - levershiftcontrolcables(16); - selectioncable(max.pull-outload:250N-max.pull-inload: 60N); - engagementcable(max.pull-outload:100N-max.pull-in load:80N). Useasuitablescrewdrivertoopenoutflexiblecablefins(18) sothatthepawlsaredisengagedfromthesupport. Undofasteningscrews(22),moveclutchcontrolcylinder(23) togetherwithitsbracketandproperlysecureittothechassis. Removethesealingfromring(1),thenunscrewthesameand disconnectthespeedindicatorcontrolcable. Disconnect electric connection (4) or (28 - for vehicles equippedwithautomatictransmission)fromthereversing lightswitch. Whenremovingthegearboxunitfromtheengine,remove thefasteningscrewsanddetachthestartingmotor. Removethefasteningscrewsandtakethegearboxunitoffthe engine. Thepowerunitshallberemovedfromtheengine compartmentwiththegreatestcare,soasnotavoid damagingthepartsleftonthevehicle,especiallythe steeringboxoilpipes. NOTE As regards the vehicles equipped with automatic transmission, carefully carry out the operations describedinthecharterofthe”Gearboxunit”section. NOTE Disconnectexhaustpipe(8)fromtheturbobloweroutlet pipe. VehiclesequippedwithD.P.F.catalyst:removethefastening screws,thentakeexhaustpipe(8)supportingbracket(10)off gearboxunit(9). Disconnectvacuumpipe(25)fromVGTactuator(24-only 176HPengines). Putasupportingjackunderthegearboxunit. Remove the bracket supporting the gearbox to the rear crosspiecebyactingonthefourscrews(5). Undo fastening screws (10), then remove gearbox unit supporting crosspiece (11) complete with its gearbox/supportingbracket. Removenuts(15)securingelasticsupports(14)tothechassis. Removebolts(3)securingpropellershaft(2)tothegearbox unit;ifnecessary,removescrews(6)securingelasticsupport (7)tothechassisandproperlysecurepropellershafttothe chassis. Removethejackfromunderthegearbox. Lift the power unit and remove it from the engine compartment. Vehicles equipped with automatic transmission: disconnectgearbox-chassiscable connector(27) fromcontrolunit. NOTE 108631 Figure 4 166 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Refitting To refit the engine assembly, carry out the operations described for removal in reverse order, following these instructions: -Beforerefittingthegearboxtotheengine,itisnecessary to remove the pressure plate bearing from the diaphragmspringbyopeningouttheretainingcirclip. Fitthepressureplatebearingonthesleeveofthedrive inputshaftcover,connectingittotheclutchrelease lever. Spread the gearbox input shaft with Molikote molybdenumdisulphidegrease. Asregardsthe6S400O.D.gearboxunits,proceedas follows. Engageageartoletthemainshaftturn,rotatingthe propellershaftconnectingflange.Pushthegearboxfully insothatthepressureplatebearingcoupleswiththe diaphragmspringcorrectly. Asregardsthe6S400O.D.gearboxunits,followthe proceduresdescribedinthespecificchapter. -Payspecialattentiontotheoperationsneededtoinstall theengineassemblyintheenginebay. -Checktheconditionsofthecoolantpipesorsleevesand oftheairducts.Replacethemiftheyshowanysignof deterioration. -Checktheflexiblemountingsoftheassemblies:engine andgearbox.Replacethemiftheyshowanysignof deterioration. -Check that the exhaust pipe members have not deterioratedandarenotabouttodeteriorate.Ifthisis so,replacethemalongwiththeflexiblepartsforsecuring them. -Tightenthescrewsornutstotherequiredtorque. -Meticulouslycheckthestateofthevacuumpipe.Itmust shownosignofcracking,cutting,scoringorofbeing crushed.Replaceitifthereisanydoubtatallaboutits soundness.Whenmountingit,makesurethepipedoes notcomeintocontactwithsharpmetalpartsorcorners or with any particularly hot parts. In addition, after assembly,thepipemusthavenobendsorconstrictions, itsradiusofcurvatureshouldbebroadanditmustbe secured to the vacuum pump fitting with a suitable clamp. -Makesurethatfuelpipesrapidengagementfittingsare accuratelyclean,andresulttohavebeenfullyinserted and not going to be disconnected after their being connectedtorelatingengagementunions. -Fillthecoolingsystemwithcoolant. -Fillthehydraulicpowersteeringcircuitandbleedtheair asdescribedundertherelevantheading. -Checkthelevelofoilintheengineandgearbox. -Recharge the air-conditioning system (if any), as describedintherelevantchapterinthe“Bodyworkand chassis”section. -Check,ifnecessary,theheadlamporientation. -No water leaks from the connecting sleeves of the enginecoolingandcabheatingcircuitpipes;tightenthe collarsifnecessary. -Nooilleaksfrombetweenthecoverandcylinderhead, oil sump and crankcase, oil filter and its seat, heat exchangerandcrankcaseorfrombetweenthevarious pipesofthelubricatingcircuit. -Nofuelleaksfrominjectionpumpandinjectorlines. Tightenfittingsifnecessary. -Checktheindicatorandwarninglightsontheinstrument panelandthedevicesdisconnectedonremovingthe engineallworkproperly. Checkthelevelofoilinthetankandtopitupifnecessary. Liftthevehicleatthefront,startuptheengineandletitidle forsometime. Checkthereisnooilleakagefromthehydrauliccircuitand checkthelevelinthetank. Slowlyturnthesteeringwheelinbothdirectionsofsteering sothattheairinthehydraulicsystemcomesout. Checkthelevelofoilinthetankagainandtopupifnecessary. Checks and tests Startuptheengine,leaveitrunningjustalittlefaster than idling speed and wait for the coolant temperature to reach the value for opening the thermostat,thencheckthat: Whenpositioningtheengineintheenginebay, takespecialcarenottodamagethetoppipeofthe power steering and the soundproof-heatproof claddingoftheenginebay. Oncepositioned,meticulouslycheckthatthetop pipeofthepowersteeringissound. Beforeusingitagain,checkthatthepowersteering oilandcoolantcontainnoimpurities.Iftheydo, filterwithsuitablemeshfilters.Foranytoppingup, refertotheREPLENISHINGFLUIDStableinthe “GENERAL”section. NOTE 501430 Power steering system air bleed F1CENGINE 167 D AILY E URO 4 Print603.93.651 Base-March2006

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102201 Placethevehicleinapitoronanautolift. Remove,fromunderthevehicle,thecentralsound-proofing guard.Removeelasticbelt(4)frompulleys(1and5). 543910 REPLACING AIR-CONDITIONING COMPRESSOR DRIVE BELT 102202 Drainthecoolingfluid,andthen removeboth thefront cross-memberandtheradiator,asdescribedinthe“Power unitdetachment/re-attachment”chapter. Takethefanofftheelectro-magneticjoint. Removeelectricconnection(3)fromtheenginecable. Stoprotationofelectro-magneticjoint(6),thenremovenut (8). Re-attachmentiscarriedoutbyreversingtheorder ofdetachmentoperations.Inparticular,tightenthe screwsandnutstothespecifiedtorquevalues. After re-attachment has been completed, fill the enginecoolingsystem,starttheengineandcheckfor coolingfluidleaks. Assembly Applywedge99360161(2)withelasticbelt(4)to pulley(1),thenplacetheelasticbeltontoroller(3) andpulley(5),takingcaretoplacethepulleyribsin thecorrespondingracesofpulleys(1and5). 543910 POWER STEERING PUMP-ALTER-NATOR BELT REPLACEMENT Disassembly Disassemblethecompressordrivebelt,ifthereisone,as describedundertherelevantheading. Slackenoffthetensionofthebelt(1)usingaspecificwrench ontheautomatictightener(2)andremovethebelt. Assembly Mountthedrivebelt(1)takingcaretopositionits ribscorrectlyintherespectiveracesofthepulleys. Release the automatic tightener (2). Turn the crankshaftbyoneturntosettlethebelt. 543210 REPLACING THE WATER PUMP Removal Unscrewnut(8)inaclockwisedirection,sincethe nutthreadgoesleftwards. Takeoffhub(6)andpulley(5). Cutthestrap( → ),removeelectriccable(3)retainingstrap fastening screw (1), remove nuts (2), then take electro-magnet(4)offwaterpump(7). Removethefasteningscrews,andthentakeoffwaterpump (7). Refitting NOTE 88330 Rotatethedriveshaftcounterclockwise( → )untilbelt(4)is correctlycoupledwithpulley(1). Mountthecompressordrivebelt,ifthereisone,andadjust thetensionasdescribedundertherelevantheading. Fitthemiddlesoundproofingguardbackon. Figure 5 Figure 6 Figure 7 Disassembly 168 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Removecap(2),thentakecover(1)offthecylinderhead. Loosenthestraps,thendisconnectairpipe(3)fromtheinlet manifoldandtheheatexchanger. Use tool 99360076 to take oil filter (4) off the heat exchanger. Remove the electric connection from pressure regulator (13). Remove connections (8 and 10), then disconnect low-pressurepipes(11)fromhigh-pressurepump(9). Removepipe(5)retainingbracket(7)fasteningscrew(6), then disconnect the retaining bracket from hydraulic accumulator(14)andhigh-pressurepump(9). Remove screws (18) and spacers (19), then remove high-pressurepump(9)fromsupport(15).Removejoint (16). 771010 REPLACING THE HIGH-PRESSURE PUMP Removal 108635 Re-attachmentiscarriedoutbyreversingtheorder ofdetachmentoperations.Inparticular,complywith thefollowinginstructions: -replacethesealrings,gaskets,high-pressurepipe andoilfilterwithnewparts; -lubricate,priortoassembling,sealring(17)with engineoil; -tightenthescrews,nuts,fittingsandoilfilterto thespecifiedtorquevalue; -checktheengineoillevel;topup,ifnecessary. Refitting Figure 8 F1CENGINE 169 D AILY E URO 4 Print603.93.651 Base-March2006

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102204 Removeoilfillingplug(1)fromoiltank(2). Remove,fromundertheenginecompartment,thecentral sound-proofingguard. Placeacontainerunderpowersteeringpump(6)torecover theoilfromthesystem,andthenremovefittings(3and8) anddisconnectoilpipes(4and7)frompowersteeringpump (6). 501450 REPLACING THE POWER STEE-RING PUMP Removal 102207 Usetool99360190(3)tostopdriveshaftrotation,then removescrew(2)andtakeoffdamperpulley(1). Applytool99340059(6)asshowninthefiguretoremove sealring(5)fromcover(4). 102205 Removescrews(6)andtakepowersteeringpump(5)off support(4).Removejoint(2)fromdrivearbor(3). Re-attachmentiscarriedoutbyreversingtheorder ofdetachmentoperations.Inparticular,takecareof thefollowing: -replace seal ring (1) with a new part, and lubricate the same with engine oil prior to assembling; -replacetheoilpipegaskets(asabove); -tighten the nuts, screws and fittings to the specifiedtorquevalues. After re-attachment has been completed, fill the hydraulicpowersteeringcircuitandbleedtheairas describedundertherelevantheading. Refitting 540440 REPLACING THE DRIVE SHAFT SEAL RING AND THE FRONT COVER GASKET Removal 102206 Proceedasfollows,byoperatingasdescribedinthe“Power unitdetachment/re-attachment”chapter: -draintheenginecoolingfluid; -removethefrontcross-member; -removetheradiator. Removefan(1)fromtheelectro-magneticjoint. Takeofftheair-conditioningcompressordrivebelt(ifany) aswellasthewaterpump-alternatordrivebelt,asdescribed intherelevantchapters. Figure 9 Figure 10 Figure 11 Figure 12 170 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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102209 Removescrew(11),andthentakeoffdipstickpipe(4). Loosenstrap(3),removescrew(2),thentakepipe(1)off cover(5). Removescrews(6),andthentakeoffcover(5).Remove snapring(8).Takeoutcentrifugalfilter(7). 102216 Fitcover(1)centringtool99396030(3)intothecentrifugal filterseat,thentightenscrews(2)tothespecifiedtorque. Removetools99346258(4)and99396039(3). 102214 Mountcover(1)withanewgasket.Screwdownscrews(2) withouttighteningthemup. Refitting 102215 Thoroughlycleancover(1)sealringseat. Screwdownpart(2)oftool99346258intothedriveshaft shank. Lubricatethedriveshaftshankandtheoutsideofpart(2), thencouplethenewsealring(3)withpart(2). Placepart(4)ontopart(2),screwdownnut(5)untilsealring (3)isfullyassembledtocover(1). Bothcentrifugalfilter(7)andcoversealring(5) mustbereplacedeverytimetheyaredismounted. Removescrews(9),andthentakeofffrontcover(10). NOTE Figure 13 Figure 14 Figure 15 Figure 16 F1CENGINE 171 D AILY E URO 4 Print603.93.651 Base-March2006

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102217 Fitanewcentrifugalfilter(1). Fitanewsnapring(2). Fitcover(3),andthentightenscrews(4)tothespecified torque. Positionconnectingjoint(1)intogear(4). Fitvacuumpumpoilpumpassembly(2)byplacing anewgasketinbetween. Tightenscrews(3)tothespecifiedtorque. Re-attachmentiscarriedoutbyreversingtheorder ofdetachmentoperations.Inparticular,tightenthe screwsandnutstothespecifiedtorquevalues. After re-attachment has been completed, fill the enginecoolingsystem,starttheengineandcheckfor coolingfluidleaks. Refitting 503010 REPLACING THE VACUUM PUMP OIL PUMP ASSEMBLY (GPOD) Removal 102218 Removescrews(3),andthentakeoffvacuumpumpoilpump assembly(2). Removeconnectingjoint(1)fromgear(4). Bothcentrifugalfilter(1)andcover(3)sealring mustbereplacedeverytimetheyaredismounted. Re-attachment is carried out by reversing the order of detachmentoperations.Inparticular,tightenthescrewsand nutstothespecifiedtorquevalues. After re-attachment has been completed, fill the engine cooling system, check the engine oil level (top up, if necessary),starttheengineandcheckforcoolingfluidleaks. Removethefrontcover,asdescribedinthe“Replacingthe driveshaftsealringandthefrontcovergasket”chapter. NOTE 3 2 1 4 Figure 17 Figure 18 172 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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102219 Stopflywheel(1)rotationbymeansoftool99360306(4). Removescrews(2),andthentakeoffengineflywheel(1). 540640 REPLACING THE DRIVE SHAFT REAR SEAL RING Removal 102222 Fitengineflywheel(1),thentightenscrews(4). Applytool99360351(3)tothebaseinordertostopengine flywheel(1)rotation. Tighten engine flywheel (1) fastening screws (4) in two separatesteps: -step1:tightento30Nmbymeansofatorquewrench; -step2:tightento90 ° anglelock. 102220 Applytool99340060(2)torearsealring(1),thentakethe latteroutoftheenginebase. Refitting 102221 Thoroughlycleanthesealringseat. Lubricatethedriveshaftrearshankwithengineoil. Applypart(2)oftool99346259tothedriveshaftrearshank, thensecureitwithscrews(5)andcouplethenewsealring (3)withthesame. Placepart(1)ontopart(2),screwdownnut(4)untilsealring (3)isfullyassembledtothebase. Thisoperationinvolves: -detaching/re-attaching the drive shafts (see relevantsection505620); -detaching/re-attaching the gear shift (see relevantsection530210; -detaching/re-attachingtheclutch(seerelevant section505210). Angle lock is performed by means of tool 99395216(2). Disassembletool99360351(3).Thenfittheclutch,gearshift anddriveshaftbackintoposition,asdescribedintherelevant sections. NOTE Figure 19 Figure 20 Figure 21 Figure 22 F1CENGINE 173 D AILY E URO 4 Print603.93.651 Base-March2006

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102223 Thoroughlycleantheelectricinjectorseat,takingcarenotto introduceforeignbodiesintothecylinderliners. Fitanewgasket(18)ontoelectricinjector(16),andthenfit thelatterintotheoverhead. Re-attachment is carried out by reversing the order of detachment operations. In particular, comply with the followinginstructions: - fuelpipesmustbereplacedwithnewpartseverytimethey aredisassembled; - tightenthenuts,screwsandfittingstothespecifiedtorque values; - to tighten the fuel pipe fittings, use a wrench of the 99317915seriesaswellastorquewrench99389829. Disconnectthefollowingelectricconnections:(4),fromthe pressuresensor,and(2),fromthelevelsensors,bothofthem locatedonexpansiontank(1). Removenuts(3)securingexpansiontank(1)tothewall, thenputtheexpansiontankaside. Removeplug(6),andthentakeoffsound-proofingcover(5). Disconnectelectricconnections(7)fromelectricinjectors (16)and(9)fromfuelpressuresensor(8). Pressclips(15)inthedirectionshownbythearrow,then disconnect fuel recovery pipe (14) fittings from electric injectors(16). Disconnectfuelpipes(11)fromelectricinjectors(16)and hydraulicaccumulator(10). Remove screws (12) and brackets (13) securing electric injectors(16)tothecylinderhead. Usetool99342153(17)totakeelectricinjectors(16)offthe overhead. Refitting Removal Figure 23 174 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 775010 REPLACING ELECTRO-INJECTORS

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108636 Remove bracket (11) securing the low-pressure pipe assemblytotheinletmanifold. Removescrew(6),thentakecoolantpipe(8)fasteningstrap (5)offthecylinderhead. Remove air conveyor (3) from the overhead, from turboblower(4). Disconnectoilpipe(7)fromtheconnectiononthecylinder head. Remove nuts (2), then remove turboblower (4) from exhaustmanifold. Removal Properlyplugtheturbochargerairoutlet/inlet,to prevent foreign bodies from penetrating accidentallyintotheturbocharger(and,therefore, damagingthesame). Removethefanfromtheelectro-magneticjoint. Takeofftheair-conditioningcompressordrivebelt(ifany) aswellasthewaterpump-alternatordrivebelt,asdescribed intherelevantchapters. Removethefrontcover,asdescribedinthe“Replacingthe sealringandthefrontcovergasket”chapter”. Proceedasfollows,byoperatingasdescribedinthe“Power unitdetachment/re-attachment”chapter: - drainthecoolingfluid; - removethefrontcross-member; - removetheexpansiontank. Cut the straps securing the cables to the engine, then disconnecttheelectricconnectionsbelow: - (12)thermostat; - (17)preheatingplugs; - (20)pressuresensor; - (21)electricinjectors; - (1)electromagneticjoint; - (22)phasesensor; - (9)pressureregulator; - (15)airtemperaturesensor; - (23)throttlevalveassemblyactuator. Removetheelectricinjectorsasdescribedintherespective charter.Removescrew(14),thentakefuelpipe(16)off high-pressurepump(10)andhydraulicaccumulator(18). Remove the fastening screws, then take off hydraulic accumulator(18). Usetool99360076toremoveoilfilter(3)fromtheheat exchanger. NOTE Figure 24 F1CENGINE 175 D AILY E URO 4 Print603.93.651 Base-March2006 540610 REMOVAL/REFITTING THE CYLINDER HEAD

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102225 Removescrews(18),thentakeoffoverhead(19)complete withpins99360614(13). Remove the screws, and then take upper cover (2) off overhead(19). Removeplugs(20)fromoverhead(19). Rotatethedriveshaftclockwise,sothatpins99360614(13) canbeinserted,throughtheholesofplugs(20),intothe correspondingholesofthedriveshafts,andpin99360615(5) canbeinsertedintothedriveshaftthroughthebaseunit hole. Removeupperchainstretcher(1). Removepin(4),thentakeoffuppershoe(3). Remove both screw (17) and washer (16), and then disassemblegear(15). Removebothscrew(10)andwasher(11),thendisassemble gear(12)andchain(14). Removebothplug(6)andscrews(7and8),thendisassemble fixeduppershoe(9). Pins99360614,appliedinordertoavoidmodifying timing after the toothed chain has been disassembled,mustberemovedfromtheoverhead onlywhenthelatterhasbeendisassembled. NOTE Removetheoverheadgasket. Removethetappetsandputthemapartcarefully. Remove the pre-heating spark plugs by means of tool 99355041. Removethecylinderheadfasteningscrews,andthentake theheadoffthebaseunit. Removethecylinderheadgasket. Figure 25 176 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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102273 102226 Refitting Unlessotherwisespecified,re-attachmentiscarriedoutby reversingtheorderofdetachmentoperations.Inparticular, complywiththefollowinginstructions: Verifytheconditionslistedbelow,whichrefertothetools usedforvalvetiming: - tool99360614(6,SENZACODICE)mustbeinserted intotheoverhead; - tool99360615(11,SENZACODICE)mustbeinserted intothebaseunit. Verifythatthejunctionplanesofthecylinderheadandthe baseunitareclean. Donotsoilthecylinderheadgasket. Placethecylinderheadgasketwiththe“TOP”writingfacing theheaditself. Fitthecylinderhead,insertthescrewsandtightenupinthree subsequentsteps,byfollowingthesequenceandindications showninthenextfigure. Thegasketmuststrictlybekeptsealedinitsown package and be unwrapped soon before being fitted. Angle lock is carried out by means of tool 99395216. NOTE NOTE 88355 Cylinderheadfasteningscrewtighteningsequence: -step 1: preliminary tightening by means of a torque wrench: • tightenscrews1-2-3-4-5-6to130Nm; • tightenscrews7-8-9-10to65Nm. -step2:anglelocking: • tightenscrews1-2-3-4-5-6to90º; • tightenscrews7-8-9-10to90º. -step3:anglelocking: • tightenscrews1-2-3-4-5-6to90º; • tightenscrews7-8-9-10to60º. -TightenscrewsAto25Nm. Thoroughlycleanhydraulictappets(2),thenlubricateandfit themtocylinderhead(3),bycorrectlypositioningrocker arms(1)onthevalves. Fitgasket(5). InsertthetwotoolsSp.2264(4)intotheelectricinjector seatsforsubsequentoverheadcentringonthecylinderhead. Fitoverhead(1)completewithtools99360614(3)forvalve timing,thentighten fasteningscrews (2)to thespecified torque. RemovetoolsSp.2264(4). Fitfixeduppershoe(1).Tightenscrews(2and3)tothe specifiedtorque. Fitplug(4)togetherwithanewbasket,thentightenittothe specifiedtorque. 88270 Figure 26 Figure 27 Figure 28 Figure 29 F1CENGINE 177 D AILY E URO 4 Print603.93.651 Base-March2006

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88359 Placechain(1)ongear(5)andongear(2). Fitthegearinsuchawaythatwhenitisinsertedontothe dowelboltoftheintakevalvedistributingshaft,slotsAwill bepositionedasshowninthefigure. Placechain(1)ongear(2),thenfitthelatterontotheexhaust valvedistributingshaft. Screwdownfasteningscrew(4)withwasher(3)without tighteningup. Checktheconditionsofmovingpads(1and3):iftheyare worn, they shall be replaced together with the other camshaftdrivecomponents. Positionmovingshoes(1and3),thensecurethemtothe baseunitwithpin(2)bytighteningthelattertothespecified torque Screwdownhydraulicchainstretcher(2),thentightenitto thespecifiedtorque. Insert, through the opening on the overhead, a suitable screwdriver,thenpressonmovingshoe(4)fin(3)untilchain stretcher(2)piston(1)ispushedtoitsendofstroke. Release moving shoe(4),andmake surethat piston(1) causes,byescapingfromitsseat,chain(5)tobesubjected totension. Screwdownfasteningscrew(4)withwasher(3)without tighteningup. Thechain(1)branchincludedbetweenthetwo gearsmustbesubjectedtotension. 102229 Chain stretcher (1) cannot be re-used for any reasonafterithasbeendisassembled.Moreover,in theeventthatpiston(1)hasbeenunintentionally madetoescapefromchainstretcher(2),thelatter mustbereplaced. Chainstretcherreconditioningisnotpermitted. 102231 102127 NOTE NOTE 3 2 1 Figure 30 Figure 31 Figure 32 Figure 33 All the camshaft drive components (fixed and movingpads,timinggears,chainnutsandtiming controlchains)shallbereplacedeventhoughthe anomalyaffectsonlyoneoftheabove-mentioned items. NOTE 178 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Re-attachment is carried out by reversing the order of detachment operations. In particular, comply with the followinginstructions: - replace the seal rings, gaskets, safety snap rings and high-pressurepipeswithnewparts; - lubricatethesealringswithengineoilpriortoassembling; - tightenthescrews,nutsandpipefittingstothespecified torquevalues; - checktheengineoillevel;topup,ifnecessary; - filltheenginecoolingsystem,starttheengine,andcheck forcoolingfluidleaks. 88372 Tighten the screw securing gear (1) to the intake valve distributingshafttothespecifiedtorque. 88373 Makesurethatchain(3)issubjectedtotensioninthelength includedbetweengear(2)andgear(4). Tightenthescrewsecuringgear(2)totheexhaustvalve distributingshafttothespecifiedtorque. Removetools99360614(1)and99360615(5,Figure25). Figure 34 Figure 35 540730 EGR HEAT EXCHANGER RE-MOVAL - REFITTING 105027 Removeplug(4)fromexpansiontank(3). Arrangespecialcontainerundertheradiator,removeplug locatedonradiatorrightsideanddrainenginecoolant. Removeoilfillingplug(1)andtakeoffsounddeadeningcover (2). Disconnectelectricalconnection(6)frompressureswitch. Loosenclampsanddisconnectcoolantventtube(5). Removesecuringscrewsanddisconnecttank(3)fromwall. Disconnectelectricalconnection(7)fromthelevelsensor placedundertank(3). Loosenclampsanddisconnectcoolanttube(8)placedunder tank(3). Removal Figure 36 F1CENGINE 179 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 37 Loosenthestraps,thendisconnectcoolantpipes(1and2) andvacuumpipe(4)fromEGRvalve(3). 112331 Refitting Forrefitting,reversetheoperationsdescribedfor removalobservingfollowingwarnings: -replacegaskets(2and3)andthestrapswith newparts. -tighten the screws to the specified torque value. -fillexpansiontankwithcoolant. Figure 38 108633 Placetheheatexchanger/valveassemblyontoaworkbench, thenremoveEGRvalve(4)fasteningscrewsandtakeEGR valve(4)offheatexchanger(1). Checks and tests Startuptheengine,letitrunatrpm’sjustalittle overidlingandwaitforcoolanttemperatureto reach the value for opening the temperature switch,thencheckfornowaterleaksexistingfrom coolingcircuitstubes. Figure 39 108632 Loosenthestraps,thendisconnectcoolantpipes(2and3) fromEGRvalve(6).Loosenscrew(7)ofstrap(8)joiningEGR valve(6)topipe(9).Removescrews(4),thentakeheat exchanger (1), complete with EGR valve (6), off the overhead. 540730 EGR HEAT EXCHANGER RE-MOVAL - REFITTING 105027 Removeplug(4)fromexpansiontank(3). Arrangespecialcontainerundertheradiator,removeplug locatedonradiatorrightsideanddrainenginecoolant. Removeoilfillingplug(1)andtakeoffsounddeadeningcover (2). Disconnectelectricalconnection(6)frompressureswitch. Loosenclampsanddisconnectcoolantventtube(5). Removesecuringscrewsanddisconnecttank(3)fromwall. Disconnectelectricalconnection(7)fromthelevelsensor placedundertank(3). Loosenclampsanddisconnectcoolanttube(8)placedunder tank(3). Removal Figure 40 180 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 41 Loosenthestraps,thendisconnectcoolantpipes(1and2) andvacuumpipe(4)fromEGRvalve(3). 112331 Figure 42 108634 Loosenscrew(5)ofstrap(6)joiningEGRvalve(4)topipe (7). Removescrews(1),thentakeEGRvalve(4)offtheheat exchanger. Refitting Forrefitting,reversetheoperationsdescribedfor removalobservingfollowingwarnings: -replacegaskets(2and3)andthestrapswith newparts. -tighten the screws to the specified torque value. -fillexpansiontankwithcoolant. Checks and tests Startuptheengine,letitrunatrpm’sjustalittle overidlingandwaitforcoolanttemperatureto reach the value for opening the temperature switch,thencheckfornowaterleaksexistingfrom coolingcircuitstubes. F1CENGINE 181 D AILY E URO 4 Print603.93.651 Base-March2006

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108626 Figure 43 Theexhaustsystemismadeupofthreecomponents: A.systemlengthwithhose; B.catalystwithparticulatefilter(DPF); C.silencer. TheexhaustsystemismanufacturedbyArvinMeritor(ArM). BURNT GAS EXHAUST SYSTEM 182 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 44 105073 Placethevehicleonapitorautolift. Carryoutthefollowingoperationsbyactingfromunderthe vehicle: -unscrew nuts (2) securing silencer (3) supporting bracket(1)tothevehiclechassis; -unscrewandremovefasteningscrews(4)offlanges(5) connectingexhaustsilencer(3)andD.P.F.particulate filter(8); -removeexhaustsilencer(3). D.P.F. catalyst removal -unscrew and remove the exhaust gas temperature sensorsatthecatalystinlet16)andoutlet(17); -unscrewtodisconnectcouplings(6and12)securing rigidpipes(7and11)runningtothepressuresensorto D.P.F.catalyst(8); -properlysecureD.P.F.catalyst(8)tothevehiclechassis; -unscrew nuts (9) securing D.P.F. catalyst (8) filter supportingbracket(10)tothevehiclechassis; -unscrewandremovefasteningscrews(13)offlanges (15)connectingD.P.F.catalyst(8)filtertotheexhaust gasoutletpipefromturbine(14); -removeD.P.F.catalyst(8)filter. Refitting Refittingiscarriedoutbyreversingtheorderofthe detachment operations. Moreover, the following instructionsshallbeobserved: -check the conditions of the elastic dowels, takingcaretoreplacethedefectiveones(ifany); -replacethegasketswithnewparts; -tightenthenutsandscrewsto thespecified torque. Aftertheoperationhasbeencompleted,andintheevent that either the D.P.F. catalyst or the differential sensor (delta-p)needsreplacing,followtheinstructionsgiveninthe respectivechapters. Exhaust silencer removal F1CENGINE 183 D AILY E URO 4 Print603.93.651 Base-March2006 REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY COMPONENTS (SYSTEMS EQUIPPED WITH D.P.F. CATALYST)

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507130 Replacing D.P.F. catalyst ReplacingD.P.F.catalystneedsthatallthecountersofbelow indicatedparametersareresetinthecentralunit,as: - particulatequantityinnewfilteriszero,so,ifparticulate quantityisnotreset,filterregenerationwillstartevenifit isnotnecessary; - quantityofaccumulatedashesiszero,so,ifashescounter isnotreset,regenerationfrequencywillbegreaterthan needed,consequentlyincreasingfuelconsumption,and particulatefilterthermalfatigue;and,inextremecases, therewillbeanunnecessaryrequesttorefillengineoil; - post-injectedfuelquantityiszero,so,ifpost-injectedfuel counterisnotreset,theremaybeanearlyrequesttorefill engineoil. The meters used to evaluate the above-mentioned parameterscanberesetbymeansoftheIVECOMODUS -E.A.SY.-IT2000diagnosisinstruments,byprogrammingthe control unit again and performing the differential sensor replacementprocedure,inaccordancewiththeinstructions givenbythediagnosisinstruments. WherebothDPFcatalystisreplacedandengineoil isrefilled,resettingpost-injectedfuelcounterisnot necessary. NOTE 540743 Replacing differential sensor (delta-p) Pressuredifferencebetweengaspressureatcatalystmodule inlet and gas pressure at ceramic walls filter outlet is convertedintoavoltagesignal(Vout)bypressuresensor. During engine running, E.D.C. 16 central unit performs checksondifferentialpressuresensordriftandcalculates enginecompensationandrunningvalues,andcorrectsthem. Consequently,afterreplacingthesensor,itisnecessaryto resetrectificationcoefficients. The meters used to evaluate the above-mentioned parameterscanberesetbymeansoftheIVECOMODUS -E.A.SY.-IT2000diagnosisinstruments,byprogrammingthe control unit again and performing the differential sensor replacementprocedure,inaccordancewiththeinstructions givenbythediagnosisinstruments. - regenerationstatus:regenerationunnecessary,inprogress, interrupted,resumed; - milescoveredandtimesfromlastcompleteregeneration; - differentialpressure(delta-p)sensordriftself-rectification; - oxidiser catalyst drift; consequently, if catalyst ageing function is not reset, quantities of unnecessary post-injectionsmightbepresent. 184 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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107864 Figure 45 F1CENGINE 185 D AILY E URO 4 Print603.93.651 Base-March2006 ENGINE VIEWS

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107865 107866 107867 Figure 46 Figure 47 Figure 48 LEFT-HANDSIDEVIEW FRONTVIEW REARVIEW 186 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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107868 Figure 49 Figure 50 TOPVIEW RIGHT-HANDSIDEVIEW A .Turbochargerwithpressurereliefvalve(Waste-Gate,ENGINE136HP) 107869 F1CENGINE 187 D AILY E URO 4 Print603.93.651 Base-March2006

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Gas emissions Engines comply with Euro4 Gas Emission Regulation (measurementatenginebenchaccordingtocyclesETCand ESC/ELR,with following limits set by Regulation 98/69-1999/102/CEI-levelB: CycleESC+ELR: - CO(carbonoxide) 1.5g/kWh .................... - NOx(nitrogenoxide) 3.5g/kWh .................. - HC(unburnthydrocarbons) 0.46g/kWh ........... - Particulate 0.02g/kWh .......................... CycleETC: - CO(carbonoxide) 1.5g/kWh .................... - NOx(nitrogenoxide) 3.5g/kWh .................. - HC(unburnthydrocarbons) --g/kWh ............. - Particulate 0.03g/kWh .......................... Testfuel:CECRTF73-T90S=0.05%. Grade of smoke Enginescomplywithgradeofsmokelimitsrequestedby regulationstohavefollowinggradeofsmokevaluesatoutlet: - maximumpower (BoschBSUopacimetergrades) 1.5 - maximumtorque (BoschBSUopacimetergrades) 1.5 Sound emissions Maximum average acoustic level, Lpa, of standard configurationenginesmeasuredaccordingtoISOStd3745 (microphonesatonemetredistancefromenginesurfaces): - atidling (800rpm) 72dBA .......... ............ - atmaximumtorque 84dBA ...................... - atmaximumpower (3800rpm) 93dBA. . .......... Engines for LD (Light Duty) vehicles Gas emissions Engines comply with Euro4 Gas Emission Regulation (measurement at engine bench according to cycle ECE15+EUDC),withfollowinglimitssetbyRegulation98/69 -1999/102/CEI-levelB: - CO(carbonoxide) 0.74g/kWh - NOx(nitrogenoxide) 0.39g/kWh - HC(unburnthydrocarbons)+ NOx(nitrogenoxide) 0.46g/kWh - Particulate 0.06g/kWh Testfuel:CECRTF73-T90S=0.05%. Grade of smoke Enginescomplywithgradeofsmokelimitsrequestedby regulationstohavefollowinggradeofsmokevaluesatoutlet: - maximumpower (BoschBSUopacimetergrades) 1.5 - maximumtorque (BoschBSUopacimetergrades) 1.5 Sound emissions Maximum average acoustic level, Lpa, of standard configurationenginesmeasuredaccordingtoISOStd3745 (microphonesatonemetredistancefromenginesurfaces): - atidling (800rpm) 72dBA ......... ............ - atmaximumtorque 84dBA .................... - atmaximumpower (3800rpm) 93dBA. .......... Engines for HD (Heavy Duty) vehicles 188 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Print603.43.671 EMISSIONS

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Engineseries Engineseriesevolution Engine Exhaustemiss.level DutyNo. Supply/injection CylinderNo. Enginecycle—cylinderposition 0= 4-stroke, vertical 4=4cylind. 6=6cylind. 8=DI.TCA 1=Truck 2=Bus 4=M.T.vehiclesandtractors 6=Marine 9=Army 0481 F= 107 kW-(146CV)3500rpm-350Nm-(35,6kgm)1500 ÷ 2800rpm 0481 H= 129 kW-(176CV)3500rpm-400Nm-(40,7kgm)1500 ÷ 2800rpm F 1 8 4 4 E C 1 C F * + Homologationpower F1CENGINE 189 D AILY E URO 4 Print603.93.651 Base-March2006 ENGINE IDENTIFICATION CODE

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Figure 51 Figure 52 CRANKCASE MARKING 107871 107870 SELF-ADHESIVE LABEL Engine variant Iveco drawing number — 9 digits Engine serial number — 7 digits GAN — 9 characters Electro-injector class 190 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 EXAMPLE A = IVECOtrademark IVECO B = IVECOnameofenginevariant** F1CE0481F/H*A001 C = Engineserialnumber 1359862 D = 1 st digit,mainjournalno.1(enginefront) E = Mainbearingselectiondiameters 12345 F = Barrelselectiondiameters 1234 G = 1 st digit,cylinderno.1(enginefront) (**)Dataobtainablefrom“XZ”engineorderingnumberinformation

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108444 Figure 53 LONGITUDINALSECTION F1CENGINE 191 D AILY E URO 4 Print603.93.651 Base-March2006

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108445 Figure 54 F1CENGINECYLINDERAXISCROSSSECTION(146HP) 192 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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108446 Figure 55 F1CENGINESUPPORTAXISCROSSSECTION(146HP) F1CENGINE 193 D AILY E URO 4 Print603.93.651 Base-March2006

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108447 Figure 56 F1CENGINECROSSSECTION(176HP) 194 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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CHARACTERISTICCURVESOFENGINEF1C(146HP) 107872 Max OUTPUT 107 kW at 3500 rpm Max TORQUE 350 Nm at 1500 ÷ 2800 rpm 146 HP 35,6 kgm Figure 57 F1CENGINE 195 D AILY E URO 4 Print603.93.651 Base-March2006 CHARACTERISTIC CURVES

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CHARACTERISTICCURVESOFENGINEF1C(176HP) 107873 Max OUTPUT 122 kW at 3500 rpm Max TORQUE 400 Nm at 1250 ÷ 3000 rpm 176 HP 40,7 kgm Figure 58 196 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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F1CENGINE 197 D AILY E URO 4 Print603.93.651 Base-March2006 GENERAL SPECIFICATIONS Type F1CE0481 F F1CE0481 H Cycle Diesel4strokes Feeding Turbochargedwithintercooler Injection Direct N.ofcylinders 4on-line ∅ Diameter mm 95,8 Stroke mm 104 + + +.. = Totaldisplacement cm 3 2998 Max.power KW (HP) 107 (146) 122 (176) rpm 3500 3500 Max.power KW (HP) 350 250 Max.power KW (HP) 350 (35,6) 400 (40,7) rpm 1500 ÷ 2800 1500 ÷ 2800 Engineidlingspeed, noload rpm 800 ± 25 Maximumengine speed,noload rpm 4200 ± 50 PressureatT.D.C. * bar 20 ÷ 26 bar Minimumpermissible pressureatT.D.C. * bar 16 (*) Thepressurevalueisrecordedbyturningtheengineoverwiththeelectricstartermotor,withoiltemperatureat40 ° -50 ° C andtheinjectionpumpinthestopcondition.

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198 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Type F1CE0481 F F1CE0481 H A B VALVETIMING opensbeforeT.D.C. A closesafterB.D.C. B 24 ° 26 ° C D opensbeforeB.D.C. D closesafterT.D.C. C 70 ° 24 ° X Fortimingcheck mm X mm Running mm X mm ----FEED HighpressureelectronicfuelfeedsystemBOSCHEDC16 ComposedofCP3.2high-pressurepump,electro-injectors, hydraulicaccumulator(rail),EDCcontrolunit,pressureand temperaturesensors Pumparrangement Withpistonn.latT.D.C. -X Startofdelivery mm -Injectornozzletype BOSCHCR122 Injectornozzletype BOSCHCR12-2 Injectionorder 1-3-4-2 ba r Releasepressure bar 1600

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F1CENGINE 199 D AILY E URO 4 Print603.93.651 Base-March2006 Type F1CE0481 F F1CE0481 H SUPERCHARGING Withintercooler Turbochargertype MITSUBISHI TD04-HL-13T-6 withWaste-Gate GARRETTGT2260V variablegeometry Turbochargershaftradialclearance 0,396 ÷ 0,602 0,086 ÷ 0,117 Turbochargershaftaxialclearance 0,034 ÷ 0,106 0,030 ÷ 0,083 Minimumopeningstrokeofpressurereliefvalve mm 1 -Maximumopeningstrokeofpressurereliefvalve mm 5 -Pressurecorrespondingtotheminimumstroke bar 1,22 ± 0,027 -Pressurecorrespondingtothemaximumstroke bar 1,38 ± 0,047 -Actuatorsetting: -lowpressure 0 mmHgvalvefullyopen . -lowpressure 0,2 bar valvestroke mm -lowpressure 0,64bar valvestroke mm --0,5 ÷ 2,5 9,5 ÷ 11,5 LUBRICATION Forcedlubricationbymeansofgearpump,pressure-relief valveandsimple-filteringoilfilter. bar Oilpressurewithenginehot (100 ± 5 ° C): atidlingspeed bar 1,0 atmaximumspeed bar 5,0 COOLING bycentrifugalpump,thermostatforadjustment,coolant temperature,fanwithelectromagneticcoupling,radiator, heatexchanger Waterpumpcontrol: bybelt Thermostat: startstoopen: N.I. 79ºC ± 2ºC fullyopen: 94ºC ± 2ºC UraniaDaily UraniaTurboLD5 OILREPLENISHMENT Totalcapacityat1stfilling liters 7,6 kg 6,79 Quantityatperiodical replacements: -enginesump liters 6,6 kg 5,81

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200 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 ASSEMBLY DATA — CLEARANCES Type F1CE0481 F F1CE0481 H CYLINDER BLOCK AND CRANK MECHANISM COMPONENTS ∅ 1 Boresforcylinderliners ∅ 1 95,802 ÷ 95,822 Cylinderliners: -L outsidediameter ∅ -∅ 2 length L -Cylinderliners-crankcasebores (negativeallowance) -Outsidediameter ∅ 2 -∅ 3 X Cylindersleeve -insidediameter ∅ 3 -∅ 1 Pistons: supplied as spare parts type: MAHLE X measuringdimension X 10 ∅ 2 outsidediameter ∅ 1 95,705 ÷ 95,715 ∅ 2 pinbore ∅ 2 36,003 ÷ 36,009 Piston-cylindersleeve 0,087 ÷ 0,117 Pistondiameter ∅ 1 0,4 X Pistonsprotrusion X 0,3 ÷ 0,6 3 ∅ Gudgeonpin ∅ 3 35,990 ÷ 35,996 Gudgeonpin-pinhousing 0,07 ÷ 0,019

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F1CENGINE 201 D AILY E URO 4 Print603.93.651 Base-March2006 Type F1CE0481 F F1CE0481 H CYLINDER BLOCK AND CRANK MECHANISM COMPONENTS Pistontype -1 X X1* 2,200 ÷ 2,230 X 1 2 X Pistonringgrooves X2 2,050 ÷ 2,070 X 3 2 X X3 2,540 ÷ 2,560 3 X *measuredonøof92.8mm 1 S 2,068 ÷ 2,097 1 2 S S Pistonrings S2 1,970 ÷ 1,990 3 2 S S S3 2,470 ÷ 2,490 *measuredonøof mm 0,103 ÷ 0,162 Pistonrings-grooves 2 0,060 ÷ 0,100 3 0,050 ÷ 0,090 Pistonrings 0,4 X1 2 X Pistonringendgapincylinder liners 3 2 X X X1 0,20 ÷ 0,35 3 X X2 0,60 ÷ 0,80 X3 0,30 ÷ 0,60 1 ∅ Smallendbushhousing Ø1 39,460 ÷ 39,490 ∅ 2 Bigendbearinghousing Ø2 67,833 ÷ 67,848 Smallendbushdiameter ∅ 4 outside ∅ 4 39,570 ÷ 39,595 ∅ 3 inside ∅ 3 36,010 ÷ 36,020 S Bigendbearingshell suppliedasspareparts S outside ∅ 4 1,883 ÷ 1,892 outside ∅ 4 1,885 ÷ 1,891 Smallendbush-housing 0,08 ÷ 0,135 Pistonpin-bush 0,014 ÷ 0,030 Pistonrings 0,254-0,508

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202 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Type F1CE0481 F F1CE0481 H CYLINDER ASSEMBLY AND CRANK MEMBERS mm X Measurement X 125 Maximumerror onalignmentof connectingrodaxes = 0,09 1 2 ∅ ∅ Mainjournals ∅ 1 No.1-2-3-4 No.5 76,182 ÷ 76,208 83,182 ÷ 83,208 Crankpins ∅ 2 64,015 ÷ 64,038 Mainbearingshells S1* 2,165 ÷ 2,174 S 1 S 2 Bigendbearingshells -superior S2* -inferior 1,883 ÷ 1,892 1,885 ÷ 1,891 *suppliedasspareparts 3 ∅ Mainbearinghousings ∅ 3 No.1-2-3-4 No.5 80,588 ÷ 80.614 87,588 ÷ 87,614 Bearingshells-mainjournals 0,032 ÷ 0,102 Bearingshells— crankpins 0,035 ÷ 0.083 Mainbearingshells 0,254-0,508 Bigendbearingshells 0,254-0,508 1 X Mainjournal forshoulder X1 32,500 ÷ 32,550 X 2 Mainbearinghousing forshoulder X2 27,240 ÷ 27,290 X3 Halfthrustwashers X3 32,310 ÷ 32,460 Crankshaftshoulder 0,040 ÷ 0,240

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F1CENGINE 203 D AILY E URO 4 Print603.93.651 Base-March2006 Type F1CE0481 F F1CE0481 H CYLINDER HEADS - VALVE GEAR ∅ 1 Valveguidehousingsinthe cylinderheads ∅ 1 9,980 ÷ 10,000 2 ∅ ∅ 2 6,023 ÷ 6,038 ∅ 3 ∅ 2 Valveguide ∅ 3 10,028 ÷ 10,039 Valveguidesandseatsonhead (interference) 0,028 ÷ 0,059 Valveguide 0,05-0,10-0,25 ∅ 4 Valves: ∅ 4 5,985 ÷ 6,000 ∅ 4 α 5,985 ÷ 6,000 60 ° ± 7,5’ ∅ 4 5,975 ÷ 5,990 α α 5,975 ÷ 5,990 60 ° ± 7,5’ Valvestemanditsguide 0,023 ÷ 0,053 Seatonheadforvalveseat: ∅ 1 34,490 ÷ 34,515 ∅ 1 ∅ 1 34,490 ÷ 34,515 2 ∅ Outsidediameterofvalveseat; angleofvalveseatincylinder 2 ∅ angleofvalveseatincylinder head: ∅ 2 34590 ÷ 34610 ∅ 2 α 34,590 ÷ 34,610 59,5 ° ± 5’ α α ∅ 2 α 34,590 ÷ 34,610 59,5 ° ± 5’ X 0,375 ÷ 0,525 X Recessing X 0,375 ÷ 0,525 Betweenvalve 0,075-0,12 Betweenvalve seatandhead 0,075-0,12 Valveseats -

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204 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Type F1CE0481 F F1CE0481 H CYLINDER HEAD — TIMING SYSTEM mm Valvespringheight: freeheight H 54 H H 1 underaloadof: H H 1 H 2 N243 ± 12 H1 45 H 2 N533 ± 24 H2 35 X Injectorprotrusion X 2,77 ÷ 3,23 ∅ Seatsfortappetson cylinderhead normal ∅ 12,016 ÷ 12,034 ∅ Tappet ∅ normal 11,988 ÷ 12,000 Betweentappetsandseats 0,016 ÷ 0,046 Camshaftpinseatsin cylinderoverhead 1 ⇒ 7 ∅ ∅ ∅ ∅ 1 ∅ 2 48,988 ÷ 49,012 46988 ÷ 47012 ∅ ∅ ∅ ∅ 2 ∅ 3 46,988 ÷ 47,012 35,988 ÷ 36,012 ∅ 2 Camshaftsupportingpins: ∅ 1 ∅ 2 48,925 ÷ 48,950 46925 ÷ 46950 ∅ ∅ 1 3 ∅ 2 ∅ 2 ∅ 3 46,925 ÷ 46,950 35,925 ÷ 35,950 Betweenseatsand supportingpins 0,032 ÷ 0,087 H Usefulcamheight H H 3,622 H 4,328

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F1CENGINE 205 D AILY E URO 4 Print603.93.651 Base-March2006 TOOLS TOOLNO. DESCRIPTION 99305047 Appliancetocheckspringloads 99317915 Setofsixbox-typewrenches(14-17-19mm) 99322205 Rotarytelescopicstandforoverhaulingassemblies (capacity700daN,torque120daN/m) 99340059 Extractorforcamshaftpulley 99340060 High-pressurepumptoothedpulleyextractor 99342153 Tooltoremovecrankshaftfrontgasket

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206 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99346258 Keyingdeviceformountingcrankshaftfrontgasket 99346259 Keyingdeviceformountingcrankshaftreargasket 99358026 Wrenchforalternatorpulley(freewheel)removal/refitting 99360076 Tooltoremovecartridgefilters 99360183 Pliersformountingringsonenginepistons 99360186 Guideforflexiblebelt

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F1CENGINE 207 D AILY E URO 4 Print603.93.651 Base-March2006 TOOLS TOOLNO. DESCRIPTION 99360187 Retainingtoolforhydraulicpowersteeringcontrolshaft 99360190 Damperpulleyretainingtool 99360260 Toolforremovingandrefittingenginevalves 99360306 Tooltoretainengineflywheel 99360543 Swingbarforenginedetachment/re-attachment 99360605 Bandtoinsertstandardandoversizedpistonsintothecylinders

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208 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99360614 Tool(2)forcamshafttiming 99360615 Toolforcrankshafttiming 99361041 Bracketssecuringenginetorotarystand99322205 99367121 Manualpumptomeasurepressureandvacuum 99370415 Dial-gauge base for various measurements (to be used with 99395603) 99389817 Dynamometricwrench(60 ÷ 320Nm)with3/4”coupling

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F1CENGINE 209 D AILY E URO 4 Print603.93.651 Base-March2006 TOOLS TOOLNO. DESCRIPTION 99389818 Dynamometricwrench(150-800Nm)with3/4”squarecoupling 99389819 Torquewrench(0-10Nm)withsquare1/4”connection 99389829 9x12couplingtorquewrench(5-60Nm) 99395216 Pairofmetersforangulartighteningwithsquare1/2”and3/4” connection 99395363 Completesquaretocheckforconnectingroddistortion 99395603 Dialgauge(0-5mm)

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210 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99395687 Boremeter(50—178mm) 99395849 Belttensioncontroldevice(frequencyfrom10.0bis600Hz) 99396039 Centringringfortiminggearcover

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EXPERIMENTAL TOOLS Thissectionshowstheworkingdrawingsfortheexperimentaltools(S.P.)usedinoverhaulingtheenginedescribedinthis section,whichmaybemadebytherepairshops. F1CENGINE 211 D AILY E URO 4 Print603.93.651 Base-March2006

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MOTORI F1A - F1C 212 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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MOTORI F1A - F1C F1CENGINE 213 D AILY E URO 4 Print603.93.651 Base-March2006

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MOTORI F1A - F1C 214 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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MOTORI F1A - F1C F1CENGINE 215 D AILY E URO 4 Print603.93.651 Base-March2006

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MOTORI F1A - F1C 216 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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MOTORI F1A - F1C F1CENGINE 217 D AILY E URO 4 Print603.93.651 Base-March2006

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218 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TIGHTENING TORQUE PART TORQUE PART Nm kgm Six-lobescrew(M15x1.5L193)forcylinderheadinternalfastening Firststage:pre-tightening 130 13 Secondstage:angle 90º Thirdstage:angle 90º Six-lobescrew(M12x1.5L165)forcylinderheadsidefastening Firststage:pre-tightening 65 6,5 Secondstage:angle 90º Thirdstage:angle 60º Six-lobescrew(M8x1.25L117/58)forchaincompartmentsidefastening(cylinderhead) 25 2,5 R1/2”bevelthreadedcapwithsockethead 40 4 R3/8”bevelthreadedcapwithsockethead 29 2,9 R1/8”bevelthreadedcapwithsockethead 7 0,7 R1/4”bevelthreadedcapwithsockethead 9 0,9 M26x1.5threadedscrewtap 50 5 ScrewwithflangeM6x1forcamshaftrearcoverfastening 10 1 ScrewwithflangeM6x1forcamshaftshoulderplatefastening 10 1 SocketheadscrewwithflangeM8x1.25L30/40/77/100forover-headfastening 25 2,5 M14x1.5L10threadedscrewtap 25 2,5 Capboltsocketscrew(M6x1x25)forcamshaftdrivecoverfastening 10 1 Flangednut(M6x1)forcamshaftdrivecoverfastening 10 1 M12x1.5L125innerfasteningscrewforlowercylinderblock Firststage:pre-tightening 50 ± 5 5 ± 0,5 Secondstage:angle 60º ± 2,5º Thirdstage:angle 60º ± 2,5º M8x1.25L77.5/40outerfasteningscrewforlowercylinderblock 26 2,6 SocketheadscrewwithflangeM11x1.25x49forconnectingrodcapfastening Preliminarytorque 50 5 Secondstage:angle 70 ° SocketheadscrewwithflangeM12x1.25x52,5forengineflywheelfastening Preliminarytorque 30 3 Secondstage:angle 90 ° Six-lobesocketscrew(M6x1x15)forsecuringthephonicwheeltothedriveshaft 15 1,5 ConnectionM10x1forpistoncoolingnozzle 25 2,5 Taperedthreadedcapwithsockethead(R3/8”x10) 40 4 TEflangedscrew(M20x1.5x58)forsecuringthecampingpulleytothedriveshaft 350 35 BevelcapR1/8x8 7 0,7 WaterdrainingplugM14x1.5L10 25 2,5 PipeuniononblockforoilreturnfromturbochargerG3/8”x12 50 5 SuctionroseM6x1fasteningscrew 10 1 SocketheadnutwithflangeM8x1.25fordepressor—oilpumpunitsupportfastening 25 2,5 Pin(M12x1.5x35)foroilpump/vacuumpumpassemblycontrol 130 13 Malethreadedcap(M26x1.5) 40 4 Connection(R1/4”)foroildeliverytotheturboblower 40 4 SocketheadscrewwithflangeM8x1.5L35foroilsumpretainingframefastening 25 2,5 ThreadedcapwithO-ring(M22x1.5L10) 50 ± 10 5 ± 1 SocketheadscrewwithflangeM8x1.25L60fordepressor-oilpumpunitfastening 25 2,5 Flanged,hexagonnut(M8x1.25)forpowersteeringpumpsupportfastening 25 2,5

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F1CENGINE 219 D AILY E URO 4 Print603.93.651 Base-March2006 PART TORQUE PART Nm kgm TEscrewwithflange(M10x1.25x60/110) 50 5 TEscrewwithflange(M8x1.25x16)forblow-bypipefastening. 28 2,8 SocketheadscrewwithflangeM8x1.25L18forsuctionmanifoldfastening 25 2,5 TEscrewwithflange(M6x1L20)forblow-bypipefastening. 10 1 M14x1.5L10cap 25 2,5 FlangednutM8x1.25L40forexhaustmanifoldfastening 30 3 FlangednutM8x1.25forexhaustmanifoldfastening 25 2,5 SocketcylinderheadscrewM8x1.25L65forPoli-Vbeltautomaticbackstand 25 2,5 FlangedscrewM10x1.25L22forPoli-Vbelttake-uppulleyfastening 40 4 FlangedheadM12x1.75L30forcamshaftgearfastening 110 11 TimingchaintightenerfastenerM22x1.5x22 50 5 Screw(M10x1.5x12)fortimingchainmovingpadfastening 40 4 SocketcylinderheadscrewM8x1.25x30forfixedskidfastening 25 2.5 SocketcylinderheadscrewM6x1L16/20forskidfastening 10 1 Watertemperature/pressuresensorfastener(M12x1.5) 30 3 SocketcylinderheadscrewM6x1forwatertemperature/pressuresensorfastening 10 1 SocketcylinderheadscrewM6x1forairtemperature/pressuresensorfastening 10 1 SocketcylinderheadscrewM6x1forenginerevsensorfastening 10 1 High-pressure injection system FlangednutM8x1.25forhighpressurepumpsupportfastening 25 2,5 HydraulicaccumulatorfasteningscrewM8x1.25L50 28 2,8 HighpressurepumpfasteningscrewM8x1.25L90 25 2,5 ScrewM6x1x16forfasteningoffueldeliverypipeanchoringbracket 10 1 Pipeunionforfueldeliverypipestorailandelectricinjectors: -M14x1.5 -M12x1.5 19 ± 2 25 ± 2 1,9 ± 0,2 2,5 ± 0,2 SocketcylinderheadscrewM8x1,25forfasteningofelectricinjectorretainingbracket 28 2,8 FlangednutM8x1,25foranchoringbracketsupportfastening 25 2,5 PinfastenerM12x1.25forhighpressurepump 110 11 Flangednut(M6x1)forlow-pressurefuelpipefastening 10 1 TEflangedscrew(M8x1.25)forpipesupportingbracketfastening 25 2,5 FillerneckM12x1.5foradjustablepipeunion 25 2,5 FillerneckM16x1.5foradjustablepipeunion 40 4 Pipeunionforrevolvingmultiple-wayconnectiontothehigh-pressurepump(M12x1.5) 25 2,5 NutM8x1.25forturbochargerfastening 25 2,5 TEflangedscrew(M8x1.25)forturboblowerexhaustgasoutletpipefastening 25 2,5 PipeunionM14x1.5orM12x1.5foroildeliverypipetoturbocharger 35 3,5 PipeunionM22x1.5foroilreturnpipefromturbocharger 45 4,5 FlangedscrewM6x1forfasteningofoilreturnpipefromturbocharger 10 1 PipeunionM14x1.5forfasteningofoildeliverypipetoturbocharger 35 3,5 ThreadedunionR1/4” 40 4 TEscrewwithflange(M8x1.25)forairconveyorbracketfastening 28 2,8 TEscrewwithflange(M8x1.25)forairconveyorfastening 28 2,8 SocketcylinderheadscrewM6x1forV-clampclosingring 8 0,8 TEscrewwithflange(M6x1x16)forairpipefastening 10 1 TEscrewwithflange(M6x1)foroilfillingpipefastening 10 1 Pre-warmingplugM8x1 8 ÷ 11 0,8 ÷ 1,1 OilfiltercartridgeM22x1.5 25 2,5 TEscrewwithflange(M8x1.25x20)forwaterinletpipefastening 25 2,5 TEscrew(M8x1.25x30)forheatexchangerfastening 25 2,5

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220 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 PART TORQUE PART Nm kgm PipeunionM24x1.5foroilfiltercartridge 80 8 TEflangedscrew(M8x1.25x30/40)forheatexchangerinnerelementfastening 25 2,5 Socketcylinderheadscrewforwaterpumpfastening: -M10x1.5x55 -M8x1.25x45 50 25 5 2,5 FlangedscrewM8x1.25forrearcoverfasteningtocylinderhead 25 2,5 FlangedscrewM8x1.25forcoolantdeliverypipefastening 25 2,5 FlangednutM8x1.25forcoolantdeliverypipesupportbracketfastening 25 2,5 PipeunionM10x1x10forvapourventfastening 12 1,2 FlangedscrewM8x1.25forthermostatfastening 25 2,5 FlangednutM6x1forelectro-magneticjointfastening 10 1 Nut(M30x1.5)forelectromagneticjoint 150 15 FlangedscrewM8x1.25forairconditionercompressorfastening 25 2,5 FlangedscrewM8x1.25L20/130forairconditionercompressorsupportfastening 25 2,5 SocketcylinderheadscrewM8x1.25forfasteningofairconditionercompressorcontrolbelt idler 25 2,5 SocketcylinderheadscrewM10x1.5foralternatorfastening 50 5 FlangedscrewM10x1,25x110forhydraulicpowersteeringpumpfastening 40 4 FlangedscrewM12x1,25securingthepowersteeringpump 50 5 FlangedscrewM8x1,25securingthepowersteeringtanksupport 25 2,5 FlangedscrewsM10x1.25forpowertakeoffcoverfastening 50 5 DepressorpipeunionM14x1.5 35 3.5 OillevelsensorM12x1.25 25 2,5 Thermometrictransmitter/switchM16x1.5(conical) 25 2,5 OilpressureswitchM14x1.5 25 2,5 Power unit suspension Screw(M8x16)securingtheelasticdoweltothegearboxcross-member 23,5 ± 2,5 2,3 ± 0,2 Nut(M12)securingthegearboxcross-membertothechassis 92 ± 9 9,2 ± 0,9 Nut(M12)securingtheenginesupportstotheelasticdowels 49 ± 4 4,9 ± 0,4 Nut(M12)securingthegearboxbracketontotherearcross-memberelasticdowel 49 ± 4 4,9 ± 0,4 Locknut(M10)withflange,securingtheenginesupportstothechassis 52,5 ± 5,5 5,2 ± 0,5 Screw(M10x30)securingthegearboxsupporttothegearshift 46,5 ± 4,5 4,6 ± 0,4 * OnthethreadingapplyLOCTITE577

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107701 107702 Figure 59 Figure 60 540110 DISASSEMBLING THE ENGINE AT THE BENCH Tofittheenginebasewiththebracketssecuringtherotor totheoverhaulbench,disassembletheleftandrightengine mounts(3),thendisconnectoilpipe(2)fromturboblower (1)andenginebaseconnection(4). Fitthebrackets99361041(11)tothecrankcaseanduse thesetosecuretheenginetotherotarystand99322205 (12).Draintheoilfromtheenginebyremovingtheplugfrom theoilsump. Iffitted,removethefan(1)fromtheelectro-magneticjoint (2). Removetheitemsbelow,iftheyhavenotyetbeenremoved priortodetachment: -uppersound-proofingcover; -engine cable complete with raceway (6), by disconnectingtheelectricconnectionsofthesame from: - electricinjectors(1); - preheatingplugs(3); - hydraulicaccumulatorpressuresensor(5); - throttlevalveactuator(7); - inletmanifoldairpressure/temperaturesensor(8); - revssensor(4); - high-pressurepumppressureregulator(10); - phasesensor(2); - thermostatcoolanttemperaturesensor(9). Blocktheturbochargerair/exhaustgasinletsand outletstopreventforeignbodiesgettinginside. NOTE F1CENGINE 221 D AILY E URO 4 Print603.93.651 Base-March2006 Print603.43.671/A OVERHAULING ENGINE F1C

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107703 107705 107704 107706 107708 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Pressthesprings(3)inthedirectionshownbythearrowand disconnectthefittingsofthepipe(1)recoveringfuelfromthe electro-injectors(2). Disconnectthefuelpipes(2)fromtheelectro-injectors(3) andfromthehydraulicaccumulator(1)(rail). Take out the screws (2) andthe brackets (3) fixingthe electro-injectors(1)tothecylinderoverhead. Usingtool99342153(1)extracttheelectro-injectors(2) fromtheoverhead(3). Removethefasteningscrew(3)ofthepiperetainingbracket (2).Disconnectthepipe(2)fromthehydraulicaccumulator (1)andthehighpressurepump(4). Removethescrews(1)andthehydraulicaccumulator(2) fromtheoverheaddevice(3). 88244 222 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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107709 107711 107710 107712 107713 88252 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Figure 72 Usetool99360076(1)totakeoilfilter(4)offheatexchanger (5). Removescrews(2)and(6),thendisconnectpipe(3)from heatexchanger(5). Removethescrew(6)andthelowpressurepipes(5)from thebracket(4). Slacken the pipe unions (1 and3) andremove the low pressurepipes(5)fromthehighpressurepump(2). Removescrews(1),thentakeheatexchanger(2),withits respectivegasket,offtheenginebase. Removescrews(5)withspacers(4),thentakeoffhigh-pressure pump(3). Remove screws (6) with spacers (7), then take off power steeringpump(8). Removescrews(1),thentakeoffpowersteeringtanksupport (2). Cutelasticbelt(1),ifany,duetoitsbeingunabletobereused. Remove screws (3), then remove air-conditioner compressor(4)fromsupport(2). Removethescrews(4)andtakeoffthesupport(3). Removethescrew(1)andthefixedbackstand(2). F1CENGINE 223 D AILY E URO 4 Print603.93.651 Base-March2006

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107714 107716 107715 107717 107718 107719 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Removescrews(3),thenremovethrottlevalveassembly(4). Removethescrew(2)andtakeofftheairtemperatureand pressuresensor(1). Removethescrews(5)andtakeoffthesuctionmanifold(6) withtherelevantgasket. UsingwrenchSP.2275(3),removetheglowplugs(4). Removetheretainingstraps,thenremovecoolantpipes(1 and2). Removescrew(3)andstrap(5),thendisconnectcoolant pipe(4)fromwaterpump(6). Loosenscrew(5),thenremovestrap(6). Removescrews(1),thentakeheatexchanger(2),together withEGRvalve(3),offoverhead(4)andconnectingpipe(7). Removescrews(2),thentakecover(3),togetherwithpipes (4and5),offcylinderhead(1). Unscrewconnections(2,4and6),thendisconnectoilpipe (5). Removenuts(2),thentaketurboblower(3),togetherwith itsrespectivegasket,offexhaustmanifold(1). 224 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88255 107721 107720 107722 88260 107723 Figure 79 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 Usingthespecificwrenchontheautomatictightener(2), slackenthetensionofthebelt(1)andremoveit. Takeoutthescrew(2)andremovetheautomatictightener (1). Removethescrew(2),thebolt(4)andpullthealternator(3) outofthesupport(1). Removethescrews(1)andtakeoffthesupport(2)fromthe cylinderblock. Usethesuitablewrenchtoremovetheoillevelsensor(1). Removethefasteningscrewandtherevsensor(2). Removethenuts(2),thespacers(1)andtakeofftheexhaust manifold(3)withtherelevantgasketfromthecylinderhead. F1CENGINE 225 D AILY E URO 4 Print603.93.651 Base-March2006

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107724 107726 107725 107727 107728 88265 Figure 86 Figure 87 Figure 88 Figure 89 Figure 90 Figure 85 Securewaterpumpshaft(5)bymeansofanAllenwrench (3)andaspeciallever.Useasuitablewrench(4)toremove nut(2)securinghub(1)toshaft(5). Disassemblehub(5)andpulley(4). Disconnectelectriccable(1)fromtheretainingclip,then removenuts(2)andtakeelectromagnet(3)offwaterpump (6). Removescrews(1),thentakewaterpump(2)off. Removescrew(3),thentakeoildipstickpipe(4)outoffront cover(5). Removethescrews(3)andthecover(4).Takeoffthesnap ring(2).Pulloutthecentrifugalfilter(1). Stoptherotationoftheengineflywheel(2)bymeansoftool 99360306(1). Removethescrew(2)andthedamperpulley(1). Slacken the nut (2) anticlockwise because its threadingisleft-handed. Thecentrifugalfilter(1)andthesealringofthe cover(4)mustbechangedateveryremoval. NOTE NOTE 226 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88266 88268 107729 88269 88270 Figure 91 Figure 92 Figure 93 Removethescrews(1)andthedistributioncover(2). Removethenut(1)andthephasesensor(2). Removethenuts(3)andthecover(4). Removethehydraulicchaintightener:top(1)andlower(2). Removethepin(4)anddisassemblethemobileskid:lower (5)andtop(3). Removethescrew(3),thewasher(2)andthegear(1). Removethescrew(7),thewasher(6),thegear(5)andthe chain(4). Removethecap(4),thescrews(2and3)andthetopfixed skid(1). 88271 Removethescrews(3)anddisassemblethedepressor/oil pumpunit(2). Removetheconnectionkey(1). Figure 94 Tool99340059(4)isusedtoremovethesealring (3)fromthecover(2)whentheengineisinstalled onthevehicle. Upperhydraulicchainstretcher(1)isequippedwith an anti-return device that makes it necessary to replace the chain stretcher every time it is disassembled. Figure 95 Figure 96 NOTE NOTE F1CENGINE 227 D AILY E URO 4 Print603.93.651 Base-March2006

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88272 88274 90311 88275 88276 88277 Figure 97 Figure 98 Figure 99 Figure 100 Figure 101 Figure 102 Removethescrews(2)andthesidefixedskid(1). Removethescrews(4)andthelowerfixedskid(3). Stoptherotationofthehighpressurepumpcontrolshaft(1) byinsertingthesuitablewrenchinsideit. Removethescrew(3)andthestemwiththedrivegear(2) fromthehighpressurepumpcontrolshaft(1). Removethegear(1)andthechain(3)fromthehighpressure pumpcontrolshaft(2). Removethehighpressurepumpcontrolshaft(3). Removethenuts(2)andthesupport(1). Stopthe rotation of the hydraulicpower steeringpump controlshaft(2)byinsertingtool99360187(3)intheshaft andfasteningthetoolonthesupport(1)bymeansofthe screws(4). 228 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88278 88280 88279 88281 88282 88283 Figure 103 Figure 104 Figure 105 Figure 106 Figure 107 Figure 108 Removethescrew(2)andthegear(1)fromthehydraulic powersteeringcontrolshaft(3). Removethehydraulicpowersteeringcontrolshaft(3). Removethenuts(2)andthesupport(1). Removethescrews(1)andtakeofftheover-head(2)from thecylinderhead(3). Removethehydraulictappets(1)withtherockerarms. Removethegasket(2). Takeoutthescrews(1)andremovethecylinderhead(2). Removethecylinderheadgasket(1). Check the protrusion of the pistons (2) as describedundertherelevantheadingtocheckthe possibilityoffacingthecrankcaseifithasdeformed. NOTE F1CENGINE 229 D AILY E URO 4 Print603.93.651 Base-March2006

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88284 88738 88285 107707 88287 Figure 109 Figure 110 Figure 111 Figure 112 Figure 113 Removethescrews(2)andtakeofftheoilsump(1)withits gasketandframe(3). Removethescrews(2)andthesuctionrose(1). Takeoutthescrews(2)andremovetheconnectingrodcaps (3). Extractthepistons(1)fromthetopofthecrankcase. Blockrotationoftheflywheel(1)withtool99360306(4). Takeoutthescrews(2)andremovetheengineflywheel(1). Takeouttheguard(3). Applytool99340060(2)totherearO-ring(1)andextract itfromthecrankcase. Onthesamesideoftheconnectingrodandits associatedcap,indicatethenumberofthecylinder fromwhichtheconnectingrodhasbeenremoved. Keepthebearingshellsintheirrespectivehousings since,iftheyareused,theywillneedtobefittedin thepositionfoundduringremoval. NOTE 230 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88288 87793 88289 75290 Figure 114 Figure 115 Figure 116 Figure 117 Removethescrews(2)andtakeofftheoilsump(1)withits gasketandframe(3). Withtheaidofahoistandarope,removethecrankshaft(1). Takeoutthecouplings(1)andremovetheoiljets(2). Thecentralhalf-bearing(3)isfittedwithshoulderhalf-rings. Notetheassemblypositionofthetopmainbearing shells(2)since,iftheyarereused,theywillneedto befittedinthepositionfoundduringremoval. NOTE Notetheassemblypositionofthetopmainbearing shells(2)since,iftheyarereused,theywillneedto befittedinthepositionfoundduringremoval. NOTE Oncompletingengineremoval,itisnecessaryto clean the removed parts thoroughly andcheck theirintegrity. Thefollowingpagesgivetheinstructionsforthe mainchecksandmeasurementstomakeinorder todeterminewhetherthepartscanbereused. NOTE F1CENGINE 231 D AILY E URO 4 Print603.93.651 Base-March2006

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Themeasurementsmustbemadeforeachsinglecylinderat threedifferentheightsupthelinerandontwoplanesatright anglestoeachother:oneparalleltothelongitudinalaxisof theengine(B)andtheperpendicular(A);thegreatestwear is generally found on this last plane with the first measurement. On finding ovalization, taper or wear, go ahead and bore/grindandfinish the face of the cylinder liners.The refacingofthecylinderlinersshouldbedoneinrelationto thediameterofthepistonssuppliedassparepartsoversized by 0.4 mm of the nominal value and to the prescribed assemblyclearance. 18837 87781 Figure 118 Figure 119 Oncetheengineremovaliscomplete,carefullycleanthe cylinderblock.Forthecylinderblocktransportationusethe suitablerings. Carefullycheckthatthecrankcasehasnocracksinit. Checkthestateoftheplugs.Iftheyarerustyorthereisany doubtabouttheirseal,replacethem.Whenfittingthecaps intoplace,applyLoctite270sealant(IVECONO.93162429) tothesame.Examinethesurfacesofthecylinderliners;they mustshownosignofmeshing,scoring,ovalization,taperor excessivewear.Theinsidediameterofthecylinderlinersis checked,toascertaintheextentofovalization,taperand wear,usingtheboremeter99395687(1)fittedwithadial gaugepreviouslyresetontheringgaugeofthediameterof thecylinderlineroronamicrometer. CYLINDER BLOCK Checks and measurements Figure 120 *Surfaceroughnessparameters: R1 = 4 ÷ 10 μ m Rz = 3 ÷ 8 μ m Ra = 0,3 ÷ 0,6 μ m W1 < 2 μ m Permissible surface porosity for machined cylinder (see Figure 121) ZONEB1= Area of greatest mechanical stress, segment/liner contact: No.2 non-continuous porosities are permissiblemax.0.5x0.5. ZONEB2= Surfaceinvolvedinsegmentrubbing: No.2non-contiguousporositiesare permissiblemax.1x0.8. C C 100% 100% 87782 Figure 121 87783 232 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 REPAIRS

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Forundersizedcrankpins,letterM. Forundersizedmainjournals,letterB. Forundersizedcrankpinsandmainjournals,letterMB. Seethattheheadmatingsurface,onthecylinderblock,has nodeformation. Thischeckcanbemade,aftertakingoutthegrubscrews(3), with a surface plate spreadwith carbon blackor witha calibratedrule(1)andafeelergauge(2).Afterascertaining theareasofdeformation,levelthebearingsurfacewitha grindingmachine. 88290 Figure 122 Figure 123 87784 Figure 124 The main journalsandcrankpinsmust alwaysbe groundtothesameundersizeclass. Theundersizingperformed,onthemainjournalsor crankpins,mustbemarkedbypunchingontheside ofcrankarmno.1. TABLEINWHICHTOENTERTHEMEASUREMENTSOFTHECRANKSHAFTMAINJOURNALSANDCRANKPINS 5408 CRANKSHAFT 540810 Measuring main journals and crank pins Checking head mating surface on cylinder block Onfindingsignsofseizure,scoringorexcessiveovalization onmainjournalsandcrankpins,itisnecessarytoregrindthe pins.Beforegrindingthepins(2),measuretheshaftpinswith amicrometer(1)toestablishtowhatdiameteritisnecessary todecreasethepins. 75298 Thecrankcasecanonlybesurfacedaftermaking sure that, on completing the work, the piston protrudesfromthecylinderlinerbynomorethan theprescribedvalue. Itisadvisabletoenterthemeasurementsinatable. SeeFigure123. NOTE NOTE NOTE NOMINAL VALUE NOMINAL VALUE NOMINAL VALUE ∅ MIN ∅ MAX ∅ MIN ∅ MAX Theundersizeclassesare: 0.254—0.508mm. F1CENGINE 233 D AILY E URO 4 Print603.93.651 Base-March2006

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87785 87786 Figure 125 Figure 126 MAINCRANKSHAFTTOLERANCES SYMMETRY BETWEEN MAIN JOURNALS AND CRANKPINS 1. Crankpins 2. Mainjournals 3. Normalposition Checking crankshaft Aftergrinding,keeptothefollowing: -Round off the edges of deburring the holes for lubricationofthemainjournalsandcrankpins. The checks on the tolerances indicated in the figuresmustbemadeaftergrindingthecrankshaft pins. NOTE 234 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL SHAPE Circularity ○ SHAPE Cylindricality ORIENTATION Parallelism ORIENTATION Perpendicularity ⊥ POSITION Concentricityorcoaxiality OSCILLATION Circularoscillation ↗ OSCILLATION Totaloscillation ↗↗ CLASS OF IMPORTANCE ATTRIBUTED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL CRITICAL E IMPORTANT ⊕ SECONDARY ⊝

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87787 87789 87788 87790 87791 Figure 127 Figure 128 Figure 129 Figure 130 Figure 131 INTERMEDIATE JOURNALS NO. 2-4 INTERMEDIATE JOURNAL NO. 3 CRANKPINS * Asfarasbothvaluesareconcerned,forthewhole360 ° . -Rollingturns:3approach,12effective,3out. -Rollingspeed:56rpm. -Reductionoftheconnectingrodpinslotdiameterafter rolling:0.15 ÷ 0.30mm*. -Reductionofthejournalslotsafterrolling:0.15 ÷ 0.30 mm. *Measuredwithcalibratedrollers ∅ 2.5mm. JOURNAL ON TIMING SYSTEM SIDE JOURNAL ON FLYWHEEL SIDE MAINDATAOFMAINJOURNALSANDCRANKPINS Since,duringthe0.254and0.508mmundersizing onthediameterofthecrankpinsandmainjournals, therolledportionofthesideracesofthepinsmay get involved, it is necessary to turn the races keepingtothedatagiveninthefigureandtodothe rollingkeepingtothefollowinginstructions. Rollingforce: -1 st mainjournal925 ± 25daN. -2 nd —3 rd —4 th —5 th mainjournal1850 ± 50daN. -crankpin1850 ± 50daN. NOTE F1CENGINE 235 D AILY E URO 4 Print603.93.651 Base-March2006

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87792 75306 88345 90064 Figure 132 Figure 133 Figure 134 Figure 135 Takeoutthescrews(4)andreplacethephonicwheel(3). Screws(4)shallbetightenedto10+1Nm. Replacing timing control gear Onfindingthetimingcontrolgearteeth(1)damagedor worn,removethemfromthecrankshaft(2)usingasuitable extractor. Thenewgearisfittedontothecrankshaftbyheatingittoa temperatureof180 ° Cfornolongerthan15minutes. Oncompletingassemblyandafterthegearhascooled,it mustwithstandatorqueof150Nmwithoutslipping. ENGINE ASSEMBLY Thefollowingpartsmustbereplacedwithnewonesatthe timeofassembly:retainingrings,sealsandgaskets,screws whosethreadiscoatedwithsealant. Fitontheoilspraynozzles(2)andtightenthecouplings(1) totheprescribedtorque. Themainbearings(1)aresuppliedassparepartsundersized ontheinsidediameterby0.254 ÷ 0.508mm. 540811 Measuring main journal assembly clearance Mountthecrankshaft(1). Checktheclearancebetweenthecrankshaftmainjournals andtheirrespectivebearingsbyproceedingasfollows: -Thoroughlycleanthepins. -Applyacalibratedwireontothemainjournals. Nothavingfounditnecessarytoreplacethemain bearings,theyneedtobefittedbackoninthesame sequenceandpositionfoundupondisassembly. Donotdoanyaccommodatingonthebearings. Assembling main bearings Thoroughlycleanthetopmainbearingshells(1)andposition theminthecrankcase. Themiddlehalfring(2)isfittedwiththrustwashers. NOTE NOTE NOTE 236 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88289 88292 75310 88293 Figure 136 Figure 137 Figure 138 Thoroughlycleanthebottommainbearingshells(2)and mounttheminthecrankcasebase(1). Mountthecrankcasebase(12). Tightenthescrewsinthesequenceshowninthefigurein threesteps: -Step1:withatorquewrench,toatorqueof50Nm. -Step2:closingtoanangleof60 ° . -Step3:closingtoanangleof60 ° . Theendfloatischeckedbysettingadialgauge(2)witha magneticbaseonthecrankshaft(1)asshowninthefigure. Thenormalassemblyclearanceis0.060—0.310mm. Ifyoufindtheclearance tobe greaterthan asrequired, replace the rear main bearing shells carrying the thrust bearings and repeat the clearance check between the crankshaftpinsandthemainbearingshells. Iftheendfloatofthecrankshaftdoesnotcomewithinthe prescribedvalues,itisnecessarytogrindthecrankshaftand accordinglychangethemainbearingshells. α Figure 139 -Removethebottomcrankcase. The clearance between the main bearings and their associatedpinsismeasuredbycomparingthelengthofthe calibratedwire(1),atthepointofgreatestcrushing,withthe graduatedscaleonthecasingcontainingthecalibratedwire. The numbers on the scale indicate the clearance of the couplinginmillimetres,whichmustbe0.032 ÷ 0.102mm. Iftheclearanceisnotasprescribed,replacethebearingsand repeatthecheck. Checking crankshaft end float Thentightentheouterscrewstotorque26Nm. Usetool99395216(11)fortheangleclosing. Themiddlemainbearinghashalfthrustwashers integratedinit,soitperformsthefunctionofa thrustbearing.Itissuppliedasasparepartonlywith thenormalshoulderthickness. NOTE NOTE F1CENGINE 237 D AILY E URO 4 Print603.93.651 Base-March2006

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88294 88292 88296 88297 Figure 140 Figure 141 Figure 142 Figure 143 Thoroughly clean the crankcase / crankcase base mating surface. Apply,onbase,sealantLOCTITE510IVECOno.93162432, asindicatedinthescheme.Thesealantmustresulttobe even,notpatchy. Mountthecrankcasebase(12)andtightenthefixingscrews inthreestages,followingthesequenceshowninthefigure: -Step1:withatorquewrench,toatorqueof50Nm. -Step2:closingtoanangleof60 ° . -Step3:closingtoanangleof60 ° . Thentightentheouterscrews(1)toatorqueof26—30Nm. Carefullycleanthesealseat. Lubricatetherearshankofthecrankshaftwithengineoil. Fitpart(2)oftool99346259ontotherearshankofthe crankshaft;secureitwiththescrews(3)andkeythefreshseal (1)ontoit. Positionpart(4)onpart(2);screwdownthenut(5)tofit theseal(1)fullyinsidethecrankcase. Mountthecrankcasebasewithin10minutesof applyingthesealant. Usetool99395216(11)fortheangleclosing. 540460 Assembling rear seal α NOTE NOTE 238 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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107730 107731 75392 Figure 144 Figure 145 Figure 146 Figure 147 Positionthemetalsheetguard(3)onthecylinderblock. Mounttheengineflywheel(1)andscrewdownthescrews(2). Fittool99360351(4)ontothecrankcasetoblockrotation oftheengineflywheel(1). Tightenthescrews(2)fixingtheengineflywheel(3)intwo steps: -Step1:withatorquewrench,toatorqueof30Nm. -Step2:closingtoanangleof90 ° . 5408 CONNECTING ROD — PISTON ASSEMBLY PISTON—CONNECTINGRODASSEMBLY 1.Piston—2.Pistonring—3.Pin—4.Trapezoidalring— 5.Oilscraperring—6.Slottedoilscraperringwithspiral spring—7.Connectingrodbody—8.Bearingshells— 9.Connectingrodcap—10.Capfixingscrews. Check the pistons.They must show nosigns ofseizure, scoring,crackingorexcessivewear;replacethemiftheydo. α Takeofftool99360351(4). Usetool99395216(1)fortheangleclosing. 88054 Double-massengineflywheel,oneintegralwiththedrive shaftandonewiththeinputshaftofthegearboxandin betweenatorsionelasticdampeningsystem. Theadvantagesofthistypeofflywheelcomparedtothe normaloneare: -Dampeningofengineirregularitiestransmittedtothe gearboxandresultingdrivenoisereduction; -Noisereductioninthecabinasaresultoftheoverall noisereduction. Checktheclutchdiscmatingsurface,iftherearetoomany scratches,changetheengineflywheel(3). Checkconditionsoftheteethofcrownwheel(1);where excessivecrackingorwearisfound,replaceengineflywheel. NOTE 540852 Replacing bearing supporting gear-box input shaft The bearing (2) supporting the gearbox input shaft is removedandfittedusingageneral-purposedrift. F1CENGINE 239 D AILY E URO 4 Print603.93.651 Base-March2006 540850 ENGINE FLYWHEEL

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75393 75394 107732 88300 Figure 148 Figure 149 Figure 150 Figure 151 Removethepistonrings(1)fromthepiston(2)usingpliers 99360183(3). Removethepiston(1)fromtheconnectingrod,takingout thepistonring(2)andextractingthepin(3). MAINDATAFORMONDIALPISTON,PINSANDPISTONRINGS * Thevalueismeasuredat1.5mmfromtheouterdiameter ** Thevalueofthediametermeasuredis91.4mm X=0.5 Usingamicrometer(2),measurethediameterofthepiston (1)todeterminetheassemblyclearance.Thediameterhas tobemeasuredatthevalueshown. Theclearancebetweenthepistonandcylinderlinercanalso becheckedusingafeelergauge(1)asillustratedinthefigure. 107733 540840 Piston Measuring piston diameter Thepistonsaresuppliedassparepartswiththe standard,normaland0.4mmoversizediameters togetherwithrings,pinandretainingrings. Figure 152 NOTE 240 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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18857 74947 75397 16552 88301 41104 Figure 153 Figure 154 Figure 155 Figure 156 Figure 157 Figure 158 Measuring the diameter of the piston pin (1) with a micrometer(2). Conditions for correct pin-piston coupling Lubricatethepin(1)anditsseatonthehubsofthepiston (2)withengineoil.Thepinmustgointothepistonbylightly pressingwiththefingersandmustnotdropoutbygravity. Thetrapezoidalsplitrings(1 st slot)andtheoilscraperrings (2 nd slot)havethewordTOPetchedinthem;whenfitting themonthepiston,thewordTOPmustbefacingupwards. Checkthethicknessofthepistonrings(2)withamicrometer (1). Checktheclearancebetweenthetrapezoidalring(2)(1 st slot)andtheassociatedslotonthepistonwithafeelergauge (1),proceedingasfollows:insertthepistonintothecylinder linersothatthering(2)comesapproximatelyhalfwayout ofit. DIAGRAMFORMEASURINGTHECLEARANCEX BETWEENTHEFIRSTPISTONSLOTANDTHE TRAPEZOIDALRING 1.Pistonslot—2.Trapezoidalpistonring— 3.Cylinderliner Using a feeler gauge (1, SENZACODICE), check the clearance(X)betweenthering(2)andtheslot(1);this clearancemusthavetheprescribedvalue. 540842 Piston rings 1 2 F1CENGINE 241 D AILY E URO 4 Print603.93.651 Base-March2006 540841 Piston pin

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-withaletter: O or X indicatingthediameterclassofthe bigendmountedinproduction; -with a number indicating the weight class of the connectingrodmountedinproduction. Inaddition,itcouldbestampedwiththenumberofthe cylinderinwhichitisfitted. In the event of replacement it is therefore necessary to numberthenewconnectingrodwiththesamenumberas theonereplaced. Thenumberingmustbedoneontheoppositesidetothe bearingshellretainingslots. Theconnectingrodsaresuppliedassparepartswiththe diameterofthebigend67.833—67.848mmmarkedwiththe letterOandtheweightclassmarkedwiththenumber33. Itisnotpermissibletoremovematerial. 75398 87796 75399 Figure 159 Figure 160 Figure 161 Figure 162 Checktheclearancebetweenthepistonrings(2)ofthe2 nd and3 rd slotandtheassociatedseatsonthepiston(3)with afeelergauge(1). Checktheopeningbetweentheendsofthepistonrings(2) insertedinthecylinderlinerusingafeelergauge(1). MAINDATAOFTHECONNECTINGROD,BUSHING, PISTONPINANDBEARINGSHELLS * Internaldiametertoobtainafterdrivingintothesmall endandgrindingwithareamer. ** Dimensioncannotbemeasuredinthefreestate. *** Thicknessofthebearingshellsuppliedasasparepart. 540830 Connecting rods Eachconnectingrodhasitscapmarked: Checkthatthebushinthesmallendhasnotcomelooseand showsnosignofseizureorscoring.Ifitdoes,replacethe completeconnectingrod. 540834 Bushing Checking connecting rods 61696 Checkthealignmentoftheaxesoftheconnectingrods(1) withdevice99395363(5),proceedingasfollows: -Fittheconnectingrod(1)onthespindleofthetool 99395363(5)andlockitwiththescrew(4). -Set the spindle (3) on the V-prisms, resting the connectingrod(1)onthestopbar(2). NOTE 242 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 163 Etchedonthetopofthepistonare:thetypeofengine(1), classselection(2)andsupplier(3)aswellasthedirectionof fittingthepistoninthecylinderliner(4).Themark(5)isfor passingthe1 st slotinsertadhesiontest. 87797 87798 Connectthepiston(1)totheconnectingrod(2)together withitscapsothatthepistonassemblyreference,position oftheconnectingrodandofthecapareobservedasshown inthefigure. Positionthepiston(1)ontheconnectingrod,insertthepin (3)andsecureitwiththesplitrings(2). Assembling connecting rod-piston assembly Checkthetorsionoftheconnectingrod(5)bycomparing twopoints( A and B )ofthepin(3)onthehorizontalplane oftheaxisoftheconnectingrod. Positionthemount(1)ofthedialgauge(2)sothatthis pre-loadsbyapprox.0.5mmonthepin(3)atpointAand zero the dial gauge (2). Shift the spindle (4) with the connecting rod (5) and compare any deviation on the oppositesideBofthepin(3):thedifferencebetweenAand Bmustbenogreaterthan0.08mm. Checking torsion 61694 Checking bending Checkthebendingoftheconnectingrod(5)bycomparing twopointsCandDofthepin(3)ontheverticalplaneofthe axisoftheconnectingrod. Positiontheverticalmount(1)ofthedialgauge(2)sothat thisrestsonthepin(3)atpointC. Swingtheconnectingrodbackwardsandforwardsseeking thehighestpositionofthepinandinthisconditionzerothe dialgauge(2). Shiftthespindlewiththeconnectingrod(5)andrepeatthe checkonthehighestpointontheoppositesideDofthepin (3).ThedifferencebetweenpointCandpointDmustbeno greaterthan0.08mm. 61695 Figure 164 Figure 165 Figure 166 Figure 167 75394 F1CENGINE 243 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 168 Figure 169 Figure 170 Figure 171 Checking for connecting rod — piston distortion Assembly piston rings Fitthepistonrings(1)onthepiston(2)usingthepliers 99360183(3). Assembly connection rod-piston assembly in the cylinder liner 88302 Lubricatethepistonswell,includingthepistonringsandthe insideofthecylinderliners. Withtheaidoftheclamp99360605(2),fittheconnecting rod—pistonassembly(1)inthecylinderliners,checkingthat: -Thenumberofeachconnectingrodcorrespondstothe capmatingnumber. -Theopeningsofthepistonringsarestaggered120 ° apart. -Thepistonsareallofthesameweight. -Thesymbolpunchedonthetopofthepistonsfacesthe engineflywheel,ortherecessintheskirtofthepistons tallieswiththeoilspraynozzles. Afterfittingtheconnectingrod—pistonassemblytogether, checkfordistortionwiththetool99395363(8)asfollows: -Fittheconnectingrod(7)togetherwiththepiston(3) onthespindle(4)oftool99395363(8)andlockitwith thescrew(5). -Resttheconnectingrod(7)onthebar(6). -Positionthemount(1)ofthedialgauge(2)sothatthis ispositionedatpointAofthepistonwithapre-loadof 0.5mmandzerothedialgauge(2). -Shiftthespindle(4)soastopositionthedialgauge(2) atpointBofthepiston(3)andcheckforanydeviation. 75403 41097 540831 Measuring crankpin assembly clearance 88303 Tomeasuretheclearance,carryoutthefollowingsteps: -Thoroughly clean parts (1) and(4) andeliminate all tracesofoil. -Placealengthofcalibratedwire(3)onthecrankshaft pins(4). The1 st and2 nd slotringsneedtobemountedwith theword”TOP”facingupwards. NOTE Notfindingitnecessarytoreplacetheconnecting rodbearings,youneedtofitthembackinexactly the same sequence and position found on disassembly. NOTE 244 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88326 88327 88285 Figure 172 Figure 173 Figure 174 Mountthesuctionstrainer(1)togetherwiththepipe. Screwdownthefixingscrews(2)andtightenthemtothe prescribedtorque. -Fit the connecting rod caps (3) with the associated bearingshells. -Tightenthescrews(2)intwosteps: - Step1:withatorquewrench,toatorqueof50Nm. - Step2:closingtoanangleof70 ° . -Remove the cap (3) and determine the existing clearancebycomparingthewidthofthecalibratedwire (3,Figure171)withthegraduatedscaleonthecase(2, Figure171) that contained the calibrated wire. On findingaclearanceotherthanasprescribed,replacethe bearingshellsandrepeatthecheck. On obtaining the prescribed clearance, lubricate the connectingrodbearingshellsandfitthempermanently bytighteningtheconnectingrodcapfixingscrewsas described. Manuallycheckthattheconnectingrodsslideaxiallyonthe pinsofthecrankshaft. Checking piston protrusion α Attheendoftheconnectingrod-pistonassemblyrefitting, checkthepistonprotrusion(2)attheT.D.C.comparedto thetoplevelofthecylinderblockbymeansofadialgauge (1)andrelevantbase99370415. Usetool99395216(1)fortheangleclosing. Theconnectingrodcapfixingscrewsmustalways bereplacedforpermanentassembly. The difference between the minimum and maximumprotrusionsofthefourpistonsmustbe =0.15mm. Thecylinderheadgasketinthesetofsparegaskets neededforcompleteengineoverhaulissupplied with a single thickness. Clearly, it is supplied separatelytoo. NOTE NOTE NOTE F1CENGINE 245 D AILY E URO 4 Print603.93.651 Base-March2006

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88329 88328 75412 88426 Figure 175 Figure 176 Figure 177 Figure 178 Fitthegasket(4)andtheframe(3)ontotheoilsump(1). Screwdownthefixingscrews(2)andtightenthemtothe prescribedtorque. Screw down the oil drain plug (5)andtightenit tothe prescribedtorque. ApplythesupportSP.2271(5)onthecylinderheadand tightenthesupportinavice. Removethebrackets(6)forliftingtheengine. Removethesensors(1and2),ifneeded. Takeoutthescrews(3)andremovethethermostatcasing (4). Fitpart(4)oftool99360260ontothecylinderhead(5)and secureitwiththescrews(3). Fitpart(2)oftool99360260ontopart(4),screwdownthe nut(1)sothatoncompressingthesprings(8)itispossible toremovethecotters(6).Thentakeouttheplates(7)and thesprings(8). Usingsuitablepliers,removetheoilseal(9). Repeattheseoperationsontheremainingvalves. Turnthecylinderheadover. Theintake(1)andexhaust(2)valveshavethesamediameter mushroom. Thecentralcavity( → )ofthemushroomoftheintakevalve (1)isdistinguishedfromthatoftheexhaustvalve(2). 560610 CYLINDER HEADS Disassembly α 541210 Disassembly the camshaft Removetheintake(1)andexhaust(2)valves. Before removing the valves from the cylinder heads,numberthevalvesinordertorefitthem correctlyiftheyarenotchanged. A=intakeside—S=exhaustside NOTE 246 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88331 87799 18625 18882 Figure 179 Figure 180 Figure 181 Figure 182 Thematingsurfaceofthehead(1)withthecylinderblock ischeckedusingarule(2)andafeelergauge(3). Thedeformationfoundontheentirelengthofthecylinder headmustbenogreaterthan0.20mm. Forgreatervalues,regrindthecylinderheadaccordingtothe valuesandinstructionsgiveninthefollowingfigure. ThenominalthicknessAofthecylinderheadis112 ± 0.1mm; themaximumpermissibleremovalofmetalmustnotexceed athicknessof0.2mm. Checking cylinder head seal Checkthehydraulicsealusingasuitabletool. Pumpinwaterheatedtoapprox.90 ° Catapressureof2 ÷ 3bars. Replacethecupplugsiftheyarefoundtoleakatoil,using asuitabledriftfortheirremoval—assembly. Checking cylinder head mating surface Ifthereisanyleakagefromthecylinderhead,itmustbe replaced. MAINDATAOFINTAKEANDEXHAUSTVALVES Removethecarbondepositsonthevalveswithawirebrush. Checkthatthevalvesshownosignsofseizure,crackingor burning. 540662 VALVES Removing deposits, refacing and checking valves Useamicrometer(2)tomeasurethevalvestem(1):itmust havethevalueshowninFigure132.Ifnecessary,grindthe valveseatsbymeansofthegrindingmachine99305018,and removeaslittlematerialaspossible. Priortofittingthecapsintoplace,applyLoctite270 water-reactivesealant(IVECONO.93162429)to thecapsealingsurface. Afterregrinding,checkthevalverecessingandif necessary regrind the valve seats to make the prescribedvalverecessing. NOTE NOTE 2,25+07.5’ 5,985 6,000 5,975 5,990 O30,8 32,3 32,5 60 +7.5’ EXHAUST VALVE INTAKE VALVE F1CENGINE 247 D AILY E URO 4 Print603.93.651 Base-March2006

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88332 87800 88333 88334 88335 Figure 183 Figure 184 Figure 185 Figure 186 Figure 187 Thechecksaremadeusingadialgauge(2)withamagnetic base, positioned as illustrated. The assembly clearance is 0.033—0.063mm. Makingthevalve(1)turn,checkthatthecentringerrorisno greaterthan0.03mm. MAINDATAOFVALVEGUIDES—SEATS Valveguideseatinside ∅ 9.980 ÷ 10.000mm Valveguideoutside ∅ 10.028 ÷ 10.039mm *Measurementtobemadeafterdrivinginthevalveguides. Removethevalveguides(2)withthedriftSP.2312(1). Warmupthecylinderheadto80 ° ÷ 100 ° Cand,bymeans ofbeaterSP.2312(1)fittedwithelementSP.2311(2),fitthe newvalveguides(3)previouslylubricatedwithengineoil. Drivingforce10 ÷ 25KN. Iftheabovementionedtoolsarenotavailable,fitthevalve guidesbypositioningtheminthecylinderheadaccordingto thevalueshowninSENZACODICE. Afterdrivinginthevalveguides(2),regrindthemwiththe smootherSP.2310(1). Checking clearance between valve stem and valve guide and centring valves 540667 VALVE GUIDE Replacing valve guide Boring valve guides 248 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88336 87801 88337 INTAKEVALVE Checkthevalveseats.Onfindinganyslightscoringorburns, regrind them with an appropriate tool according to the anglesgiveninFigure188. Havingtoreplacethem,withthesametoolandtakingcare nottoaffectthecylinderhead,removeasmuchmaterial fromthevalveseatsaspossibleuntil,withapunch,itis possibletoextractthemfromthecylinderhead. Heatthecylinderheadto80 ÷ 100 ° Cand,usingasuitable drift,fitinitthenewvalveseats,previouslychilledinliquid nitrogen. Usingaspecifictool,regrindthevalveseatsaccordingtothe anglesgiveninFigure188. Usingthemillingcutter99394038(1),cleantheinjectorseat ofanydeposits. Mountthevalves,blocktheseatoftheelectro-injectorsand glow plugs; using a suitable tool, check the seal of the valves/seats. Usingadialgauge(1),checkthat,fromtheplaneofthe cylinderhead,thevalverecessing(2)andtheprotrusionof theinjector(3)andoftheglowplughavetheprescribed value: - Valverecessing:0.375 ÷ 0.525mm. - Injectorprotrusion:2.77 ÷ 3.23mm. - Glowplugprotrusion:3.78mm. 540661 VALVE SEATS Recutting and replacing valve seats Figure 188 Figure 189 Figure 190 EXHAUSTVALVE F1CENGINE 249 D AILY E URO 4 Print603.93.651 Base-March2006

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62386 50676 75461 75942 Figure 191 Figure 192 Figure 193 Figure 194 Beforeassembly,checktheflexibilityofthevalvespringswith the tool 99305047. Compare the load and elastic deformationdatawiththoseofthenewspringsgiveninthe followingfigures. MAINDATATOCHECKINTAKEANDEXHAUST VALVESPRINGS COMPLETEROCKERARMASSEMBLY Therockerarmassemblyiscomposedoftherockerarm(1), hydraulictappet(3),madeintegralwitheachotherbytheclip (2). 540665 VALVE SPRINGS ROCKER ARMS — TAPPETS CROSS-SECTIONOFTHEHYDRAULICTAPPET A=32.44 ± 0.3,endofstroke B=31.30,workingposition C=29.75 ± 0.25,startofstroke 250 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Height Underaloadof mm kg H54 Free H145 P243 ± 12 H235 P1533 ± 24

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87803 87802 75587 Figure 195 Figure 196 Figure 197 Checks Theslidingsurfaceofthetappetsmusthavenoscoring/dents; replacethemiftheydo. Usingamicrometer,measurethediameterofthetappets and,usingaboremeter,measurethediameteroftheseats inthecylinderhead;thedifferenceinthemeasurementswill givetheassemblyclearance. Lubricatethestemofthevalves(1)andinsertthemintothe associatedvalveguides(4)accordingtothepositionmarked duringremoval.UsingtoolSP.2264(2),mounttheoilseals (3)onthevalveguides(4). MAINDATAHYDRAULICTAPPETS—SEATS Positionthesprings(8)andplates(7)onthecylinderhead (5). Fitthepart(4)oftool99360260ontothecylinderhead(5) andsecureitwiththescrews(3). Fitthepart(2)oftool99360260ontopart(4),screwdown thenut(1)sothatbycompressingthesprings(8)itispossible toinserttheretainingcotters(6);thenunscrewthenut(1) checkingthatthecotters(6)havesettledincorrectly. Repeattheseoperationsontheremainingvalves. ASSEMBLING CYLINDER HEADS The suction valves (5) are different from the exhaustonesforaslot( → )inthecentreofthe valvehead. NOTE F1CENGINE 251 D AILY E URO 4 Print603.93.651 Base-March2006

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108441 88339 88340 88341 Figure 198 Figure 199 Figure 200 Figure 201 Fitthethermostatcasing(2)withanewsealandtightenthe fixingscrews(3)totheprescribedtorque. Fitthetemperaturesensors(1)andtightenthemtothe prescribedtorque. Fitthebracketsforliftingtheengineandtightenthefixing screwstotheprescribedtorque. Removethescrews(2and3)andthecovers(1and4) togetherwiththeover-headsealrings. Removethenuts(4)andthetopskid(3). Removethescrews(1)andtheshoulderplate(2). Tilttheover-head(1)andtakecarenottodamagetheseats, thentakeoffthecamshafts(2and3)fromtheoverhead. 540650 Overhead Overhead removal 252 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Description Thetimingsystemisthetypewithatwincamshaftinthehead andfourvalvespercylinderwithhydraulictappets. Thecontrolistransmittedbytwochains: -adoublechainby3/8”issetinmotionbythedrivingshaft andsetsthecontrolshaftsinmotion:oilpump/depressor —highpressurepump; -asinglechainissetinmotionbythehighpressurecontrol shaftgearandsetsthecamshaftsinmotion. Thecamshaftgearsaremutuallyinterchangeableandare fittedwithslotstomakeitpossibleforthephasesensorto detectthephase. Therockerarms,oneforthevalve,arekeptincontactwith the corresponding cam by an hydraulic tappet, thus eliminatingtheneedforregularadjustments. 88055 108432 Figure 202 Figure 203 Figure 204 TIMINGSYSTEMANDAUXILIARYSYSTEMDIAGRAM 1.Camshaftcontrolgear-2.Singlechain-3.Hydraulic chainstretcherwithanti-returndevice-4.Chain-5.Hydraulicbeltstretcher-6.Drivegearondrivingshaft-7.Fixedskid-8.Oilpump/depressorcontrolshaftgear— Hydraulicpowersteeringpump-9.Doublechain-10.Highpressurepumpcontrolshaftgear. 5412 TIMING SYSTEM NOTE HYDRAULICBELTSTRETCHER WITHANTI-RETURNDEVICE A=Max.range:76.9±0.4mm B=Pistonengaged:53.6mm C=Min.travelforpistondisengagement:2.3mm D=Workingtravel:24.5mm Both chains shall be replaced,even thoughthe anomalyaffectsonlyonechain:inthiscase,gears (8-10),pads(7)andbeltstretchers(3and5)shall alsobereplaced(seefigure204). Hydraulicbeltstretcher(5)withanti-returndevice shallbereplacedeverytimeitisdisassembled.In factthebeltstretchercannotbeassembledback into place after the piston has come off the hydraulicbeltstretcherhousing. 1.Rockerarm-2.Reactionhydraulictappet-3.Valveassembly-4.Camshaftonexhaustside-5.Camshaftonsuctionside-6.Camshaftcontrolchain. F1CENGINE 253 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 205 87804 TIMINGSYSTEMDIAGRAM 541210 Camshaft Checks Thesurfacesoftheshaftsupportingpinsandofthecams mustbefinelyhoned;ifthereisanysignofmeshingorscoring, replacetheshaft. 75474 Figure 206 Usingamicrometer(1),measurethediameterofthepins(2) of the camshaft and, using a bore meter, measure the diameterofthesupportingseatsintheoverhead. Thedifferencebetweenthesetwomeasurementsgivesthe existingclearance. Thenominalassemblyclearanceis0.037 ÷ 0.088mm. 87806 Figure 207 541211 Checking cam lift and pin alignment Placetheshaft(1)ontheparallelsanduseacentesimaldial gauge fitted on the central support to check that the alignment error does not exceed 0.04 mm; otherwise, changetheshaft.Checkalsothecamlift:itmustcorrespond to the prescribed value; if different values are detected, changetheshaft. 254 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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87807 Figure 208 MAINDATA,CAMSHAFTPINSANDSEATS 1.Intakevalvecamshaftseats—2.Exhaustvalvecamshaftseats—3.Intakevalvecamshaft—4.Exhaustvalvecamshaft. Thecamshaft(3)ofthesuctionvalvescanberecognisedthroughthespringcup(4)andthedowel(6). NOTE F1CENGINE 255 D AILY E URO 4 Print603.93.651 Base-March2006

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88343 88344 88340 88346 88347 Figure 209 Figure 210 Figure 211 Figure 212 Figure 213 Lubricatethenewsealrings(1)withengineoilandfitthem onthecovers(2). Fitthecovers(2)ontheoverhead,driveinthefastening screws(3)andtightenthemtotheprescribedtorque. Lubricatethesupportpinsofthesuctioncamshafts(2)and exhaustcamshafts(4)andfitthemontheoverhead(1). Fitthetopskid(3)anddriveinthenuts(4),thentightenthem totheprescribedtorque. Fittheshoulderplate(2)anddriveinthescrews(1),then tightenthemtotheprescribedtorque. Positionthecamshafts(3and4)sothatthepins99360614 (1)canbeinsertedinthecamshaftslots(2)throughthe over-headthreadedholes. Rotatethedrivingshaftsothatthetool99360615(1)canbe insertedintheshaftcrankholethroughthecylinderblock hole,inordertostoptheengineinthetimingsystemsetting condition. AUXILIARY ORGAN CONTROLS During this operation do not exchange the assemblypositionoftheshafts. The suction camshaft can be recognised (2) throughthedowel(3)onthefrontsideandthe retainerontherearside. Inaddition,takecarenottodamagethesupport seatsoftheover-headshafts. NOTE 256 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Assembling overhead

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88348 88277 88279 88278 88349 88276 Figure 214 Figure 215 Figure 216 Figure 217 Figure 218 Figure 219 Lubricatethesealrings(1and2)withengineoilandfitthem onthesupport(3). Fitthesupport(1)anddriveinthenuts(2),thentightenthem totheprescribedtorque. Fitthestem(3). Stopthestemrotation(2)ofthehydraulicpowersteering pumpbyinsertinginthelatterthetool(3)andfasteningthe toolonthesupport(1)bymeansofthescrews(4). Fitthegear(1)onthestem(3)ofthe hydraulicpower steeringpump. Driveinthescrew(2)withoutlockingit. Lubricatethenewsealrings(1and2)withengineoilandfit themonthesupport(3). Fitthesupport(1),driveinthenuts(2)andtightenthemto theprescribedtorque. Fitthecontrolstem(3)ofthehighpressurepump. F1CENGINE 257 D AILY E URO 4 Print603.93.651 Base-March2006

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Check the conditions of the fixed skids (1 and 3) and change them if worn out. Fit the skid (1) and drive in the fastening screws (2), then tighten them to the prescribed torque. Fit the skid (3) and drive in the fastening screws (4), then tighten them to the prescribed torque. 88351 88274 88352 88353 Figure 220 Figure 221 Figure 222 Figure 223 Position the chain (1) on the gears (2, 3 and 5) and fit the gear (3) on the stem (4) so that the chain (1) in tracts A and B is tensioned. Fit the stem with the drive gear (2) on the high pressure pump control stem (1). Drive in the fastening screw (3). Cynder head refitting Check that the mating surfaces of the cylinder head and crankcase are clean. Keep the cylinder head gasket clean. Place the gasket (1) of the cylinder head with the thickness given in section “Check piston protrusion”, with the “TOP” sign facing the head. It is essential to keep the gasket sealed in itspackage until just before assembly. 88354 Figure 224 Mount the cylinder head (2). Screw down the fixing screws (3) and tighten them, in three successive stages, following the order and methods shown in the following figure. NOTE α The angle closure is done with tool 99395216 (1). NOTE 258 F1C ENGINE D AILY E URO 4 Base - March 2006 Print 603.93.651

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88355 Figure 225 Diagramofthetighteningsequenceforthecylinderhead fixingscrews: -1 st phase:pre-tighteningwithtorquewrench • screws1-2-3-4-5-6toatorqueof130Nm; • screws7-8-9-10toatorqueof65Nm. -2 nd phase:angleclosing • screws1-2-3-4-5-690 ° ; • screws7-8-9-1090 ° . -3 rd phase:angleclosing • screws1-2-3-4-5-690 ° ; • screws7-8-9-1060 ° . -ScrewsA,toatorqueof25Nm Thoroughlycleanthehydraulictappets(2),lubricatethemand fittheminthecylinderhead(3),positioningtherockerarms(1) onthevalvescorrectly. Fitonthegasket(5). InsertthetwotoolsSP.2264(4)intotheelectro-injectorseats forsubsequentcentringoftheoverheadonthecylinderhead. Mounttheoverhead(1)togetherwiththetools99360614 (3)forthetimingandtightenthefixingscrews(2)tothe prescribedtorque. TakeoutthetoolsSP.2264(4). Figure 226 88356 Figure 227 88357 TIMING SYSTEM CONTROL Figure 228 88270 Fitthetopfixedskid(1).Driveinthescrews(2and3)and tightenthemtotheprescribedtorque. Fittherubbercap(4)ofthenewgasketandtightenittothe prescribedtorque. F1CENGINE 259 D AILY E URO 4 Print603.93.651 Base-March2006

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88359 88360 88361 88362 Figure 229 Figure 230 Figure 231 Figure 232 Figure 233 Positionthechain(1)onthegear(5)andgear(2). Mountthegearinsuchawaythatfittingonaspirationvalve timingsystemshaftdowelmakesslotsAtoresulttobe positionedasinfigure. Positionthechain(1)onthegear(2)andfitthelatteronthe camshaftoftheexhaustvalves. Driveinthefasteningscrew(4)withthewasher(3)without tighteningitcompletely. Checktheconditionsofthemobileskids(1and3),ifworn outchangethem. Positionthemobileskids(1and3)andclampthemonthe cylinderblockbythepin(2)andtightenittotheprescribed torque. Driveinthechainhydraulictightener(1)andlockittothe prescribedtorque. Tightenthefasteningscrewofthegear(1)onthehydraulic powersteeringcontrolstemtotheprescribedtorque. Driveinthefasteningscrew(4)withthewasher(3)without tighteningitcompletely. Thechainarm(1)betweenthetwogearsmustbe tensioned. NOTE 88358 260 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Fitanewgasket(5)inthecover(2). Fitthecover(2),driveinthescrews(1)andtightenthemto theprescribedtorque. Fitthephasesensor(4). Driveinthefasteningnut(3)andtightenittotheprescribed torque. 88372 102127 88373 88374 Figure 235 Figure 236 Figure 237 Screwdownhydraulicchainstretcher(2),thentightenitto thespecifiedtorque. Insert, through the opening on the overhead, a suitable screwdriver,thenpressonmovingshoe(4)fin(3)untilchain stretcher(2)piston(1)ispushedtoitsendofstroke. Release moving shoe(4),andmake surethat piston(1) causes,byescapingfromitsseat,chain(5)tobesubjected totension. Tightenthefasteningscrewofthegear(1)onthesuction valvecamshafttotheprescribedtorque. Makesurethatthechain(3)inthetractbetweenthegear (2)andgear(4)istensioned. Tightenthefasteningscrewofthegear(2)ontheexhaust valvecamshafttotheprescribedtorque. Removetools99360614(1). Figure 234 Stoptherotationofthehighpressurepumpcontrolshaft(1) byinsertingthesuitablewrenchinsideit. 90311 Chain stretcher (1) cannot be re-used for any reasonafterithasbeendisassembled.Moreover,in theeventthatpiston(1)hasbeenunintentionallymadeto escapefromchainstretcher(2),thelattermustbereplaced. Chainstretcherreconditioningisnotpermitted. NOTE Figure 238 88370 Makesurethatthechain(2)andthetractbetweenthegear (1)andgear(3)istensioned. Tightenthefasteningscrewofthestemwiththedrivegear (1)onthehighpressurepumpcontrolstemtotheprescribed torque. Figure 239 F1CENGINE 261 D AILY E URO 4 Print603.93.651 Base-March2006

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88375 88377 88376 90156 107727 Figure 240 Figure 241 Figure 242 Figure 243 Figure 244 Positionthejoint(5)inthegear(6). Fittheoilpump/depressorunit(4)byinsertinganewgasket (1). Driveinthescrews(2)andtightenthemtotheprescribed torque. Removetool99360615(2). Fitthecover(1)withanewgasket.Driveinthescrews(2) withouttighteningthemcompletely. Cleanaccuratelytheseatofthecoversealring(1). Driveintheelement(2)oftool99346258inthedrivingshaft tang. Lubricate the tang of the driving shaft and the element outside(2)andfitflushthenewsealringonthiselement(3). Positiontheelement(4)onelement(2),lockthenut(5)until fittingthesealring(3)completelyinthecover(1). Fitanewcentrifugalfilter(1). Fitanewsnapring(2). Fitthecover(3),driveinthescrews(4)andtightenthemto theprescribedtorque. Mount tool 99396030 (3), for centering cover (1), into centrifugalfilterseatandtightenscrews(2)atprescribed torque.Remove:99346258(4)and99396039(3)tools. 262 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88379 107725 108431 107723 88260 Figure 245 Figure 246 Figure 247 Figure 248 Figure 249 Fitthewaterpump(2)withanewgasket. Driveinthescrews(1)andtightenthemtotheprescribed torque. Fittheelectricmagnet(3)ofthecoolingfanjointonthe waterpump(6). Driveinthenuts(2)andtightenthemtotheprescribed torque. Securetheelectriccabletoretainingclip(1). Fitthepulley(4)andthehub(5). Stoptherotationofwaterpumpshaft(5)bymeansofan Allenwrench(3)andaspeciallever.Screwdownhub(1) fasteningnut(2).Useasuitablewrench(4)totightennut(2) tothespecifiedtorque. Drive in the oil level sensor (1) and tighten it to the prescribedtorque. Fittherevsensor(2),driveinthefasteningscrew(3)and tightenittotheprescribedtorque. Fitthesupport(2),driveinthescrews(1)andtightenthem totheprescribedtorque. 88378 Stoptherotationoftheengineflywheel(2)bymeansoftool 99360306(1). Fitthedamperpulley(3).Driveinthescrew(4)andtighten ittotheprescribedtorque. Figure 250 Thenut(2)mustbedriveninanticlockwise( → ) becauseitsthreadingisleft-handed. NOTE F1CENGINE 263 D AILY E URO 4 Print603.93.651 Base-March2006

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88419 107722 88420 88330 88255 Figure 251 Figure 252 Figure 253 Figure 254 Figure 255 Thefreewheel(2)functionistopreventthattheengine idlingoscillationsbouncebackthoughthecontrolbeltonthe alternator(1). Ifitisnecessarytochangethefreewheel(2),operateas follows. Removetheprotectioncapfromthefreewheel(2). Applytool99358026(3and4)asillustratedinthefigure. Stoptherotationofthefreewheel(2)withtheelement(3) and slacken the stem(5) of the alternator (1) with the element(4). Fit the new free wheel (2) by reversing the removal operations.Thefreewheel(2)mustbeclampedonthestem (5)byapplyingamaxtorqueof85Nm. Fitthealternator(3)onthesupport(1),lockitwiththebolt (4)andthescrew(2)andtightenthemtotheprescribed torque. Fittheautomaticbackstand(1),driveinthescrew(2)and tightenittotheprescribedtorque. Operate the automatic backstand (2) with the suitable wrench,fitthebelt(1)andmakesuretheribsarepositioned correctlyintherespectivepulleyraces. Fittheexhaustmanifold(3)withanewgasket. Fitthespacers(1),driveinthenuts(2)andtightenthemto theprescribedtorque. 544017 Replacement of alternator free wheel 264 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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88421 107736 107737 107738 Figure 256 Figure 257 Figure 258 Figure 259 Fittheturbocharger(3) withthe relevantgasket onthe exhaustmanifold(1).Driveinthenuts(2)andtightenthem totheprescribedtorque. Connecttheoilpipe(5)totheturbocharger(3)andthe cylinderhead,andtightenthepipeunions(4and6)tothe prescribedtorque. Fitheatexchanger(2),togetherwithEGRvalve(3),backto theoverhead,thentightenfasteningscrews(1)tothespeci-fiedtorque.ConnectEGRvalve(3)topipe(6)withanew collar(4),thentightenfasteningscrew(5)tothespecified torque. Fitrearcover(4)withanewgasket(2)backtocylinderhead (1). Screwdownfasteningscrews(3)andtightenthemtothe specifiedtorque. Fit coolant pipes (1 and 3) to rear cover (2) and heat exchanger(4),andsecurethemwithnewclampsandcollars. Figure 260 107739 Connectpipeassembly(3)towaterpump(4),thensecure the latter to supporting bracket (1) with screw (2), by tighteningthelattertothespecifiedtorque. F1CENGINE 265 D AILY E URO 4 Print603.93.651 Base-March2006

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88423 107740 Figure 261 Figure 262 Removethefasteningscrews(1)andremovetool99360187 (2). Positionthejoint(2)onthestem(3). Slightlylubricatethesealring(1)andfititonthepower steeringpump(5). Fitthepowersteeringpumponthesupport(4). Screwdownfasteningscrews(7)completewithspacers(6) andtightenthemtothespecifiedtorque. Figure 263 107741 Lubricateanewsealring(3)andfititonthehighpressure pump(4). Positionthejoint(2)onthehighpressurepumpstem(4). Fitthehighpressurepump(4)onthesupport(1),drivein thescrews(5)completewithspacers(6)andtightenthem totheprescribedtorque. Figure 264 107711 Fitheatexchanger(2),completewithanewgasket,ontothe enginebase. Driveinthescrews(1)andtightenthemtotheprescribed torque. Figure 265 107710 Connectthelowpressurepipes(5)withthenewgasketsto thehighpressurepump(2)andtightenthepipeunions(1 and3)totheprescribedtorque. Driveinthefasteningscrew(6)ofthepipe(5)onthebracket (4)andtightenittotheprescribedtorque. Figure 266 107742 Lubricateanewsealring(3),thenfititontothepipe. Fitpipe(2)ontoheatexchanger(4). Screwdownscrews(1and5),thentightenthemtothe specifiedtorque. 266 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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107743 107745 75508 107746 Figure 267 Figure 268 Figure 269 Figure 270 Figure 271 Fitthesuctionmanifold(1)withanewgasket. Driveinthescrews(2)andtightenthemtotheprescribed torque.Fittheairtemperatureandpressuresensor(3). Driveinthescrew(4)andtightenittotheprescribedtorque. Fitanewseal(3)ontheelectro-injector(1)andmountthis intheoverhead(2). Mounttheglowplugs(1)and,usingthebox-typewrenchSP. 2275(2)andtorquewrench99389819(3),tightenthemto atorqueof8 ÷ 10Nm. Mountthehydraulicaccumulator(1)andtightenthefixing screws(2)totheprescribedtorque. Fitthepressuresensor(3)onthehydraulicaccumulator(1) andtightenittotheprescribedtorque. 107744 Fitthrottlevalveassembly(2),togetherwithanewgasket, ontoinletmanifold(1). Screwdownfasteningscrews(3),thentightenthemtothe specifiedtorque. 107705 Mountthebrackets(3)fasteningtheelectro-injectors(1) andscrewdownthescrews(2)withoutlockingthem. Figure 272 F1CENGINE 267 D AILY E URO 4 Print603.93.651 Base-March2006

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107747 107748 Figure 273 Figure 274 Figure 275 Figure 276 Connectthefuelpipes(2)totheelectro-injectors(3)andto thehydraulicaccumulator(1). Tightenthescrews(4)fixingtheelectro-injectorbrackets(5) totheprescribedtorque. Usingthewrench(2)ofthe99317915seriesandthetorque wrench99389829(1),tightenthefuelpipefittings(3)and(4) totheprescribedtorque. Pressclamps(3)inthedirectionshownbythearrow,then disconnect the connections of fuel recovery pipe (1) to electricinjectors(2). Whenevertheygetremoved,thefuelpipesmust bereplacedwithnewones. 107749 Connectthefuelpipe(3)tothehydraulicaccumulator(1) andtothehigh-pressurepump(8). Tightenthecouplings(2and5)usingawrench(7)inthe 99317915seriesandthetorquewrench99389829(6). Fastenthepipe(3)onthesupportbracketwiththebolt(4) tightenedtotheprescribedtorque. Whenevertheygetremoved,thefuelpipes(3) mustbereplacedwithnewones. NOTE 107703 NOTE 268 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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90650 Figure 277 Figure 278 Figure 279 Figure 280 Fittheflexiblebelt(3)equippedwithtool99360191(2)on thepulley(4)andapplythetoolonthepulley(1). Turnthedriveshaftcounterclockwise( ⇒ )untilthebeltfits perfectlyonthepulley(1). 107709 Lubricatethesealringoftheoilfilter(2)withengineoiland fastenitontheheatexchanger(3).Usetool99360076(1) totightentheoilfiltertotheprescribedtorque. 88252 Ifpresent,fitthesupport(3),driveinthescrews(4)and tightenthemtotheprescribedtorque. Fitthefixedbackstand(2),driveinthescrew(1)andtighten ittotheprescribedtorque. Fittheair-conditionercompressor(ifany)intoplace,then tightenthefasteningscrewstothespecifiedtorqueandfit elasticbelt(4)intoplace,asdescribedbelow. Tofittheair-conditionercompressorelasticdrive beltintoplace,tool99360191(2)mustbeused. Anyothertoolormethodmaycausedangerous tensiontotheelasticbelt. Theelasticbeltshallbereplacedwithanewone everytimeitisdisassembled. NOTE NOTE 107750 Fitthepipe(4)oftheoilleveldiprodandfastenthesupport bracketonthecylinderheadbytighteningthescrew(3)to theprescribedtorque. Fitcoolingfan(1),ifany,backtoelectromagneticjoint(2). F1CENGINE 269 D AILY E URO 4 Print603.93.651 Base-March2006

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107702 107701 Figure 281 Figure 282 Completeengineassembly. Fitontheleftandrightenginemountings(3)andtightenthe fixingscrewstotheprescribedtorque. Connecttheoilpipe(2)totheturbocharger(1)andtothe crankcaseandtightenthefixingscrewsandthecouplingof theoilpipe(2)totheprescribedtorque. Fittheitemsbelow,ifany,intoplace: -enginecable,byconnectingtheelectricconnectionsof thesameto: -electricinjectors(1); -preheatingplugs(3); -hydraulicaccumulatorpressuresensor(5); -throttlevalveactuator(7); -inletmanifoldairpressure/temperaturesensor(8); -high-pressurepumppressureregulator(10); -phasesensor(2); -thermostatcoolanttemperaturesensor(9). -channellingduct(6); -uppersound-proofingcover(ifany); -filltheenginewithlubricatingoiloftheprescribedgrade andamount. Fittheswingbartotheengineliftinghooks,thensecurethe swingbartothehoistandtaketheengineoffrotarystand (12).Takeoffbrackets99361041(11). 270 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 283 5450 LUBRICATION General Theengineislubricatedbyforcedcirculationperformedbythe followingparts: -agearoilpumpwithbuilt-indepressor(GPOD); -apressurereliefvalveintegratedintheoilpump; -aheatexchangermadeupoffiveelements; -Adoublefiltrationoilfilterwithbuilt-insafetyvalve. Operation (seeFigure283) Engineoilisdrawnupfromthesumpbytheoilpumpvia thesuctionstraineranddeliveredunderpressuretothe heatexchangerwhereitiscooled. Theoilcontinuesthroughtheoilfilterandgoestolubricate therelevantpartsthroughductsorpipes. Attheendofthelubricationcycle,theoilreturnstothe sumpbygravity.Theoilfiltercanbeexcludedbythesafety valvebuiltintoitifitgetsclogged. Inaddition,thelubricatingoilfeedsthechainhydraulic tighteningdevicesforthecontroloftheauxiliaryelements andthetimingsystemandthehydraulictappet. 107751 A.Pressureregulatingvalveclosed-B.Pressureregulatingvalveopen-C.Oilpressureswitch Oil under pressure Oil in freefall Coolant F1CENGINE 271 D AILY E URO 4 Print603.93.651 Base-March2006

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1.Oilpump-2.Oilpressureadjustingvalve-3.Depressor. 88625 Figure 284 Figure 285 OIL PUMP/DEPRESSOR UNIT SECTIONSOFOILPUMP/DEPRESSORUNIT 1.Oilinputpipefromcylinderblock-2.Oilsuctionpipe-3.Oilpressureadjustingvalve-4.Oildeliverypipe-5.Depressorairsuctionpipe-6.Depressoroilsuctionpipe. 88689 503010 Oil pump Characteristic data transmissionratio 1 displacement 23.52 cm 3 pumpingdiameter 49.5 mm numberofteeth 7 height 16 mm oilpumpminimumspeed 780 rpm oilpumpmax.speed 3500 rpm oilpumpover-revs 4200 rpm oilpumpforcedover-revs 4900 rpm speed 3500 rpm torque - Nm powerdraw(calc.) - W Figure 286 SECTIONB-B Figure 287 SECTIONA-A 88690 88691 Should the unit be faulty, not due to the oil pressureadjustingvalve,changethewholeunit. NOTE F1CENGINE 273 D AILY E URO 4 Print603.93.651 Base-March2006 Oiltemperature:100 ° C—closedrecirculation— max.outletpressure5bars enginespeedrpm (oilpumpspeed—rpm) capacity(l/min) 780(862) 3500(4485) -

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88626 88627 88058 Figure 288 Figure 289 Figure 290 1.Valve-2.Spring-A.Oilinletductfromthesump-B.Oilsupplyducttothecrankcase-C.Oilreturnduct fromthecrankcase-D.Oildrainageport Pressureatopeningstart: 4.4bar Description of oil pressure adjusting valve closed Ifinpipe C theoilpressureisbelow4.4bar,thevalve(1) closestheholes D -E . Oilpressureadjustingvalveopen Ifinpipe C theoilpressureisequalorabove4.4bar,thevalve (1),asaresultofthepressureitself,winsthroughthespring reaction(2)andgoesdown,thusopeningcommunication betweenthedeliverypipe A andthesuctionpipe B ,through drainingholes D -E ,andthereforethepressuredrops. Whenthepressurefallsbelow4.4bar,thespring(2)takes thevalve(1)totheinitialpositionofclosedvalve. Usethesuitablewrenchtoremovetheoilpressureadjusting valve(1)fromtheoilpump. Vacuum pump Thevacuumpump(2,Figure284),withradialblades,isalso incorporatedintheGPOD(1,Figure285).Itisdrivendirectly bytheoilpump. transmissionratio 1 displacement 150 cm 3 volumetodrain 4.5 litres chamberdiameter 65 mm rotordiameter 45.5 mm cam 7.5 mm numberofblades 3 height 34 mm vacuumpumpminimumspeed 780 rpm vacuumpumpmax.speed 3500 rpm vacuumpumpover-revs 4200 rpm vacuumpumpforcedover-revs 4900 rpm theoreticalflowrateatminimum(air) - l/min actualflowrateatminimum(air)— atatmosphericpressure - l/min Theoreticalspeedatmax.speed—(air) - l/min Actualflowrateatmax.speed—(air) atatmosphericpressure - l/min measuredpowerdraw(maximum) speed 3500 rpm torque - Nm powerdraw(calc.) - W 543475 Oil pressure adjusting valve Disassembly 274 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 Oiltemperature:100 ° C—enginespeed780rpm (pumpspeed994rpm) tank (litres) vacuum (bar) 0,5 0,8 4,5 4,5 12,5 9 9,5 26,0

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88059 88060 88061 107752 Figure 291 Figure 292 Figure 293 Figure 294 PARTSCOMPRISINGTHEOILPRESSURE CONTROLVALVE 1.Splitring—2.Valve—3.Spring—4.Valvecasing. Usethesuitableplierstoremovethesnapring(1),takeoff thevalve(4)andthespring(3)fromthevalvebody(2). MAINDATAOFTHEOILPRESSURECONTROL VALVESPRING Oilfilterwithbuiltinby-passvalve—differentialopening pressure2.5 ± 0.2bar. HEATEXCHANGERCOMPONENTDETAILS 1.Heatexchangermadeupoffiveelements-2.Gasket-3.Box-4.Pipeunion-5.Screw-6.Oilfiltersupport-7.Oilpressureswitch-8.Screw-9.Heatexchangerbox-10.Gasket. Assembly Forrefitting,reversetheremovaloperations. 543070 Oil filter 543110 Heat exchanger Disassembly Removethescrews(5)andtakeofftheheatexchanger(1) fromthebox(3)withthegasket(8). Removethescrews(7)andtakeofftheoilfiltersupport(6) fromthebox(3). Assembly Forrefitting,reversetheremovaloperationsandobservethe followingwarnings. Cleanaccuratelytheheatexchanger(1). Alwayschangethegaskets(2,9and8).ApplyLOCTITE577 onthethreadingofthepipeunion(4)(ifremoved),driveit inthesupport(1)andtightenittotheprescribedtorque. Tightenthescrewstotheprescribedtorque. F1CENGINE 275 D AILY E URO 4 Print603.93.651 Base-March2006

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88686 88685 88687 88688 Figure 295 Figure 296 Figure 297 Figure 298 HEATEXCHANGERSECTIONS Oilflowfromheatexchangertooilfilter Oilflowfromoilfiltertocylinderblock Oilflowfromcylinderblocktoheatexchanger 276 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 299 540480 Oil vapour recirculation (Blow-by) Part of the gas producedby the combustion during the engineoperationblowsbythepistonsnapringports,inthe oilsump,andmixeswiththeoilvapourspresentintheoil sump.Thismixture,conveyedfromthechaincompartment tothetop,ispartiallyseparatedfromtheoilbymeansofa devicesituatedonthetopsideofthedistributioncoverand isintroducedintheairsuctionsystem.Thisdeviceconsists mainlyofarotatingfilter(3),fitflushonthestem(1),ahigh pressure/shaftcontrolandacover(2)wherethevalves(4 and5),usuallyclosed,arefitted.Thediaphragmvalve(4) regulatesthepartiallypurifiedmixtureandkeepsthepressure insidethechaincompartmentaroundavalueof~10 ÷ 15 mbar. Theumbrellavalve(5)dischargessomeoftheoilstillpresent in the mixture coming from the filter (3) in the chain compartmentandtheoilcondensesinthechamber(6). Operation Themixturewhichpassesthroughtherotatingfilter(3)is partially purified from the oil particles, as a result of centrifugation,andsotheseparticlescondenseonthecover wallstoreturntothelubricationcircuit.Theresultingpurified mixture is let in through the stem holes (1) and the diaphragmvalveconsensus(4)insidetheairventupstream oftheturbocharger.Theopening/closingofthevalve(4) dependsmainlyintheratiobetweenthepressureoperating thediaphragm(4)andthedepressionbelowit.Theoilstill presentinthemixturecomingfromtherotatingfilter(3)and whichcondensesinthechamber(6)isdrainedintothechain compartment through the umbrella valve (5), when the pressurethatkeepsitcloseddropsasaresultoftheengine stop. 88062 Gaswithoillevelabove10g/h Gaswithoillevel~0,2g/h Condensedoilreturningtotheoilsump F1CENGINE 277 D AILY E URO 4 Print603.93.651 Base-March2006 Print603.43.671

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Figure 300 5432 COOLING Description Theenginecoolingsystemisthetypewithforcedcirculation inaclosedcircuit.Itcomprisesthefollowingparts: -An expansion tank whose plug has two valves incorporatedinit:anoutletandaninlet,whichgovern thepressureofthesystem. -Acoolantlevelsensoratthebaseoftheexpansiontank. -Apressureswitch(3),ofnormallyclosedtype(calibrated at 0.4 bar, absolute pressure 1.4 bar), located on expansion tank and connected to EDC central unit, protectsengineagainstoverheatingcausedbycooling systemfailure.Wherecoolanttemperatureexceedsa certainthresholdandpressureinsideexpansiontankis lowerthan0.4bar,EDCcentralunitreducesengine performancebychangingfuelflowrate(De-rating)until enginegoesoff. -Anenginecoolingmoduletodissipatetheheattaken fromtheenginebythecoolantwithaheatexchanger fortheintercooler. -Aheatexchangertocoolthelubricatingoil. -Acentrifugalwaterpumpincorporatedinthecrankcase. -Anelectricfancomprisinganelectromagneticcoupling onwhoseshaftahubturnsidlethatisfittedwithan axially mobile metal plate on which is mountedthe impeller. -A3-waythermostatgoverningthecirculation ofthe coolant. Operation Thewaterpumpdrivenbyapoly-Vbeltbythecrankshaft sendscoolantintothecrankcaseandwithagreaterheadinto thecylinderhead. Whenthecoolanttemperaturereachesandexceedsthe workingtemperature,itcausesthethermostattoopenand thefluidischannelledfromheretotheradiatorandcooled bythefan. Thepressureinthesystemduetothechangeintemperature isgovernedbytheoutlet(2)andinlet(1)valvesincorporated intheexpansiontankfillerplug(detailA). Theoutletvalve(2)hasatwofoldfunction: -tokeepthesystemslightlypressurizedsoastoraisethe boilingpointofthecoolant; -todischargeintotheatmospheretheexcesspressure producedincaseofhighcoolanttemperatures. Thefunctionoftheinletvalve(1)istopermittransferringthe coolantfromtheexpansiontanktotheradiatorwhena lowerpressureiscreatedinthesystemduetothereduction in volume of the coolant as a result of its temperature lowering. Outletvalveopening1 ± 0.1kg/cm 2 . Inletvalveopening0.005—0.02kg/cm 2 . 107753 278 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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CROSS-SECTIONOFTHEELECTROMAGNETICJOINT Characteristics Transmissibletorqueat20 ° Cwithclutchrunin 85Nm Voltage 12Volts Powerinputat20 ° C 48W The electric fan control relay is activated or deactivated accordingtothetemperaturesof:theenginecoolant,thefuel superchargingairandthepressureoftheairconditionerfluid (ifpresent). Turbocharging air temperature Itactivatesat>75 ° Canddeactivatesat<65 ° C. Coolanttemperature(ifthesensorisnotdefective) Itactivatesat>96 ° Canddeactivatesat<84 ° C. Fuel temperatures (ifthecoolanttemperaturesensorisacknowledgedtobe defectivebytheEDCcontrolunit) Itactivatesat>20 ° Canddeactivatesat<10 ° C. With climate control system Withpressureinthesystem itturnson 18.5 ± 0.98bar itturnsoff 14.58 ± 0.98bar 107754 Figure 301 Thewaterpumpcannotbeoverhauled.Incaseofcoolant leakingfromthesealordamage,itmustbereplaced. 543212 Electromagnetic pulley 543210 Water pump LONGITUDINALCROSS-SECTIONOFTHE WATERPUMP 1.Pumpcasing—2.Pumpdriveshafttogetherwith bearing—3.Seal—4.Impeller. Figure 302 107755 Theby-passthermostat(1)needsnoadjustment. Ifthereisanydoubtaboutitsoperation,replaceit. The thermostat casing is fitted with the thermometric switch/transmitterandwatertemperaturesensor. Valvetravelat79+25C=0.1mm Valvetravelat94+25C,min.7mm 543250 Thermostat Figure 303 107756 F1CENGINE 279 D AILY E URO 4 Print603.93.651 Base-March2006

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107757 Figure 304 TURBOCHARGINGDIAGRAM Description The turbocharging system comprises an air filter, turbochargerandintercooler. Theairfilteristhedrytypecomprisingafilteringcartridgeto beperiodicallyreplaced. Thefunctionoftheturbochargeristousetheenergyofthe engine’sexhaustgastosendpressurizedairtothecylinders. Theintercoolercomprisesaradiatorincludedintheengine coolantradiatoranditsfunctionistolowerthetemperature oftheairleavingtheturbochargertosendittothecylinders. HOT AIR AT ATMOSPHERIC TEMPERATURE HOT COMPRESSED AIR COLD COMPRESSED AIR EXHAUST GAS COLD EXHAUST GAS 280 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 TURBOCHARGING

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88620 Figure 305 A.THROTTLEVALVESHUT TheturbochargerinstalledontheengineF1CAE0481F(146 CV)isfittedwithpressurereliefvalve(waste-gate). Itisbasicallycomposedof: -acentralcasinghousingashaftsupportedbybushingsat whoseoppositeendsarefittedtheturbinewheeland thecompressorrotor; -aturbinecasingandacompressorcasingmountedon theendofthecentralbody; -apressurereliefvalveappliedontheturbinebody.Its functionistochoketheoutputoftheexhaustgases (detailB)andsendpartofthemdirectlyintotheexhaust pipe,whenthesuperchargingpressuredownstreamof theturbochargerisabovetheratedvalued; 542410 Turbocharger type MITSUBISHI TD 4 HL-13T - 6 88621 B.THROTTLEVALVEOPEN Figure 306 F1CENGINE 281 D AILY E URO 4 Print603.93.651 Base-March2006

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88622 Figure 307 Figure 308 88623 Cover the air, exhaust gas and lubricating oil inlets and outlets.Thoroughlycleantheoutsideoftheturbocharger usinganticorrosiveandantioxidantfluid.Disconnectthepipe (2)fromtheunionofthepressurereliefvalve(1)andfiton itthepipeofthedevice99367121(3,SENZACODICE). 542418 Pressure relief valve Pressure-relief valve check Restthetipofthedialgauge(1)withamagneticbaseonthe endofthetierod(2)andzeroit.Usingthedevice99367121 (3),introducecompressedairintothevalvecasing(4)atthe prescribedpressureandmakesurethisvaluestaysconstant throughoutthecheck;replacethevalveifitdoesn’t.Inthe aboveconditions,thetierodmusthavemadetheprescribed travel. Onfindingirregularengineoperationduetothe turbocharging system, it is first expedient to performthechecksontheturbocharger,checkthe efficiencyofthesealsandthefixingofthecouplings, additionallycheckingthereisnoclogginginthe intake sleeves, air filter or radiators. If the turbochargerdamageisduetoalackoflubrication, checkthattheoilcirculationpipesarenotburstor clogged,inwhichcasereplacethemoreliminate thetrouble. NOTE 282 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 REPAIRS

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62870 Figure 309 542410 GARRET GT 2260 V variable geometry turbosupercharger General The variablegeometry turbosuperchargerconsists ofthe following: -centrifugalsupercharger(1); -turbine(2); -setofmobileblades(3); -mobilebladecontrolpneumaticactuator(4),vacuum controlledbyproportionalsolenoidvalvecontrolledby EDC16ECU. Variablegeometryenables: -toincreasethespeedoftheexhaustgasesrunninginto theturbineatlowenginerpm; -todecreasethespeedoftheexhaustgasesrunninginto theturbineathighenginerpm. Toobtainthemax.enginevolumetricefficiencyalsoatlow rpm(withon-loadengine). Operation at low engine rpm 1.TURBINE-2.MOBILEBLADES-3.PNEUMATICACTUATOR-4.REVOLVINGRING Operation at high engine rpm 82871 Figure 310 62872 Figure 311 Whenengineisrunningatlowspeed,theexhaustgases show weak kinetic energy; under these conditions a traditionalturbineshallrotateslowly,thusprovidingalimited boosterpressure. Inthevariablegeometryturbine(1),themobileblades(2)are settomax.closedpositionandthesmallthrough-sections betweenthebladesincreasetheinletgasspeed.Higherinlet speedsinvolvehighertipspeedsoftheturbineandtherefore oftheturbosupercharger. Enginespeedincreaseresultsinagradualincreaseofexhaust gaskineticenergy,andalsointurbine(1)speedandbooster pressureincrease. The ECU, through the actuator control solenoid valve, modulatesthevacuumactingonthediaphragm,soactuator (3)controlsthroughthetierod,thegradualopeningofthe mobileblades(2)untilreachingthemax.openposition. Bladethrough-sectionsresultslargerthusproducingaspeed decreaseinexhaustgasflowthroughtheturbine(1)with speeds equal to or lower than those of the low rpm condition. Turbine(1)speedisthereforeadjustedtoapropervalue enablingsuitableengineoperationathighspeeds. F1CENGINE 283 D AILY E URO 4 Print603.93.651 Base-March2006

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Proportional solenoid valve controlling turbocharger actuator 62876 Figure 312 Thesolenoidvalvemodulatesthelowpressurecontrolling theturbochargeractuator,takenfromtheaircircuitofthe servo brake, according to the information exchanged betweentheelectroniccontrolunitandthesensors:engine speed, throttle pedal position and pressure/temperature fittedontheintakemanifold. Asaresult,theactuatorvariestheopeningofthebladesof theturbochargerthatadjusttheflowofexhaustgases. 62869 TURBOCHARGINGFUNCTIONALDIAGRAM 1.Variablegeometryturbocharger-2.Pneumaticactuator-3.Proportionalsolenoidvalve-4.Airfilter-5.EDC16controlunit-6.Servobrake-7.Vacuumdevice-8.High-pressurepump. Figure 313 Theactuatordiaphragm,connectedtothecontrolrod,is governedbythelowpressureonthetopoftheactuator. Thelowpressuremodulatedbytheproportionalsolenoid valvevariesthemovementofthediaphragmand,asaresult, oftherodgoverningtheturbine’smobileblades. 62875 SECTIONONTHEACTUATOR Figure 314 Actuator 284 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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62873 Figure 315 REPAIRS 542451 Checking and adjusting the actuator Operatethevacuumpumpandcheckwhetherthetierod (3)strokevaluescorrespondtothevacuumvaluesshownin thefollowingtable: Whereadifferentvalueisfound,replaceturbocharger. Duringthecheckthevacuumvalueshallnotfall, otherwisetheactuatorshallbereplaced. NOTE NOT ALLOWED ARE: -any replacement or regulation of the actuator, since the calibration of such component is made in an optimal way for each turbocharger and is guaranteed for the turbocharger; -any operation on nut (5) and ring nut (4), since such operation does not change engine supply characteristics but may impair engine reliability and duration. Ring nut (4) is sealed with antitempering yellow paint. In case of engines under guarantee, each above specified intervention and/or alteration to paint applied on ring nut (4) causes the lapse of the guarantee. NOTE Coverair,exhaustgasandlubricantinletsandoutlets. Clean the turbosupercharger outside accurately using anticorrosiveandantioxidantfluidandchecktheactuator (6). Clamptheturbosuperchargerinavice. Applyvacuometer99367121(1)pipetoactuator(6)hose. Applythemagneticbasegauge(2)toexhaustgasinletflange intheturbine. Setgauge(2)feelerpinontierod(3)endandsetgauge(2) tozero. F1CENGINE 285 D AILY E URO 4 Print603.93.651 Base-March2006 - vacuum0mmHg Fullyopenvalve - vacuum0,2bar Valvestroke0,5 ÷ 2,5mm - vacuum0,64bar Valvestroke9,5 ÷ 11,5mm

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Thus,theexhaustgas,passingthroughtheheatexchanger whereitiscooled,willbeconveyedintothethrottlevalve assemblychamberwhereitwillbemixedwiththeairfrom theintercoolerandmadetoflowoutintotheinletmanifold. IfthevehicleisequippedwiththeD.P.F.catalyst,theEDC controlunit16willsimultaneouslyadapttheflowrateoffuel tobeinjectedintothecylinders,dependingontheamount ofcirculatedexhaustgas. During the engine operating phases not requiring gas circulation (e.g. particulate filter regeneration, start-up, enginecold,idlerunning,loaddemands,vehiclerunningat high altitudes), the control unit control signal to the modulatingsolenoidvalvewillbecancelled.Thesolenoid valvewillclosetheconnectionbetweentheservobrake vacuumcircuitandtheE.G.R.one,andwillsimultaneously resumetheatmosphericpressurewithintheE.G.R.circuit. Figure 316 a.Servobrakevacuumcircuit-b.E.G.R.modulatedvacuumcircuit-c.V.G.T.modulatedvacuumcircuit 1.Electroniccontrolunit-2.Throttlevalveassembly-3.Vacuumconnector-4.Watertemperaturesensor-5.Enginerevssensor-6.E.G.R.pneumaticvalve-7.Airflowmeter-8.Inletairfilter-9.EGRmodulatingsolenoidvalve-10.VGTactuatormodulatingsolenoidvalve(ifany)-11.Auxiliaryvacuumtank(vehiclesequippedwith176HPengines)-12.Vacuumservobrake-13.Vacuumtank 112220 Operating The E.D.C. electronic control unit E.D.C. processes the informationfromtheatmosphericpressuresensor,water temperature sensor, engine revs sensor and accelerator pedal potentiometer. It drives, according to ways and proceduresproperlyprogrammedwithinitsownmemory, boththemodulatingsolenoidvalveandthethrottlevalveby meansofaPWMsignal. Themodulatingsolenoidvalvewill,everytimeisitdriverby theE.D.C.controlunit16,communicatetheservobrake vacuumcircuitwiththeE.G.R.one.Avacuumvaluewillbe obtainedwithintheEGRcircuit,dependingonthecontrol signal. Such vacuum will act on the E.G.R. pneumatic valve membrane, by withdrawing and lifting the shutter that normallyobstructsthepassageoftheexhaustgastowards theintake. 286 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

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Figure 317 TheE.G.R.valveisfittedtotheheatexchangerend. Toensureoptimumvalveefficiencyandservicelife,thevalve is cooledby theengine coolantflowing outof theheat exchanger. Theamountofcirculatinggasiscontrolledbymeansofa mushroom valve pneumatically controlled through the vacuumdrawn,bymeansofacalibrated-sectionconnector, fromthepipeconnectingthevacuumpumpwiththeservo brake. Thecontrolvacuummodulatedbythesolenoidvalvewill overcometheforcegeneratedbycounterspring(1)andwill lift membrane (2) connectedwith shutter(3) whichwill moveupwardsandallowburntgastocirculatetowardsthe inletmanifold. Figure 318 105060 Operating Theoperatingprincipleisbasedonaheatedmembraneput inameasuringchannelthroughwhichtheintakeairdirected totheengineflows. The hot-filmmembrane is kept at a steady temperature (approximately 1205C higher than the incoming air temperature)bytheheatingresistor. Theairmassflowingthroughthemeasuringchanneltends totakeheatawayfromthemembrane;therefore,thecurrent shallgothroughtheresistorinorderforthemembraneto bekeptatasteadytemperature. Theabsorbedcurrentisproportionaltotheairmassflowing totheengine.ItcanbemeasuredbymeansofaWheatstone bridge,andthesignalobtainedwillbesenttotheelectronic controlunit. IfthevehicleisequippedwithaD.P.F.catalyst,thecontrol unitprogramwillfeatureafunctioncapableofcorrectingthe flowratemeterdeviationintime.Thecontrolunitwill,during vehicledecelerationwiththepedalreleased(overrun),carry outafewchecks,thusdeterminingcorrectionfactorsforthe flow rate meter readings (self-adapting process). The replacementoftheflowratemeterwillthereforeinvolvea self-correctionprocess. Ifthecontrolunitisreplaced,theflowratemetercorrection coefficients(ZFC)storedintheoldcontrolunitshallbe copiedandenteredintothenewcontrolunit.Ifthisisnot possible,theyshallbereset,andtheself-learningprocessshall beinitiated. 772652 Air flow rate meter (flow meter) Main system components 540744 E.G.R. valve 1.Connector-2.Flowmeterbody -3.Recirculatedoil vapoursairinletgrid-4.Powersupply-5.Earth-6.Inlet airtemperaturesensor-7.Flowrateoutputsignal. The air flow meter is of thehot-filmtypeandisplaced betweentheturboblowerandtheintercooler. Theairflowmeterincorporatesthesuckedairtemperature sensor. The modulating solenoidvalve is an integral part to the vacuumpipesfortheE.G.R.systemandtheservobrake. AproportionalsolenoidvalvemodulatestheE.G.R.valve controlvacuumdependingonthePWMsignalgeneratedby EDCcontrolunit16. 105059 540746 Modulator solenoid valve 112333 Figure 319 Theairflowmeterbodybearsanarrowwhich indicatestheairflowand,therefore,thecorrect assemblingofthemeteronthevehicle. NOTE F1CENGINE 287 D AILY E URO 4 Print603.93.651 Base-March2006

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107949 Figure 320 540730 Heat exchanger 108399 107948 1.Throttlevalve-2.Electricactuator-3.Throttleposition signal-4.Ground-5.Voltage-6.PWMsignal Thethrottlevalve(N.O.)assembly,fittedontheinletmani-fold,controlstheamountofairfromtheintercooler,tobe mixedwiththeexhaustgasmadetocirculatebytheE.G.R. valve,accordingtoaprogrammedpercentage. Thecirculatedexhaustgaswillbemixedwiththeairfromthe intercoolerwithinaductobtainedinthecylinderhead. Thethrottlevalveisoperatedbyanelectricactuatorcontrol-ledbyaPWMsignalfromEDCcontrolunit16. Intheeventthatthethrottlevalvegetsstuck,thecontrolunit willreducetheengineperformancetoavoidpossibledamage totheengineitself. Whentheengineisswitchedoff,thethrottlevalvewillcloset oreducetheenginenoiseduringthisphase. Figure 321 Theheatexchangerfittedbetweentheturboblowerandthe throttlevalveassemblyisusedtolowertheexhaustgas temperatureinordertoaccordinglyreducethevolumeof thesame. It consists of a body that incorporates a number of corrugatedpipes.Thecirculatedexhaustgasflowingthrough thepipesarecooledbytheenginecoolantflowinginsidethe body. Figure 322 EXHAUSTGASCOOLINGSCHEME A.Intakeexhaustgasses-B.Cooledexhaustgasses-C.Coolanttoheater-D.E.G.R.valveexhaustgasses-E.Coolantincomingfromcylinderhead-F.Airfromintercooler Airfromintercooler Cooledexhaustgasses Enginecoolant Hotexhaustgasses Circulatedexhaustgas/airmixture 288 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 540760 Throttle valve assembly

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Figure 323 Tokeeptheexhaustemissionlevelsofpollutantssuchasnitricoxides(NOx),hydrocarbons(HC)andparticulate(PM)within thelimitsestablishedbytheEuro4standard,theengineisequippedwithanEGRsystemcombined,whereapplicable,tothe DPFcatalyticsilencerforpost-treatmentoftheaforesaidpollutingsubstances. General 1.E.G.R.heatexchanger-2.E.G.R.valve-3.Enginecoolanttemperaturesensor- 4.Enginerevssensor-5.E.G.R.modulatingsolenoidvalve-6.V.G.I.modulatingsolenoidvalve-7.Vacuumtank(onlyvehiclesequippedwith176 HPengines)-8.Airfilter-9.Airflowratemeter(airflowmeter)-10.VGTactuator(176HPengine)-11.Oilvapour circulatingpipe-12.Differentialpressuresensor(deltap)-13.Incomingexhaustgastemperaturesensor-14.Outgoing exhaustgastemperaturesensor-15.DPFcatalyticsilencer-16.Vacuumtank-17.Vacuumpumpconnector-18.EDCcontrolunit16-19.Servobrake-20.Throttlevalveassembly-21.Airpressure/temperaturesensor. 108419 Exhaustgasses Recirculationcooledexhaustgasses Airfromintercooler Recirculationoilvapours Under-pressuretube F1CENGINE 289 D AILY E URO 4 Print603.93.651 Base-March2006 EXHAUST SYSTEM REMOVAL-REFITTING

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105064 Figure 324 D.P.F. catalyst is made up of an oxidiser catalyst and a particulatefilter. Oxidisercatalyst(3)isanexhaustgaspost-treatmentdevice. Activesubstances,containedinthecatalyst,oxidise,at250 ° C ÷ 450 ° C temperature, carbon oxide (CO) and hydrocarbons(HC),turningthemintocarbondioxide(CO 2 ) andsteam(H 2 O). Catalyst module is made up of a ceramic structure impregnated with platinum, as platinum is a catalysing substanceinoxidationreactions.Exhaustgassesheatthe catalyst,sotriggeringtheconversionofpollutantsintoinert compounds. Particulatefilter(4),connectedtothecatalyst,hasadouble task:retainingparticulateparticles(PM)depositingbetween theporesoftheceramicstructureofwhichthefilterismade up and working as a particulate particles combustion chamberwhenthefilterisbeingclogged. Iffilterinterioriskeptatatemperaturehigherthan530ºC andoxygenpercentage ishigher than8%(oxygenbeing producedbythedecompositionofnitrogenoxideNO 2 ), thensomecombustionreactions,boostedbythecatalystput beforethefilter,burnparticulateparticles(regeneration),so keepingthefilterclean. On the contrary,if its temperature is lower,the filteris clogged, with negative effects, on counterpressure, on exhaustgassesgeneratedbythefilter. Inthiscase,toregeneratethefilter,temperatureofexhaust gassesisartificiallyraised(upto630ºC)byfuelpost-injection. A differential pressure sensor (7), connected to D.P.F. catalyst,asitdetectsapressuredifferencebetweeninletand outlet,sendsa(feed-back)signaltothecentralunittowarn aboutparticulatefilterpossibleclogging. Description D.P.F.CATALYSTVIEW 1.Exhaustgasinlet-2.Exhaustgastemperaturesensorconnection-3.Catalystmodule-4.Particulatefilter-5.Exhaustgasoutlet-6.Pipesconnectingpressuresensortocatalyst-7.Differentialpressure( ∆ p)sensor 290 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 507130 D.P.F. (Diesel Particulate Filter) CATALYST

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105065 Figure 325 ParticulatefilterregenerationismanagedbyengineE.D.C.16 centralunit.Thecentralunit,basedonthetemperatureof exhaustgassesdetectedbysensors(3and4)andparticulate filterclogginggradedetectedbydifferentialpressuresensor (3),whenexhaustvalve(2)isclosingatabout1º ÷ 3ºfrom T.D.C.,causeselectricalinjectors(8)toinjectsmallquantities of fuel into the cylinders. The combustion of this fuel increasesthetemperatureofflowinggasses. Atthesametime,thecentralunitshutsout: -Throttlevalve(11),toprevent,atopeningstart,airfrom entering through inlet valve (9), as air would cool exhaustgasses; -E.G.R.valve(1),topreventrecirculatedoilvapoursand gassesproducedbypost-injectionfrombeingsucked intothecylinders. Exhaustgasses,soheatedenterintothesilencer,where, passing through the catalyst, the pollutants they are composedof(nitrogenoxides)arereducedortransformed intoinertsubstances(carbondioxide-steam),thenpassinto particulatefilterwheretheregenerationprocesstakesplace: exhaust gas high temperature causes the combustion of particulateparticlesaccumulatedinthefilter. Particulate filter regeneration is realised when following conditionsarepresent: - catalystinletexhaustgastemperature>230ºCwiththe helpfrompost-injection; - exhaustgastemperatureinparticulatefilter>530ºCwith presenceoffreeoxygenhavingapercentage>8%; - minimumtimeofpermanenceinaboveconditions>10’. Operation 1.E.G.R.valve-2.Exhaustvalve-3.Differentialpressuresensor-4.Inletexhaustgastemperaturesensor-5.Outletexhaustgastemperaturesensor-6.D.P.F.catalysedsilencer-7.E.D.C.16centralunit-8.Piston-9.Inletvalve-10.Electricalinjector-11.Throttlevalve A.Post-injection-B.Exhaustgassesheatedbypost-injection-C.Catalyst-D.Particulatefilter-E.Purifiedexhaustgasses F1CENGINE 291 D AILY E URO 4 Print603.93.651 Base-March2006 SYSTEM TO REDUCE POLLUTANTS AT EXHAUST

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Forced regeneration In order that a regeneration can take place, following conditionsarenecessary: - exhaustgastemperature>530ºCatparticulatefilterinlet andfreeoxygenpresent(>8%); - oxicatinletgastemperature>230ºCwiththehelpfrom post-injection; - minimum time of permanence in such conditions approximately>10minutes. Inmanycasesofdoubtsaboutparticulatefiltercleanness actual conditions and/or of impossibility to regenerate it owingtoveryparticularengine/vehiclerunningconditions (persistentidling,veryslowspeedsandveryfrequentstops), asafetyforcedregenerationhastobeperformed. Independentlyofallparametersactivatingtheregeneration, theengineistakentorunwithoutloadtoapointwhere exhaustgasseshaveatemperature(>230ºC)suchasto activate the reaction in the Oxicat in presence of post-injection. Theonlylimittothisoperationisthepresenceinthefilter of a particulate quantity that is in excess, being anyhow calculated by the central unit and set as a condition to regenerationstartup. Duringvehicleuse,thecentralunitcountspost-injectedfuel quantityinordertoactivateandmaintainparticulatefilter regeneration. A small quantity of this fuel, which is injected into the cylinders after combustion has already taken place and remainspartiallyunburnt,leaksoutthroughpistonsspring ringsintooilsump,accumulatingtolubricationoil.Although apartofit,evaporating,willbeburntintheenginethrough recirculation system, its remaining part can degrade oil characteristics,impairingitsfunctionality. Quantityofaccumulatedfuelmayincreaseincaseofcatalyst orengineinefficiency,andvehicleuseinconditionsoflow temperatureand/orsmallamountsofmilescovered. Thecentralunitcountstheamountsofpost-injectionsand consequentlydeterminesthequantityoffuelaccumulatedin engineoil,andwarnsaboutrefillingneeded. If,afterrefillingengineoil,thefunctionisnotreset,thecentral unitwillkeeponcountingfuelaccumulationincreaseeven withnewoil,withconsequentengineoilrefillingwarning. Refilling engine oil 292 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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DIAGRAMILLUSTRATINGTHEPOSITIONOFTHEELECTRONIC,HIGH-PRESSUREINJECTIONSYSTEMCOMPONENTS 1.Phasesensor-2.Electricinjectors-3.Preheatingplug-4.EDCcoolanttemperaturesensor-5.Electromagneticfan-6.V.G.T.andE.G.R.valvemodulator(ifany)-7.Enginerevssensor-8.Compressor(if any)-9.High-pressurepump-10.Pressureregulator-11.Connectorforheater,fueltemperaturesensorandfuelfiltercloggingsensor-12.Fuelfilter-13.Fueltank-14.Fuelgaugewithelectricfuelpump-15.Controlunitwithatmosphericpressuresensor-16.Battery-17.Acceleratorpedalsensor -18.Clutchpedalsensors-19.Brakepedalsensors-20.Low-pressurefuelpipeassembly-21.Throttlevalve assemblyactuator-22.Airpressure/temperaturesensor-23.Hydraulicaccumulatorfuelpressuresensor(rail)-24.Hydraulicaccumulator(rail)-25.Slottedgearforphasedetectionfromsensor(1)-26.Enginerevscounter-27.Display-28.Tachograph The main characteristics of the high pressure electronic injectionsystemare: - highinjectionpressuresavailable(1600bar); - thesepressurescanbemodulatedbetween150barupto themaximumoperatingpressureof1600bar,irrespective ofthespeedofrotationandengineload; - capacitytooperateatveryhighspeeds(upto6000rpm); - injection control precision (injection duration and advance); - lowerconsumption; - loweremissions. Themainfunctionsofthesystemarebasicallyasfollows: - checkingfueltemperature; - checkingenginecoolanttemperature; - checkingamountoffuelinjected; - checkingidlingspeed; - cuttingofffuelinreleasephase; - checkingcylinderbalancingwhenidling; - checkinganti-sawing; - checkingsmokinessatexhaustonacceleration; - checkingexhaustgasrecirculation(E.G.R.ifpresent); - checkingtopspeedlimit; - checkingglowplugs; - checkingactivationofair-conditioningsystem(ifany); - checkingauxiliaryfuelpump; - checkingpositionofcylinders; - checkingmainandpilotinjectionadvance; - checkingclosedcycleofinjectionpressure; - checkingturbochargingpressure; - self-diagnosis; - connectionwithimmobilizerunit; - checkingmaximumtorquelimitation. The system makes pre-injection (pilot injection) possible before the TDC with the advantage of decreasing the derivative of the pressure in the combustion chamber, loweringthenoiselevelofcombustion,whichistypicalof directinjectionengines. Thecontrolunitcheckstheamountoffuelinjected,adjusting thelinepressureandinjectiontimes. Theinformationthecontrolunitprocessestoregulatethe amountoffueltobeinjectedcomprises: - enginespeed; - coolanttemperature; - turbochargingpressure; - airtemperature; - intakeairquantity; - batteryvoltage; - dieselpressure; - positionofthrottlepedal. 107759 HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM (EDC 16) General Highpressurepipings Lowpressurepipings Figure 326 F1CENGINE 293 D AILY E URO 4 Print603.93.651 Base-March2006 FUEL SUPPLY

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SYSTEM OPERATION Self-diagnosis — BLINK CODE Thecontrolunitself-diagnosissystemchecksthesignalsfrom thesensors,comparingthemwiththeadmittedlimits(see relativeheading): Immobilizer recognition Whenthecontrolunitreceivesthesignalofthekeyon”MAR” itcommunicateswiththeimmobilizercontrolunittoenable starting. Checking fuel temperature Withthefueltemperaturegreaterthan75 ° C,detectedbythe sensoronthefuelfilter,thecontrolunitoperatesthepressure regulatortodecreasethelinepressure(injectiontimesarenot changed).Ifthetemperatureexceeds90 ° C,thepoweris reducedto60%. Checking engine coolant temperature Thecontrolunit,dependingonthetemperature: - oftheenginecoolant,turbochargingairandfuel,operates theelectromagneticfan(Baruffaldi)andswitchesonthe coolanttemperaturewarninglight. Checking quantity of fuel injected Accordingtothesignalsfromthesensorsandthemapped values,thecontrolunit: - operatesthepressureregulator; - variesthe”pilot”injectiontimeto2200rpm; - variesthe”main”injectiontime. Checking idling adjustment Thecontrolunitprocessesthesignalsfromthevarioussensors andregulatestheamountoffuelinjected: - itoperatesthepressureregulator; - itvariestheinjectiontimesoftheelectro-injectors. Withincertainthresholdsthespeedtakesaccountofthe batteryvoltage. Fuel cut-off in release phase Inthephaseofreleasingthethrottlepedalthecontrolunit actuatesthefollowinglogicelements: - itcutsoffsupplytotheelectro-injectors; - itpartiallyreactivatessupplytotheelectro-injectorsbefore reachingidlingspeed; - itoperatesthefuelpressureregulator. Checking cylinder balancing on idling Accordingtothesignalsreceivedfromthesensors,thecontrol unitcontrolstheregularityofthetorqueatidlingspeed: - it varies the amount of fuel injected into the single electro-injectors(injectiontime). Checking regular engine rotation(anti-sawing) Itensuresregularenginerotationataconstantratewhile increasingrevs. The control unit processes the signals received from the sensorsanddeterminestheamountoffueltobeinjectedvia: - thepressureregulator; - theelectro-injectoropeningtime. Checking smokiness at exhaust on acceleration Withheavyacceleration,onthebasisofthesignalsreceived fromtheairintroductionmeterandenginespeedsensor,the controlunitdeterminestheoptimumamountoffueltoinject: - itoperatesthepressureregulator; - itvariestheelectro-injectorinjectiontime. Checking exhaust gas recirculation (E.G.R.) Depending on the engine load and the signal from the acceleratorpedalsensor,thecontrolunitlimitstheamountof airtakenin,actuatingpartialsuctionoftheexhaustgases. Checking top speed limit Dependingonthenumberofrevs,thecontrolunitactuates twoactionstrategies: - at 4250 rpm it cuts off the fuel, decreasing the electro-injectoropeningtime; - over5000rpmitdeactivatestheelectro-injectors. Checking regular rotation on acceleration Regularprogressionisassuredinallconditionsbythecontrol ofthepressureregulatorandtheelectro-injectoropening time. Checking glow plug control unit Theinjectioncontrolunit,inthephaseof: - starting - after-starting timesoperationoftheglowplugsaccordingtotheengine temperature. Checking activation of air-conditioning system Thecontrolunitoperatestheair-conditioningcompressor: - switchingiton/offwhentherelativeswitchispressed; - momentarily turning it off (approximately 6 sec.) if the enginecoolantreachesthesettemperature. Checking fuel pump Irrespectiveofthespeed,thecontrolunit: - suppliestheauxiliaryfuelpumpwiththekeyonMAR; - cutsoffauxiliarypumpsupplyiftheengineisnotstartedup withinafewseconds. F1CENGINE 295 D AILY E URO 4 Print603.93.651 Base-March2006 Print603.93.281

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Checking diesel warming Ittimesoperationofdieselwarminginrelationtoambient temperature. Checking cylinder position Duringeachturnoftheengine,thecontrolunitrecognizes which cylinder is in the power stroke and operates the injectionsequencefortheappropriatecylinder. Checking pilot and main injection timing Accordingtothesignalsfromthevarioussensors,includingthe absolutepressuresensorbuiltintothecontrolunit,thecontrol unitdeterminestheoptimumpointofinjectionaccordingto internalmapping. Checking injection pressure closed cycle Dependingontheengineload,determinedbyprocessingthe signalsfromthevarioussensors,thecontrolunitoperatesthe regulatortoobtainoptimumlinepressure. Fuel supply Thefuelsupplyiscalculatedinrelationto: - acceleratorpedalposition - enginespeed - quantityofairintroduced. Theoutcomemaybecorrectedinrelationto: - thewatertemperature. Ortoavoid: - noise - smoke - overloading - overheating - turbineover-revving. Thedeliverycanbemodifiedinthecaseof: - actionofexternaldevices(ABS),ABD,EDB - serioustroubledecreasingtheloadorstoppingtheengine. Afterdeterminingthemassofairintroducedbymeasuringits volume and temperature, the control unit calculates the correspondingmassoffueltoinjectintotherelevantcylinder (mgperdelivery)alsotakingintoaccountthetemperatureof thediesel. Themassoffuelcalculatedinthiswayisfirstconvertedinto volume(mm 3 perdelivery)andthenintodegreesofthrow, ordurationofinjection. Correcting flow rate according to water temperature Acoldenginemeetswithgreaterresistanceduringoperation: frictionishigh,theoilisstillveryviscous,andthevarious clearancesarenotyetoptimized. Inaddition,theinjectedfueltendstocondenseonthemetal surfacesthatarestillcold. Thefuelsupplyforacoldengineisthereforegreaterthanfor awarmone. Correcting flow rate to avoid noise, smoke or overloading Thebehaviourthatcouldleadtothiskindoftroubleiswell known. Thedesignerhasthereforeincludedspecialinstructionsinthe controlunittoavoidit. De-rating Intheeventoftheengineoverheating,injectionismodified, decreasingthedeliverytoavaryingdegree,inproportionto thetemperaturereachedbythecoolant. Injection timing electronic test Theadvance(startofdelivery,expressedindegrees)maybe differentfromoneinjectiontothenext,alsodifferentiated fromonecylindertoanother.Itiscalculated,similarlytothe delivery,inrelationtotheengineload(acceleratorposition, enginespeedandairintroduced). Theadvanceisappropriatelycorrected: - inphasesofacceleration; - accordingtothewatertemperature. Andalsotoobtain: - loweremissions,noiseandoverloading; - bettervehicleacceleration. Anextremelyhighadvanceissetonstarting,dependingonthe watertemperature. Feedbackfromthestartofdeliveryissuppliedbythechange inimpedanceoftheinjectorsolenoidvalve. Speed governor The electronic speed governor has both features of governors: - idlingandtopspeed - allspeeds Itisstableinrangeswhereconventional,mechanicalgovernors areimprecise. Engine starting Duringthefirstfewturnsoftheengine,thetimingandcylinder no.1recognitionsignals(flywheelsensorandcamshaftsensor) aresynchronized. Theacceleratorpedalsignalisignoredonstarting.Starting delivery issetonly accordingto watertemperature, bya specialmap. Whenthecontrolunitdetectssuchspeedandaccelerationof theflywheelastobeabletoconsidertheenginestartedup andnolongerdrivenbythestartermotor,itre-enablesthe acceleratorpedal. 296 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Cut-off This function cuts off fuel delivery when the vehicle is decelerating(acceleratorpedalreleased). Cylinder balancing Individualcylinderbalancingcontributestoincreasingcomfort andhandling. Thisfunctionpermitsindividual,customizedcontroloverthe deliveryoffuelandthestartofdeliveryforeachcylinder,even differentlyfromonecylindertoanother,tocompensatefor thehydraulictolerancesoftheinjector. Thedifferencesinflow(deliveryspecifications)betweenthe variousinjectorscannotbeevaluateddirectlybythecontrol unit.ThisinformationissuppliedbyModusreadingthebar codeofeachinjectoratthetimeofassembly. Synchronization search Ifthereisnosignalfromthecamshaftsensor,thecontrolunit isanyhowabletorecognizethecylindersintowhichthefuel istobeinjected. If this occurs when the engine is already running, the combustion sequence has already been acquired, so the controlunitcontinueswiththesequenceonwhichithas alreadybeensynchronized. Ifthisoccurswhenthemachineisatastandstill,thecontrol unitenergizesasinglesolenoidvalve.Withinatmost2turns ofthecrankshaft,injectionwilltakeplaceinthatcylinder,so thecontrolunitjustneedstogetsynchronizedonthefiring sequenceandtostartuptheengine. Cold starting Ifevenjustoneofthethreetemperaturesensors(water,air ordiesel)recordsatemperaturelowerthan10 ° C,pre-post heatingisactivated. Whenthekeymakescontactthepre-heatingindicatorlight comesonandstaysonforalengthoftimethatvariesin relation to the temperature (while the glow plugs in the cylinderheadheattheair),thenflashes.Itisnowpossibleto startuptheengine. Whenthemotorisrunningthisindicatorlightgoesout,while theglowplugscontinuetobepoweredforacertainlengthof time(variable)forpost-heating. If,withtheindicatorlightflashing,theengineisnotstartedup within 20-25 seconds (inattention time), the operation is cancelledsoasnottorundownthebatteriespointlessly. Thepre-heatingcurveisalsovariableinrelationtothebattery voltage. Warm starting Ifthereferencetemperaturesallexceed10 ° C,whenthekey makescontacttheindicatorlightcomesonforapproximately 2sec.,forashorttest,andthengoesout.Itisnowpossibleto startuptheengine. Run up Whenthekeymakescontact,thecontrolunittransfersthe information stored in memory when the engine was last stoppedintothemainmemory(seeAfterRun)andmakesa diagnosisofthesystem. After run Whenevertheengineisswitchedoffwiththekey,thecontrol unitstayspoweredforafewsecondsbythemainrelay. Thismakesitpossibleforthemicroprocessortotransfersome data from the main memory (volatile) to a non-volatile memory,whichcanbeerasedandwrittenover(EEPROM), soastomakeitavailableatthenextstartup(seeRunUp). Thesedatabasicallyconsistof: - varioussettings(engineidlingadjustment,etc.); - settingsofsomecomponents; - faultmemory. The process lasts a few seconds, typically from 2 to 7 (dependingontheamountofdatatosave),afterwhichthe ECU sends a command to the main relay and makes it disconnectfromthebattery. Itisextremelyimportantforthisprocedurenotto be broken off, for example byswitchingoffthe enginewiththebatterycut-out,orbydisconnecting thebatterycut-outbefore10secondshavepassed sinceswitchingofftheengine. If this happens, the functioning of the system is ensured,butrepeatedinterruptionsmaydamage thecontrolunit. NOTE F1CENGINE 297 D AILY E URO 4 Print603.93.651 Base-March2006

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112218 Figure 327 OPERATION In this injection system, the pressure regulator, located upstreamfromthehigh-pressurepump,governstheflowof fuel needed in the low-pressure system. Afterwards, the high-pressure pump correctly supplies the hydraulic accumulator. Thissolution,pressurizingsolelythenecessaryfuel,improves theenergyefficiencyandlimitsheatingthefuelinthesystem. Thereliefvalvefittedonthehigh-pressurepumphasthe functionofkeepingthepressure,atthepressureregulator inlet,constantat5bars;irrespectiveoftheefficiencyofthefuel filterandofthesystemupstream.Theactionofthereliefvalve causesanincreaseintheflowoffuelinthehigh-pressurepump coolingcircuit. Thehigh-pressurepumpcontinuallykeepsthefuelatthe workingpressure,irrespectiveofthetimingandthecylinder thatistoreceivetheinjectionandaccumulatesitinaduct commontoalltheelectro-injectors. Attheelectro-injectorinlet,thereisthereforealwaysfuelat theinjectionpressurecalculatedbytheelectroniccontrolunit. Whenthesolenoidvalveofanelectro-injectorisenergizedby the electronic control unit, fuel taken straight from the hydraulicaccumulatorgetsinjectedintotherelevantcylinder. The hydraulic system is made out of a low-pressure fuel recirculationcircuitandahigh-pressurecircuit. Thehigh-pressurecircuitismadeupofthefollowingpipes: - pipe connecting the high-pressure pump outlet to the hydraulicaccumulator(rail); - hydraulicaccumulator(rail); - pipes feeding the electric injectors from the hydraulic accumulator. Thelow-pressurecircuitismadeupofthefollowingpipes: - fuelintakepipefromthetanktothefilter; - pipeassemblymadeupofthefollowing: - feedpipefromthefuelfiltertothehigh-pressurepump; - fuelreturnpipefromthehigh-pressurepumptothetank; - fuelexhaustpipefromtheinjectorstothefuelreturnpipe tothetank. Accordingtothehighperformanceofthishydraulicsystem, forreasonsofsafetyitisnecessaryto: - avoid connecting high-pressure pipe fittings with approximatetightening; - avoiddisconnectingthehigh-pressurepipeswiththeengine running(NEVERtrybleeding,whichisbothpointlessand dangerous). Theintegrityofthelow-pressurecircuitisalsoessentialforthe systemtoworkproperly;itisthereforenecessarytoavoidall manipulationandmodificationsandactonlyintheeventof leakage. HYDRAULIC SYSTEM Thehydraulicsystemiscomposedof: - tank - fuelpre-filter - electricsupplypump - fuelfilter - high pressure supply pump with supply pump built inpressureregulator - manifold(rail) - electro-injectors - supplypipesandfuelrecirculation Fuel pipes 1.Quick-connectcouplingforhigh-pressurepumpfeed pipe-2.Quick-connectcouplingforfeedpipe-3.Fuelfiltersupport Duetotheveryhighpressureexistingwithinthis hydraulicsystem,thefollowingprecautionsshallbe takenforsafetyreasons: -avoidconnectingthehigh-pressurepipefittings bymeansofmakeshiftfasteners:tightenthem to thespecifiedtorque; -avoid disconnecting the high-pressure pipes whentheengineisrunning(DONOTmake anyattempt at draining: this is absolutely uselessanddangerous!). Toensurecorrectoperationofthesystem,itis essential that the low-pressure circuit is intact. Therefore, any modification or attempt at tamperingshallbeavoided,andcorrectiveactions shallbetakenimmediatelyincaseofleaks. In the event that fuel pipes (1 and 2) are disconnectedfromsupport(3),makesure,when reattachingthepipes,thattheirrespectivefittings arefullyclean. Suchprecautionsshallbetakentoavoiddetective sealing,withresultingfuelleaks. NOTE 298 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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112217 Figure 328 FUELFEEDANDCIRCULATIONSYSTEM 1.Injectorfuelexhaustpipe-2.Cap-3.Electricinjector-4.Coupling-5.Pressureregulator-6.CP3.2high-pressurepumpwithbuilt-infeedpump-7.Connectorforheaterconnection,temperaturesensor,cloggingsensor (optionalitem)andwatersensor-8Waterdrainscrew-9.Fuelfilter-10.Fuelreturnpipefromthetank-11.Fueldeliverypipetothehigh-pressurepump-12.Airdrainscrew-13.Fuelreturnpipetothetank-14.Pressurizedfuelpipeassembly-15.High-pressurefueldeliverypipetothehydraulicaccumulator(rail)-16.Pressuresensor-17.High-pressurefueldeliverypipetotheelectricinjectors-18.Hydraulicaccumulator(rail) Lowpressurefuelrecirculationpipes Highpressurefuelpipes F1CENGINE 299 D AILY E URO 4 Print603.93.651 Base-March2006 FEED SYSTEM AND FUEL RECIRCULATION

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109124 Figure 329 FUNCTIONALDIAGRAMOFHYDRAULICSYSTEM 1.High-pressurepump-2.High-pressuredeliverypipe-3.Electricinjectorreturnpipe-4.Electricinjectors-5.Commonrail-6.Fuelpressuresensor-7.Filterwithwaterseparator-8.Fuelelectricpumpnon-returnvalve-9.Injectorreturnline pressure-reliefvalve-10.Tank-11.Fuelelectricpump-12.Fuelelectricpumpintakefilter-13.Fuelelectricpump overpressurevalve-14.Pressure-reliefvalve-15.Proportionalpressure-reliefvalve Relativepressureswithinthecircuit: a. 4,15bar<p< 5,35bar b. 3,5bar <p< 5,0bar c. p<0,8bar d. 0,3bar <p< 0,8bar 300 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 330 HYDRAULIC SYSTEM Thehydraulicsystemismadeupofthefollowingitems: - tank; - electronicfuelpump; - fuelfilter; - high-pressurefeedpump; - pressureregulator; - manifold(rail); - electricinjectors; - low-pressurefeedpipeassembly; - high-pressurepipes. FUELELECTRICPUMPASSEMBLYSECTION 1.Return-2.Connector-3.Delivery-4.Float-5.Levelsensor(+)-6.Levelsensor(-)-7.Pump(-)-8.Pump(+)-A.Returnline-B.Deliveryline-C.Levelsensor-D.Prefilter-E.Jetpump 773010 Fuel pump Thefuelelectricpumpisofthevolumetric,low-pressuretype. Itisbuiltintothefuellevelindicatorlocatedinthefueltank. Electricconnector(2),locatedintheupperportionoftheassembly,featuresthepinsbothfortheelectricpumpandthelevel sensor.Duringtheinstallation,theassemblyshallnotbestressedwithaxialloadsofmorethan67Nandtorqueofmorethan3 Nm.Themaximumfasteningtorqueonthegasketshallbe60Nm. Figure 331 109073 109123 CHARACTERISTICCURVES F1CENGINE 301 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 332 542011 ”Filtrauto” fuel filter Thefuelfilterconsistsofaninternalfiltering-papercartridge (15)andisequippedwithawaterseparator. Themaximumwaterstoragecapacityofthefilteris150cm3. Thewatersensordetectsthepresenceofwaterinthefilter startingfromanexistingvolumeof70cm3. Thissensorislocatedinthelowerpartofthefilter. Thetemperature,waterandclogging(ifany)sensorsareinter-facedwiththeelectroniccircuit(13)locatedinsideinthe upperportionoftheassembly. Whenthedieselfueltemperatureislowerthanalimitvalue, theelectricresistorwillcomeintooperationbyproperlyhea-tingthedieselfuelbeforethelatterisconveyedtothehigh-pressurepump. 109072 1.Body-2.Gasket-3.Coverbottom-4.Drainscrewgasket-5.Customerreference-6.Dieseloiloutlet-7.Dieseloilinlet-8.Airdrainscrew-9.Suppliercode-10.Airbleedingorwaterdrainingscrew-11.Lowerbottom-12.Innerpipe-13.Filteringpaper-14.Upperbottom-15.Heatingearth-16.NTC1-17.NTC2-18.Cloggingsensor(ifforeseen)-19.Watersensor-20.Heating-21.Feed-22.GND Clogging sensor (if any) features -differentialworkingpressure: 0.7 ÷ 0.85bar Tightening torque 5. Cover 35 ± 5Nm 12. Air/waterdrainscrew 1 ± 0.2Nm NTC and heating features -ratedvoltage 13.5V -max.permittedvoltage 30V -ratedoutput 250Wat185l/h,T=-10 ˚ C -temperaturerange -30 ÷ 120 ˚ C 302 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 333 542011 ”UFIfilters” fuel filter Fuelfilter(4)ismadeupofafilteringcartridgewithwater separator,insidewhichelectronicunit(6)ishoused. Wateraccumulationcapacityisequalto140cm3. Electronicunit(6)includeswaterpresentsensor,(optional) filtercloggingsensorandtemperaturesensor. Water present sensor Water presentsensor detectswater presentin the filter starting from 110 cm volume present. Water present sensorprovidesvaluesof: -lowvoltageinpresenceofwater; -highvoltageinabsenceofwater. Characteristics 12Vnominalvoltage (8Vminimum-16Vmaximum) Absorbedcurrent: -lowerthan15mAinrestconditions; -lowerthan150mAinalarmconditions(includingload). Voltageonload: -inrestconditions:higherthan11.8V; -inalarmconditions:lowerthan3.9V. Atkey-onoperation,thesensormakesaself-testissuing2.5 seconddurationsoundsignal. 112723 (Optional) filter clogging sensor Normallyopencontacttype. Operationdifferentialpressuredeltap: 0.8bar NTC temperature sensor -30 ˚ C= 26.114ohm ± 9,7% 0 ˚ C= 5.896ohm ± 7,3% +25 ˚ C= 2.057ohm ± 5,6% +60 ˚ C= 596ohm ± 3,8% +100 ˚ C= 186ohm ± 2,0% +110 ˚ C= 144ohm ± 2,4% Temperaturerange:-40 ˚ Cto+130 ˚ C Heater Nominalvoltage 12V Maximumallowedvoltage 30V Nominalpower 250W Tightening torques 9. Screwsecuringfilter 1.5+0.5Nm 4. Waterdrainingorairbleedingscrew 1.5+0.5Nm +0,05 -0,5 1.Fuelfiltersupport-2.Dieseloiloutlet-3.Dieseloilinlet-4.Dieseloilfilter-5.Drainscrew-6.Electronicunit-7.Fastener -8.12-wayconnector-9.ScrewsecuringDieseloilfilter:H-G-B,waterpresentsensor;-H-C,cloggingsensor(ifforeseen);-D-E,NTCtemperaturesensor;-F-A,heater. F1CENGINE 303 D AILY E URO 4 Print603.93.651 Base-March2006

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109126 Figure 334 Pumpwiththreeradialplungers,controlledbythetimingbelt gear.Itdoesnotrequiretiming. Thepumpislubricatedandcooledbythefuelitself. ItdiffersfromtheCP3.2high-pressurepump(Euro3version) isthatitdoesnotfeaturethemechanicfeedpump. The high-pressure pump/feed pump assembly cannot be overhauled; therefore, the fastening screwsshallnotberemovedortamperedwith.The only operation that can be carried out is the replacementofthepressureregulatordrivegear. NOTE 304 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 775010 CP3.2 high-pressure pump

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Figure 335 1.Solenoid—2.Magneticcore—3.Shuttercylinder— 4.Fuelinlet—5.Fueloutlet. Whentheenginecontrolunitgovernsthepressureregulator (viaPWMsignal),thesolenoid(1)isenergizedthat,initsturn, generatesthemovementofthemagneticcore(2).Theshift ofthecorecausestheshuttercylinder(3)tomoveaxially, chokingtheflowoffuel. 75574 75575 1.Solenoid—2.Magneticcore—3.Pre-loadspring— 4.Shuttercylinder. Whenthesolenoid(1)isnotenergized,themagneticcoreis pushedintotherestpositionbythepre-loadspring(3).Inthis condition,theshuttercylinder(4)isinsuchapositionasto offerthefuelthegreatestsectionofpassage. Figure 336 Accuratelycleanhighpressurepump. Takeoffscrews(2)andunthreadpressureregulator(3)from highpressurepump. 108359 Figure 337 Figure 338 Accuratelycleantheseat( → )ofpressureregulatorandthe connectionsurface( → )oftheregulator. 88408 Mountnewsealrings(1and2)onpressureregulator(3)and lubricatetheringswithvaseline. 771034 Pressure regulator Thefuelpressureregulatorismountedonthelow-pressure circuitoftheCP3pump.Thepressureregulatormodulates theamountoffuelsenttothehigh-pressurecircuitaccording tothecommandsreceiveddirectlyfromtheenginecontrol unit. The pressure regulator is mainly composed of the followingcomponents: - connector - casing - solenoid - pre-loadspring - shuttercylinder. Whenthereisnosignal,thepressureregulatorisnormally open,thereforewiththepumpprovidingmaximumdelivery. The engine control unit, via the PWM (Pulse Width Modulation)signal,modulatesthechangeinfuelflowratein thehigh-pressurecircuitbypartiallyclosingoropeningthe sectionsofpassageofthefuelinthelow-pressurecircuit. Operation Replacing pressure regulator Forcleaning,donotuseatoolwhichcoulddamage thesurfacesandpayattentionthatimpuritiesare notintroducedintochannels. Figure 339 NOTE 108360 F1CENGINE 305 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 340 Mountpressureregulator(1)onhighpressurepump(2). 108361 108362 Screwupscrews(1)andtightenthemat6 ÷ 7Nm(0.6 ÷ 0.7 kgm)torque. Figure 341 Mountingoperationmustbeperformedkeeping the regulator perpendicular to connection plane withoutanglingit,inordernottodamagesealrings (1-2,Figure339). Wherepressureregulatorisreplacedontheengine mounted on the vehicle, it is needed, after replacement,tocheckthattherearenofuelleaks afteranengineworkingperiod. 774510 Hydraulic accumulator (rail) NOTE 108387 Figure 342 Thehydraulicaccumulatorisfittedonthecylinderheadonthe suctionside. Withitsvolumeofapproximately23cm 3 itdampensthe pressureripplesofthefueldueto: -theoperationofthehigh-pressurepump; -theopeningoftheelectro-injectors. Onthehydraulicaccumulator(1)thereisthefuelpressure sensor(2). Fuelpressuresensor(2)isfittedonhydraulicaccumulator(1). Smallvalves(throttlevalves)orcontrolbushes(3),with”j”= 0.85mm,havebeenfittedtothefueldeliverycouplings,which control the fuel pressure waves generated by the high-pressurepump.Theirfunctionistoprotecttheelectric injectorsbyreducingtheirwearintime. Fuelpressuresensor(2)mayaffecttheaccuracyoftheinjector minimumflowratecorrection,sincetheminimumflowrate dependsbothontheinjectiontimeandtheactualpressureof thehydraulicaccumulator. Incaseofreplacement,theEDCcontrolunit16correction coefficients(ZFC)shallbesettozero. Thecorrectioncoefficients(ZCF)canbecorrectedbymeans of the IVECO MODUS - E.A.SY. - IT 2000 diagnosis instruments, by programming the control unit again and performingthesensorreplacementprocedure,inaccordance withtheinstructionsgivenbythediagnosisinstruments. NOTE 306 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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Theelectro-injectorshavehigh-pressuresupply(upto1600 bar)andrecirculationatatmosphericpressure,necessaryfor thedieselusedtooperatethepilotvalve. Thetemperatureofthedieselputbackintocirculationbythe electro-injectorcangetveryhigh(approximately120 ° C). Theheadoftheelectro-injectorhasafittingfortheelectrical connector. Theyaremountedonthecylinderheadandoperatedbythe injectioncontrolunit. Theelectricinjectorcanbesubdividedintotwoparts(see SENZACODICE): Theelectro-injectorcanbedividedintotwoparts: - actuator/jetcomposedofpressurerod(1),pin (2)and nozzle(3); - controlsolenoidvalvecomposedofcoil(4)andpilotvalve (5). 75588 Figure 343 775010 ELECTRO-INJECTORS Operation Electro-injectoroperationcanbebrokendownintothree phases: - ”restposition” Thecoil(4)isde-energisedandtheshutter(6)isinclosed positionanddoesnotallowthefueltogetinthecylinder, Fc>Fa(Fc:duetothefuelpressureoperatingtherod(1) controlarea(7).Fa:duetothelinepressureoperatinginthe pressurechamber(8). - ”startofinjection” Thecoil(4)isenergizedandcausestheshutter(6)torise. Thefuelofthecontrolvolume(9)flowsofftowardsthe return manifold (10) causing a drop in pressure in the controlarea(7). Atthesametime,thelinepressurethroughthefuelpipe (12)exertsinthepressurechamber(8)aforceequaltoFa >Fcandthusmakesthepin(2)liftandsothefuelgetsin thecylinders. - ”endofinjection” Thecoil(4)isde-energizedandmakestheshutter(6)return toitsclosedposition.Thisrecreatessuchabalanceinthe forcesastomakethepin(2)returntoitsclosedposition andconsequentlyendinjection. 1Pressurerod—2Pin—3Nozzle—4Coil—5Pilotvalve— 6Ballshutter—7Controlarea—8.Pressurechamber-9Controlvolume—10Low-pressurefuelreturn— 11Controlpipe—12.Feedingpipe-13Electrical connection—14High-pressurefuelinletfitting—15Spring. Fc Fa 50704 Figure 344 Figure 345 ElectricalinjectorsarenotassignedanymoretoclassesMin(01) -Med(02)-Max(03);therefore,flowratedeviationsfromdesign valuesaredetected,duringfinalcheckstep,bythemanufacturer oneachsingleinjectorandprintedwithI.M.A.(InjectorMenge Abgleichung)[InjectorQuantityOffset]codeoninjectormagnet. Atengineproductionplant,I.M.A.codeisreadonlinefroman automaticreadingstation,convertedintobarcode,printedon engineidentificationlabelandappliedontheengineitself. Atvehiclesproductionplant,atlineend, E.D.C.16centralunitis programmedautomaticallyreadingtheengineidentificationlabel. 755010 Replacing an electrical injector 1.IMAMatrixcode-2.Boschsparepartno.-3.IMAcode inclear-4.Ivecosparepartno.-5.Code-6.Seriesno.-7.Productiondate 105066 F1CENGINE 307 D AILY E URO 4 Print603.93.651 Base-March2006

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105067 Figure 346 ConversiontableofOCR charactersintoARIELcharacters Atassistance,codewritteninclearhastobeused(3,Figure31) forcentralunitreplacementandreprogrammingprocedures. InthetablethereisshowntheconversionofOCRcharactersinto Arielcharacters. Whenelectricalinjectorsmountedonthevehiclemustbe replaced,meetfollowingwarnings: -whereelectricalinjectorsaredismountedanddonot needtobereplaced,theirmountingpositionhastobe noteddowninordertoremountthemlaterinthesame position;thisisdonetoavoidtoreprogramthecentral unit; -afterreplacingoneormoreinjectors,thecentralunithas tobereprogrammed; -beforemountinganewelectricalinjector,notedownIMA codeprintedontheinjector,becausethecodeisdifficult toreadaftertheinjectorhasbeenmounted; -wherethecentralunitisreplaced,reprogramthenew centralunitwiththeIMAcodesoftheelectricalinjectors mountedontheengineandcopydowntherectification coefficients(ZFC)ofreplacedcentralunit;whereitisnot possible,theymustberesetandself-learningprocess mustbestartedupagain. Duringenginerunning,EDC16centralunitperformssome checksonelectricalinjectorsminimumflowrate. Incertainconditions(overrun:vehicledecelerationwithpedal released)anincreasing(verysmall)fuelquantitystartingfrom zeroisinjectedanditseffectonenginerotationsmoothness isobserved. Injectionstartthresholdisdetectedandstoredbythecentral unit. Thisself-learningprocessiscarriedoutoneachsinglecylinder. Therefore,replacinganelectricalinjectorinvolvestheneedof reprogrammingthecentralunitbyenteringtheIMAcodesof newelectricalinjectorsandresettingtherectificationfactors (ZFC)ofthecylinderconsidered. Replacingallelectricalinjectorsextendstheneedofresetting to all the rectification coefficients (ZFC) of each single electricalinjector. Thecontrolunitisofthe”flashEPROM”type,i.e.itcanbe reprogrammed from the outside without acting on its hardware. Thecontrolunitprocessesthesignalsfromthesensorsby applyingsoftwarealgorithms,andalsocontrolstheactuators (inparticular,theelectricinjectorsandthepressureregulator). Thecontrolunitrecords,inthememorynon-labilearea,the information on the engine parameters originally set or acquiredduringengineoperation. Theinjectioncontrolunitincorporatestheabsolutepressure sensor, in order to further improve the injection system control. The control unit is fitted to the left side of the engine compartmentandisconnectedtothevehiclewiringbymeans oftwoconnectors: - 60-poleconnector”A”forthecomponentsavailableonthe engine; - 94-poleconnector”K”forthecomponentsonthevehicle. Inadditiontocontrollingthesystemfunctionsdescribedinthe respectivecharter,theelectroniccontrolunitisinterfaced withtheotherelectronicsystemsfoundonthevehicle,such as ABS - EBD, cruise control, speed limiter, immobilizer (IVECOCODE),EGR,preheatingplugs. OnthevehiclesequippedwithD.P.F.catalyst,thecontrolunit alsocontrolsthecatalystregenerationsystem.Inthiscase, afteranyoftheoperationsbelowiscarriedout: - replacingoneorseveralinjectors, - replacingalltheinjectors, - replacingtheairflowmeter, - replacing the hydraulic accumulator pressure sensor (commonrail), - replacingtheEDCcontrolunit16; - changingtheengineoil, - replacingtheD.P.F.catalyst, - replacingthefilterdifferentialpressure(Dp)sensor, - replacingany significantcomponentas regardsemission levels, - performingforcedregeneration, thecontrolunitshallbeprogrammedagainbymeansofthe IVECOMODUS-E.A.SY.-IT2000diagnosisinstrument,and thereplacementprocedurefortheconcernedcomponent shallbeperformed,inaccordancewiththeindicationsofthe diagnosisinstruments. ELECTRIC/ELECTRONIC COMPONENTS 766161 Electronic control unit EDC 16 Figure 347 k 85711 Thecorrectioncoefficients(ZFC)canbesettozerobymeans of the IVECO MODUS - E.A.SY. - IT 2000 diagnosis instruments, by programming the control unit again and performing the replacement procedure indicated by the instrumentitself. 308 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651 llllk

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SENSORS 764266 Engine speed sensor Itisaninductivesensorandispositionedonthephonicwheel fittedonthefrontendofthedriveshaft Itgeneratesthesignalsresultingfromthemagneticflowlines whichclosethroughtheteethofthephonicwheel. Toothnumber58. Theelectroniccontrolunitusesthissignaltomeasurethe speedofrotationoftheengine,itsangularpositionandto operatetheelectronicrevcounter. Ifthissignalfailstherevcounterwillnotwork. 764264 Camshaft timing sensor Itisaninductivesensorandispositionedonthecamshaftgear ofthesuctionvalves. Itgeneratesthesignalsresultingfromthemagneticflowlines whichclosethroughaslotonthegearitself. Thesignalgeneratedbythissensorisusedbytheelectronic controlunitasaredundantsignaltomeasurethedifferent enginespeeds. Figure 348 761917 Glow plug electronic control unit Duringthephasesbelow: -startingphase, -post-startingphase, the engine management control unit will time the plug preheatingcontrolunitoperationdependingontheengine temperature. Theplugswillbetriggeredthroughtheplugpreheatingcontrol unit, depending on the engine temperature, under direct controloftheenginemanagementcontrolunit. The preheating control unit incorporates a ”smart” remote-control switch that sends a return response (”feed-back”)tothemanagementcontrolunit:thelatterwill therefore be informed about the preheating control unit failure(ifany)ortheplugshort-circuittotheground. 75578 761915 Glow plugs Figure 349 75579 CONTROLVALUES Withaconstantsupplyvoltageof11V: -max.currentdrawn 18A -min5sec. 11 ± 1.5A -in30sec. 6 ± 0.9A -temperatureafter7sec. 850 ° C -tighteningtorque 8-10Nm 88056 Figure 350 Thesensorgapshallbeasfollows: -1+0.5mm,betweendistributingshaftpulley(4)and phasesensor(1); -1mm,betweenphonicwheel(2)andrevssensor(1). SENSORASSEMBLINGDIAGRAM F1CENGINE 309 D AILY E URO 4 Print603.93.651 Base-March2006

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772655 Airtemperatureand pressuresensor Positionedontheintakemanifold,itmeasuresthepressureof theturbochargingairintroducedintotheintakemanifold. Thisvalue,togetherwiththatoftheairtemperaturesensor, makesitpossiblefortheelectroniccontrolunittocalculatethe exactquantityofairintroducedintothecylinderssoasto operate the injectors adjusting the fuel delivery, limiting harmfulemissions,improvingconsumptionandperformance. The sensor contains an electronic temperature correction circuittooptimizethepressuremeasurementinrelationtothe temperatureoftheintakeair. 772656 Fuel temperature sensor Integratedinthefuelfilter,itmeasuresthefueltemperature andtransmitsittotheelectroniccontrolunit. Whenthefueltemperatureistoohigh(ambienttemperature condition,engineatfullloadandtankinreserve),correct lubricationofthehigh-pressurepumpisnolongerassured.On thebasisofthevaluesreceived,thecontrolunitdeterminesthe densityandvolumeofthefuel,correctingthedeliverylimiting engineperformance. 774511 Fuel pressure sensor It is fitted on the hydraulic accumulator end(rail) andits functionistotransmita“feed-back”signaltotheinjection controlunitfor: - adjustinjectionpressure -adjustthedurationofinjection. 772641 Clutch pedal position sensor Mountedonthepedalboard,itprovidesthecontrolunitwith apositivesignalwhentheclutchisengaged(pedalreleased). Everytimetheclutchisdisengagedtochangegear,thecontrol unit fails to receive this signal and deactivates the Cruise Controlfunction. 772642 Brake pedal position sensor Therearetwoofthesesensorsmountedonthepedalboard. Withthebrakepedalreleased,theyprovidethecontrolunit withapositivesignalthatisusedtodetectbrakeoperationso astodeactivatetheCruiseControlfunctionandstopdelivery offuel. Inaddition,asensorswitchesonthebrakelights. 764261 Vehicle speed sensor Thissensor,mountedonthegearboxbythedriveoutput shaft,transmitsthevehiclespeedsignal,throughtheelectronic tachograph,tothecontrolunit. 540743 Differential pressure sensor - delta p (Dp) Thissensordetectsthedifferencebetweenthepressure(Dp) oftheincomingexhaustgasandthepressureofthegasflowing outoftheD.P.F.catalyst. Themeasuredvalueindicatestheextentofparticulate(PM) particleaccumulationorcloggingintheD.P.F.filter. This value will, through a proper signal (feed-back), be processed by the EDC control unit 16, which will cause post-injectionsoastoincreasetheexhaustgastemperature (630 ˚ -650 ˚ C) and also cause the particulate particles accumulatedintheD.P.F.filtertobeburned. 766161 Atmospheric pressure sensor Thisisintegratedintheelectroniccontrolunit.Itprovidesa criterionofcorrectionforthemeasurementoftheairflow rateandtocalculatethereferenceairflowratetocheckthe EGR. 764254 Engine coolant temperature sensor Thisprovidesthecontrolunitwithanindexofthethermal statusoftheengineinordertodeterminecorrectionsforthe fueldelivery,injectionpressure,EGRinjectionadvancewhen startingcold(ifmounted)andwarm-up. 505910 Throttle pedal position sensor Theacceleratorpedalpositionsensorprovidesthecontrol unit with a voltage value in proportion to the angle of operationofthepedaldeterminingfueldelivery. Incaseofreplacement,thecontrolunitshallbe programmed again by means of the IVECO MODUS-E.A.SY.-IT2000diagnosisinstrument,by performingthereplacementprocedureindicated bythediagnosisinstrumentitself. NOTE Incaseofreplacement,thecontrolunitshallbe programmed again by means of the IVECO MODUS-E.A.SY.-IT2000diagnosisinstrument,by performingthereplacementprocedureindicated bythediagnosisinstrumentitself. NOTE Exhaust gas temperature sensor TheD.P.F.catalystincludestwotemperaturesensorslocated attheD.P.F.catalystinletandoutlet,respectively. Thetemperaturevaluesareprocessedbythecontrolunitto determinepost-combustion,inordertoincreasetheexhaust gastemperatureneededtoburntheparticulateparticles. 310 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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ACTUATORS The injection system comprisesthreeclassesofactuators interlockedwiththeelectroniccontrolunit: -electro-injectors(seerelevantheading); -regulators(seerelevantheadings)requiringPWMcontrol (PulseWidthModulation): • forpressure • EGR(ifmounted) • turbochargerwithvariablegeometry(ifmounted); -actuatorswithcontinuousON/OFFsignalto: • engageelectromagneticcouplingforradiatorcooling fan; • turnon/offair-conditionercompressor(ifmounted); • CruiseControl; • starterheatercontrol; • fuelfilterheating; • electricsupplypump. PWM (Pulse Width Modulation) controls A PWM control has an active and an inactive state that alternatewithinaconstantsetlengthoftime.Duringtheactive state the actuator control circuit is closed, which is thus powered with the control voltage; whereas, during the inactivestatethecircuitisopen. The duration of the two states may be varied with the conditionthatthesumofthetwotimesisequaltothelength ofthemodulationdelivery. Thedurationoftheactivestatedeterminestheduty-cycle, whichisnormallyexpressedasapercentageofthetotaltime. Therefore,ifthedurationofthetwoactiveandpassivestates arethesame,theduty-cycleisequalto50%. Forreasonsofdiagnostics,theduty-cycleislimitedbetween 1% and 99%; the control resolution is equal to 0.005% (1/20000ofthetime). The time length has been chosen taking account of the dynamicactuatorresponsespecifications. Toolowacarrierfrequencycouldcauseoscillationsinthe actuator,whiletoohighafrequencywoulddecreasecontrol resolution. ThecontroloftheE.G.R.(iffitted)andtheturbochargerwith variable geometry (if fitted) occurs through the idle modulatingvalve. Allthepowercontrolsaremadewithrelayslocated inthecab. NOTE F1CENGINE 311 D AILY E URO 4 Print603.93.651 Base-March2006

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312 F1CENGINE D AILY E URO 4 Base-March2006 Print603.93.651

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CLUTCH 1 D AILY E URO 4 Print 603.93.651 Base - March 2006 SECTION 3 5052 Clutch Page DESCRIPTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTICS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . CHARACTERISTICS AND DATA 7 . . . . . . . . . . . TIGHTENING TORQUES 13 . . . . . . . . . . . . . . . . . TOOLS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH REMOVAL AND REFITTING 14 . . . . . . . -Removal 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKS 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THRUST BEARING REMOVAL AND REFITTING 15 . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CLUTCH DRIVE 16 . . . . . . . . . . . . . . HYDRAULIC CLUTCH DRIVE REMOVAL - REFITTING 18 -Removal 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PEDAL BOARD REMOVAL - REFITTING 20 . . . . . -Removal 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PEDAL BOARD 21 . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH WITH AUTOMATIC WEAR RECOVERY -COMBINED WITH 6 AS’300 VD GEARBOX 22 -Description 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Operation 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND REFITTING OF CLUTCH WITH DEVICE RECOVERY COMBINED 24 . . . . . . . . . -Removal 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKS 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Theclutchunitconsistsofthefollowing: -adrivendisk-linedonbothsideswithfrictionsealsand fittedwithahubatthecentre.Additionally,ahubspring isprovidedtomakeitmoreelasticandsoft; -athrustpad-fixedtothecoverorbodyofthefriction clutchmechanismbymeansofplatesthatallowforaxial movementwhenthediaphragmspringisdrivenbythe collarbearing; -adiaphragmspringmadefromacertainnumberofblades arrangedinadialform; -acollarbearingmountedonthediaphragmspringand lockedtothesamebymeansofthesplitring.Withthis solutionitisnolongernecessarytoadjusttheclearance betweenthecollarbearinganddiaphragmspringsince boththecomponentsareincontact.Moreover,theclutch isreleasedbytractionofthecollarbearing. 52233 Figure 1 Theintroductionofadiaphragmspring(orBelvillewasher)as anelasticdrivingbringsaboutimportantadvantages,suchas: -smalleraxialsizeandreducedsensibilityofthecentrifugal force,duetotheabsenceofthereleaselever; -greaterconstructiveaccuracyduetothereducednumber ofcomponents; -improvedcoolingcapacityduetothereducedcontact surfacesbetweendiaphragmanddiskdriver; -lessunbalance; -easymaintenancethanksto: 1. noregulationrequiredforclearance; 2. nofurtherneedtolevel-offthethrustpad. Finally,itmustbenotedhowthenon-linearcharacteristicsof thediaphragmspringofferareducedvariationoftherelease forceasthecontrolpedalgraduallycompletesitstraveland, withaloadonthediskdrivernotlessthantheratedvalueeven withwornseals. VIEWOFCLUTCHASSEMBLY CLUTCH 3 D AILY E URO 4 Print603.93.651 Base-March2006 DESCRIPTION

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4 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651 DIAGNOSTICS Mainoperatingfaultsoftheclutchare: 1.-Noisewhentheclutchpedalispressed; 2.-Noisewhenthepedalisreleased; 3.-Clutchjerks; YES NO Collar bearing excessively worn, damaged or not properlylubricated. Replacethecollarbearing. Excessiveplaybetweentheclutchengagementgrooves ontheshaftandtherelevantseatonthehubofthe drivendisk. Replacetheshaftand,ifnecessary,thedrivendiskalso. Drivendiskspringsarebrokenorweakened. Replacethedrivendisk. Clutchengagementshaftworn. Replacetheshaftand,ifnecessary,thedrivendiskalso. Collarbearinghasexcessiveplayinthejoint. Replacethecollarbearing. 4.-Theclutchdoesnotrelease; 5.-Theclutchslips; 6.-Abnormalwearofdrivendiskseals. YES 1 YES NO YES NO YES 2 NOISE WHEN THE PEDAL IS RELEASED NOISE WHEN CLUTCH PEDAL IS PRESSED

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CLUTCH 5 D AILY E URO 4 Print603.93.651 Base-March2006 YES NO Oilorgreaseontheengineflywheel,oronthesealsof thedrivendisk. Replace the oil or grease, clean the flywheel, and replacethedrivendisk. Thrustpaddeformed. Replacetheclutch. Frictionsealswornduetooffcentringofthedrivendisk. Replacethedrivendisk. Clutchdiaphragmspringweakorbroken. Replacethedrivendisk. Oilorgreaseonthesealsofthedrivendisk. Remove the oil or grease; clean the flywheel and replacethedrivendisk. Groovesontheclutchengagementshaftarewornand impedethemovementofthedrivendisk. Replacetheshaftand,ifnecessary,thedrivendisk. YES NO 3 YES NO YES YES NO YES 4 CLUTCH JERKS THE CLUTCH DOES NOT RELEASE Drivendiskspringsbrokenoryielded. Replacethedrivendisk. NO YES (Continue)

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6 CLUTCH D AILY E URO 4 Base - March 2006 Print 603.93.651 YES NO Driven disk seals worn or burnt. Replace the driven disk. Clutch diaphragm springs weak or broken. Replace the clutch. Oil or grease on the seals of the driven disk. Remove the oil or grease, and replace the driven disk. YES NO 5 YES YES NO YES 6 THE CLUTCH SLIPS ABNORMAL WEAR OF DRIVEN DISK SEALS The driver keeps the clutch pedal pressed while driving. The driver must stop this habit and use the clutch pedal only when necessary. Clutch diaphragm spring blades weakened or broken. Replace the clutch. YES NO YES Clutch pedal height not adjusted (only mechanical control). The driver must stop this habit and use the clutch pedal only when necessary. Adjust the height of the clutch pedal. Clutch release hydraulic control not efficient. Replace the hydraulic control.

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CLUTCH 7 D AILY E URO 4 Print603.93.651 Base-March2006 CHARACTERISTICS AND DATA Models 29 L 10 - 29 L 12 - 35 S 10 - 35 S 12 - 35 C 10 - 35 C 12 - 40 C 10 - 40 C 12 (except for the vehicles equipped with 6 S 400 A O.D. gearbox unit) 9” 1 / 4 CLUTCH BORG&BECK Type Drysingledisk Clutchmechanism “Pull”withdiaphragmspring Drivendisk Withfrictionseals Drivendiskhub withsingleelasticcoupling ExternalØseal mm 235 0 − 1 Internal ∅ seal mm 160 + 1,5 Diskthickness(new) mm 7,7 ± 0,3 Underload N 6850 Minimumthicknessduetowear mm 1,25 Max.offcentringdriven disk mm ~ 0,2 Minimumloadon thrustplate N 6850 Max.releaseloadat9 Max.releaseloadat9 mm.releaseheight N 1400 Maximumrisethrustpad Maximumrisethrustpad at9mm.releaseheight mm 1,6 Disengagementstroke mm 9 +1 Max.depressionstroke mm 9,5 Disengagementcontrol hydraulic Lubricant -Valuesrefertonewclutch NOTE

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8 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651 Models 29 L 10 - 29 L 12 - 35 S 10 - 35 S 12 - 35 C 10 - 35 C 12 - 40 C 10 - 40 C 12 (only vehicles equipped with 6 S 400 A O.D. gearbox unit) 10” 1 / 2 CLUTCH SACHS Type Drysingledisk Clutchmechanism Pull-type,withautomaticwearrecoverydiaphragmspring Drivendisk Withfrictionseals Drivendiskhub withdoubleelasticcouplingsprings ExternalØseal mm 266 0 − 1 Internal ∅ seal mm 180 + 1,5 Diskthickness(new) mm 7,6 ± 0,3 Underload N 9000 Minimumthicknessduetowear mm 1,25 Max.offcentringdriven disk mm ~ 0,4 Minimumloadon thrustplate N 7900 Max.releaseloadat9 Max.releaseloadat9 mm.releaseheight N 9100 Maximumrisethrustpad Maximumrisethrustpad at9mm.releaseheight mm 1,1 Disengagementstroke mm 12 +1 Max.consumptiontravel atthethrustblock mm 4 Disengagementcontrol Electricactuatorcontrolledbythegearboxcontrolunit Lubricant -Valuesrefertonewclutch NOTE

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CLUTCH 9 D AILY E URO 4 Print603.93.651 Base-March2006 Models 29 L 14 - 35 S 14 - 35 C 14 - 40 C 14 (except for the vehicles equipped with 6 S 400 A O.D. gearbox unit) 10” 1 / 2 CLUTCH VALEO Type Drysingledisk Clutchmechanism “Pull”withdiaphragmspring Drivendisk Withfrictionseals Drivendiskhub Withdoublehubsprings ExternalØseal mm 267 0 − 1 Internal ∅ seal mm 171 + 1 − 0,5 Diskthickness(new) mm 8,5 ± 0,3 Underload N 8000 Minimumthicknessduetowear mm 1,25 Max.offcentringdriven disk mm ~ 0,2 Minimumloadon thrustplate N 6500 Max.releaseloadat9 Max.releaseloadat9 mm.releaseheight N 1600 Maximumrisethrustpad Maximumrisethrustpad at9mm.releaseheight mm 1,4 Disengagementstroke mm 9 +1 Max.depressionstroke mm 10,7 Hydrauliccontrol hydraulic Lubricant -Valuesrefertonewclutch NOTE

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10 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651 Models 35 C 15 - 40 C 15 - 45 C 15 - 50 C 15 - 60 C 15 - 65 C 15 (except for the vehicles equipped with 6 S 400 A O.D. gearbox unit) 11” CLUTCH VALEO Type Drysingledisk Clutchmechanism “Pull”withdiaphragmspring Drivendisk Withfrictionseals Drivendiskhub Withdoublehubsprings ExternalØseal mm 280 0 -0.4 Internal ∅ seal mm 170 0 -0.4 Diskthickness(new) mm 8,5 ± 0,3 Underload N 8000 Minimumthicknessduetowear mm 1,5 Max.offcentringdriven disk mm ~ 0,2 Minimumloadon thrustplate N 7000 Max.releaseloadat9 Max.releaseloadat9 mm.releaseheight N 1850 Maximumrisethrustpad Maximumrisethrustpad at9mm.releaseheight mm 1,5 Disengagementstroke mm 9 0 -0.4 Max.depressionstroke mm 13,6 Disengagementcontrol hydraulic Lubricant -Valuesrefertonewclutch NOTE

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CLUTCH 11 D AILY E URO 4 Print603.93.651 Base-March2006 Models 35 S 18 - 35 C 18 - 40 C 18 - 45 C 18 - 50 C 18 - 60 C 18 - 65 C 18 (except for the vehicles equipped with 6 S 400 A O.D. gearbox unit) 11”CLUTCH VALEO Type Drysingledisk Clutchmechanism “Pull”withdiaphragmspring Drivendisk Withfrictionseals Drivendiskhub Withdoublehubsprings ExternalØseal mm 280 0 -0.4 Internal ∅ seal mm 170 0 -0.4 Diskthickness(new) mm 8,5 ± 0,3 Underload N 8000 Minimumthicknessduetowear mm 1,5 Max.offcentringdriven disk mm ~ 0,2 Minimumloadon thrustplate N 7500 Max.releaseloadat9 Max.releaseloadat9 mm.releaseheight N 1850 Maximumrisethrustpad Maximumrisethrustpad at9mm.releaseheight mm 1,4 Disengagementstroke mm 9 0 -0.4 Max.depressionstroke mm 13,6 Disengagementcontrol hydraulic Lubricant -Valuesrefertonewclutch NOTE

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12 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651 Models 35 S 18 - 35 C 15/18 - 40 C 15/18 - 45 C 15/18 - 50 C 15/18 - 60 C 15/18 - 65 C 15/18 (only vehicles equipped with 6 S 400 A O.D. gearbox unit) 11”CLUTCH SACHS Type Drysingledisk Clutchmechanism “Pull”withdiaphragmspring Drivendisk Withfrictionseals Drivendiskhub Withdoublehubsprings ExternalØseal mm 280 0 -0.4 Internal ∅ seal mm 175 0 -0.4 Diskthickness(new) mm 8,4 ± 0,3 Underload N 9100 Minimumthicknessduetowear mm 1,5 Max.offcentringdriven disk mm ~ 0,2 Minimumloadon thrustplate N 7900 Max.releaseloadat9 Max.releaseloadat9 mm.releaseheight N 1100 Maximumrisethrustpad Maximumrisethrustpad at9mm.releaseheight mm 1,1 Disengagementstroke mm 12 0 -0.4 Max.consumptiontravel atthethrustblock mm 4 Disengagementcontrol Electricactuatorcontrolledbythegearboxcontrolunit Lubricant -Valuesrefertonewclutch NOTE

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CLUTCH 13 D AILY E URO 4 Print603.93.651 Base-March2006 TIGHTENING TORQUES PART TORQUE PART Nm kgm Screwsecuringclutchtoengineflywheel 46,5 4,7 Screwsecuringoperatorcylindermountingtogearbox 10 ± 1 1 ± 0,1 Screwsecuingpedalboardmounting --Screwtosecureclutchdisengagementleversupporttogearboxfrontcover 23,5 ± 2,5 2,3 ± 0,2 TOOLS TOOLNO. DESCRIPTION 99370205 Guidepinforcentringclutchdrivendisk 52230 Figure 2

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44571 44570 Figure 3 Figure 4 Removal Theoperationconsistsof: -removal-refitting of transmission shafts (see section 505620) -removal-refittingofgearbox(seesection530210). Insertthecenteringpin99370205(1)inthegearinfeedshaft supportbearing,tofacilitateclutchremovaloperations. Removethefixingscrews(2)andremovethethrustpad(3) fromtheengineflywheel. Removetheclutchdisk(3)byextractingthecentringpin 99370205(2). Diskplatecenteringpin(1)locatedontheengineflywheel. CHECKS Thecheckstobemadeareasfollows: -thematingsurface,ontheengineflywheel,ofthedriven diskmustnotbeexcessivelywornorscored. -theteethofthetoothedcrownmustnotbewornor broken. If this is not the case, disassemble the engine flywheel (operation540850)asdescribedintherelevantparagraphat section2. Proceed on the engine flywheel as described in relevant paragraph(operation540853)atsection2. Checkthattherearenooilleaks,evenofaslightentity,from thesealofthereardriveshaft;otherwiseremovetheflywheel asdescribedintherelevantparagraph.Removetherearcover completewithsealingringsandreplacethesameasdescribed atsection2. Checkthatthesupportbearingorbushingofthetakeupshaft onthegearsfittedtothedriveshaftarenotwornorbroken and,ifnecessary,replacethemasdescribedintherelevant paragraph(540852). Checktheconditionofthethrustpad;thedrivendisksupport surfacemustnotbescoredorexcessivelywornorshould therebesignsofoverheating;thediaphragmspringmustbe inperfectcondition. Checktheconditionofthedrivendisk: -thefrictionsealsmustnotbeexcessivelywornorpresent signsofoverheating,ortracesofoilorgrease; -thereshouldbeverylittlebacklashbetweenthehuband geartakeupshaft; -thehubringsmustnotbelooseorbroken. Whenanydefectsarefound,replacethepartinquestion. Thecompleteclutchissuppliedwithasparekit. Thefollowingaresuppliedsingularly: -thedrivendiskandcollarbearing. Inthiscaseitwillnecessarytoassemblethenewpartsofthe drivendiskspringthatistobereused. 505210 CLUTCH REMOVAL AND REFITTING 14 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651

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Refitting Followthesameproceduresasforremovalinreverseorder and: Ifthediskisoutoflineuseahookwrench(1)asinthefigure. -removetheguidepin; -reconnectthegearsafterspreadingthegroovedshaft withmolybdenumdisulphideMolikoteasdescribedin Section4; -adjust the clutch travel as described in the relevant paragraph(operation..). Beforefittinganewdrivendiskcheckthatitiscentredas follows: Positionthedrivendisk(1)onalatheand,withtheuseofa magneticbasedialgauge(2),checkthatthesurfaceofthedisk isnotoutoflineatanypoint. Maximumtoleranceallowedforthedrivendiskis0.20mm. Figure 5 Figure 6 -carefullycleanthefayingsurfaceoftheflywheel diskusingmethylatedspiritsorpetrol;ifanyslight scratches are noted remove with an abrasive cloth; -positionthedrivendisk(3,SENZACODICE),usingthe guidepin(2,SENZACODICE)toobtainperfectcentring and to avoid straining the hub when the gears are reconnected; -positionthethrustpadbyaligningtheholeswiththe centring grub screws (1, SENZACODICE) on the engineflywheel; -assembleandlockthethrustpadfixingscrewstothe correcttorque; Theoperationconsistsof: -removal-refitting of transmission shafts (see section 505620); -removal-refittingofgearbox(seesection530210). Byusingtheappropriatepliersopenthesplitpin(1)and extractthecollarbearing(2)fromthethrustpad(3). Toassemble,carryoutthedisassemblyoperationsinreverse. 36800 Figure 7 Thenewpartmustbeofthesamesupplyasthe drivendiskthatistobereused. 505254 THRUST BEARING REMOVAL AND REFITTING NOTE CLUTCH 15 D AILY E URO 4 Print603.93.651 Base-March2006

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Figure 8 Thehydraulicclutchdriveiscomposedof: -amastercylinder(1)mountedonthepedalboardand connectedtotheclutchpedal(5),withanintegratedoil tank(3). -anoperatingcylinder(7)fixedtothegearbox(6). -anoilpipe(4). Thecomponentsofthehydraulicdrivemustnever bedismantledorseparatedfromeachotherinany way. The cover (2) of the oil tank (3) must not be removed. Thisassemblyrequiresnomaintenance andthe hydrauliccircuitmustnotbevented. Intheeventofdefectiveness,theentireassembly needstobereplacedasitissuppliedasasparepart, proceeding as described under the relevant heading. The clip (8) holding the push rod (9) on the assembly supplied as a spare part must not be removedorcut. 50967 NOTE 16 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651 505260 HYDRAULIC CLUTCH DRIVE

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Figure 9 62090 SPECIFICATIONSANDDATA CLUTCH 17 D AILY E URO 4 Print603.93.651 Base-March2006 Maincylinderdiameter 18mm Maincylindersection 254,47mm 2 Operatingcylinderdiameter 22mm Operatingcylindersection 346,36mm 2 Clutchpedalratio 5,85 Hydraulicratio 1,36 Clutchdisengagementleverratio 1,67 Overallreductionratio 13,28 MaxdisengagementstrokeX Y (94) F (99) J (98.7)mm MaxwearstrokeY Y (67,5) F (70.8) J (69,1)mm Y 9” 1 / 4 CLUTCH F 10” 1 / 2 CLUTCH J 11” CLUTCH

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Positionthevehicleoverthepitoronthelift. Frominsidethecab,usingascrewdriver,unhooktheswivel head(2)ofthemastercylinderpushrodfromtheclutchpedal linkpin(3). Figure 10 Workingfromtheenginebay,turnthemastercylinder(4)to theright(approx.1/8ofaturn)toalignthesquareofthehole (A)inthepedalboard(1)withthesquare(B)ofthemaster cylinderbodyandextractitfromthepedalboard(1). Workingunderthevehicle,disengagetheoperatingcylinder (8detailC)byunscrewingthescrews(6detailC)securingthe cylindermounting(7detailC)fromthegearbox. Removethehydraulicclutchdriveassemblyfromthevehicle. Donotactonthepin(3)topreventitcomingoutof thepedalboard(1). 50968 Forrefitting,carryouttheoperationsforremovalinreverse order,takingthefollowingprecautions: -Donotpresstheclutchpedaluntilrefittingiscomplete. -Duringassembly,handlepartscarefully. -Lubricate the contact surfaces of the clutch disengagementleverwiththeclutchpedallinkpin. -Lubricatethecontactsurfaceofthemastercylinderswivel headwiththeclutchpedallinkpin. -Afterrefittingtheoperatingcylindermountingtothe gearbox,checkthatthecylinderpushrodisalignedwith theclutchdisengagementleverseat. -Ifreplacingwithanewhydraulicdriveassembly,after refitting,pressfirmlyontheclutchpedalsoastobreakor freetheclampholdingthepushrod(9). -Lifttheclutchpedalbyhandwithaforceofnogreater than5daNtoitslimitandholditinthispositionforatleast fivesecondssothattheoilfromthetankwillsupplythe mastercylinder.Repeatthisoperationifnecessary. Removal Refitting NOTE 18 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651 HYDRAULIC CLUTCH DRIVE REMOVAL - REFITTING

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52235 52236 87895 Figure 11 Figure 12 Figure 13 MASTERCYLINDER OPERATINGCYLINDER Theoperatingcylindermakesupforthewearofthedrivendiscmarkinganincreaseinloadonthepedalduringdisengagementwhen thewearonthedrivendiscgetstobe90%. Maximumdisengagementpositionwhennew a =121.8mm. a1=112.8mm. Engagementpositionwhennew b = 99.35.8mm. b1= 89.8mm Minimumpositionwithworndisc c = 73.3mm. c1= 63.8mm CLUTCH 19 D AILY E URO 4 Print603.93.651 Base-March2006

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Removethefournuts(2)fixingtheservobrake(3)andtake thisoutoftheenginebay. Disconnecttheelectricalconnection(1)fromthesensoron theclutchpedalandtheelectricalconnection(4)fromthe sensor on the brake pedal. Disconnect the electrical connection(5)fromtheswitchonthebrakepedal. Frominsidethecab: Remove the side guard (7), disconnect the electrical connection(6)fromtheacceleratorpedal(4).Takeoutthe screws(5)andremovetheacceleratorpedal(4)fromthe pedalboard. Whendrainingthebrakeoil,takecareitdoesnot comeintocontactwithanyone,clothes,orpainted parts. 52238 52239 52240 52241 Figure 14 Figure 15 Figure 16 Figure 17 Setapropercontainerunderthebrakepipes(4)andremove themfromthebrakepump(1)ofthevacuumbrake(3). Refitting Forrefitting,carryouttheoperationsdescribedforremoval inreverseorder,takingthefollowingprecautions: -tightenthenuts/screwstotherequiredtighteningtorque undertherelevantheading; -refit the clutch drive cylinder asdescribed under the relevantheading; -fillthebrakeliquidtankwiththerequiredquantityand gradeandbleedtheair(operation784010)asdescribed undertherelevantheading; -after making the electrical connections, check the efficiencyoftheconnectedcomponents. Disconnecttheelectricalconnection(2)fromthebrakeliquid tankplug. Disconnecttheclutchdrivemastercylinder(1)fromthepedal boardasdescribedundertherelevantheadingandsetitaside appropriatelyintheenginebay,takingcarenottodamageor bendtheoilpipe. Takeoutthenuts(2)andremovethepedalboard(3). Removal 502601 PEDAL BOARD REMOVAL - REFIT-TING 20 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651

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A.Pedalboardwithmechanicalacceleratorpedal B.Electronicacceleratorpedal 62091 Figure 18 Theonlyrepairoperationstobeperformedonthepedal-assyarethefollowing: -acceleratorpedalreplacement; -sensorreplacement. Inanyothercase,replacethepedalusingtheabove-mentionedcomponentsiftheyareserviceable. NOTE CLUTCH 21 D AILY E URO 4 Print603.93.651 Base-March2006 PEDAL BOARD

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1.Slidingwedge-2.Wedge(1)actuatingspring-3.Wearrecoveryring(6&7)actuatingspring-4.Wearindicator-5. Retainer-6.Wearrecoveryupperslidingring-7.Wearrecoverylowerring-8.Diaphragmspring 102089 Figure 19 Description Theautomaticwearrecoverydeviceisplacedbetweenthediaphragmspringandthethrustplateofthepressureplateassembly. Itisessentiallymadeupofwedge-shapedringswhichrecover,underslidingconditions,theclutchdiscwearreal-time,whilekeeping boththediaphragmspringcharacteristicsandtheforcerequiredtoactuatethespringunchanged. Operation Automaticwearrecoverytakesplaceintwoseparatephases: -Phase1: everytimetheclutchisclosed(engaged)andtheclutchdiscwear—asdetectedbyretainer(3)—issuchthatthe pressureplateismadetotravelanextrastroke,spring(4)willdisengagewedge(1),whichwillbepulledbyspring (2)andwillstopagainagainstspring(4)andretainer(5)aftertravellingastrokeequaltothediscwear. -Phase2: whentheclutchisopened(disengaged),diaphragmspring(8)willreleasewearrecoveryrings(6&7);asaresult,spring (3)will,bycausinglowerring(6)toslideoverupperring(7)duetotheinclinedplanesofthesame,liftthelatterby anamountequaltotheclutchdiscwear. CLUTCH WITH AUTOMATIC WEAR RECOVERY - COMBINED WITH 6 AS’300 VD GEARBOX 22 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651

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CLUTCHDISCAUTOMATICWEARRECOVERYDIAGRAM A.Positionofthediaphragmspringwithanewclutchdisc-B.Positionofthediaphragmspringwithawornclutchdiscpriorto operationoftheautomaticwearrecoverydevice-C.Positionofthediaphragmspringwithawornclutchdiscafteroperation oftheautomaticwearrecoverydevice 1.Retainer-2.Lowerring-3.Upperring-4.Clutchdisc-5.Retainer(1)spring-6.Diaphragmspring-7.Wearrecoveryringactuatingspring 102090 Figure 20 = ring(2)sliding = ring(3)lifting CLUTCH 23 D AILY E URO 4 Print603.93.651 Base-March2006

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102092 Figure 21 Figure 22 Figure 23 Loosen screws (4) that secure pressure plate (1) to the flywheelin5stepsincrossedsequenceuntiladistanceof2 mmisobtainedbetweenretainer(2)andtheclutch.Also makesurethatretainer(2)isreleasedfrompressureplate(1); otherwise,useasuitablebeater(3)tohitthetopofretainer (2). Thenremovescrews(4)andtakethepressureplateoffthe engineflywheel. 102091 44571 505210 REMOVAL AND REFITTING OF CLUTCH WITH DEVICE RECOVERY COMBINED Removal Theoperationconsistsof: -removal-refitting of transmission shafts (see section 505620) -removal-refittingofgearbox(seesection530210). Insertclutchcentringpin99370205(1)intheshaftsupport bearing. Locatethepositionofretainer(2):itispositionedbetweenthe engineflywheelplugforclutchassemblycenteringandahole forthescrewusedtofastenthesame.Itsticksouttheclutch assemblybyapproximately3mm. Removetheclutchdisk(3)byextractingthecentringpin 99370205(2). CHECKS Thecheckstobemadeareasfollows: -thefayingsurface,ontheengineflywheel,ofthedriven diskmustnotbeexcessivelywornorscored. -theteethofthetoothedcrownmustnotbewornor broken. If this is not the case, disassemble the engine flywheel (operation540850)asdescribedintherelevantparagraphat section2. Proceed on the engine flywheel as described in relevant paragraph(operation540853)atsection2. Checkthattherearenooilleaks,evenofaslightentity,from thesealofthereardriveshaft;otherwiseremovetheflywheel asdescribedintherelevantparagraph. Replacethesealringasdescribedinsection2. Checkthatthesupportbearingorbushingofthetakeupshaft onthegearsfittedtothedriveshaftarenotwornorbroken and,ifnecessary,replacethemasdescribedintherelevant paragraph(540852). Checktheconditionofthethrustpad;thedrivendisksupport surfacemustnotbescoredorexcessivelywornorshould therebesignsofoverheating;thediaphragmspringmustbe inperfectcondition. Checktheconditionofthedrivendisk: -thefrictionsealsmustnotbeexcessivelywornorpresent signsofoverheating,ortracesofoilorgrease; -thereshouldbeverylittlebacklashbetweenthehuband geartakeupshaft; -thehubringsmustnotbelooseorbroken. Shouldanyanomalybefound,thefullclutchshallbereplaced. Inspecttheconditionsoftheclutch-releasebearingandthe releaselever,shouldanyanomalybefound,theconcerned partshallbereplaced. Intheeventthattheclutchreleaseleverisreplaced, calibrationshallbecarriedoutafterre-attachingthe gearbox,asdescribedintherelevantcharterofthe “Gearbox”section. NOTE 24 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651

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Refitting Followthesameproceduresasforremovalinreverseorder and: -carefullycleanthefayingsurfaceoftheflywheel diskusingmethylatedspiritsorpetrol;ifanyslight scratches are noted remove with an abrasive cloth; -positionthedrivendisk(3,SENZACODICE),usingthe guidepintoobtainperfectcentringandtoavoidstraining thehubwhenthegearsarereconnected; -positionthethrustpadbyaligningtheholeswiththegrub screws (1,SENZACODICE)ontheengineflywheel; -screwdownthepressureplatefasteningscrewsinfour subsequentstepsandincrossedsequence,thentighten themtothespecifiedtorque CLUTCH 25 D AILY E URO 4 Print603.93.651 Base-March2006

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26 CLUTCH D AILY E URO 4 Base-March2006 Print603.93.651

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TRANSMISSION 1 D AILY E URO 4 Base-March2006 Print603.93.651 SECTION 4 5302 Transmission Page DIAGNOSTICS 3 .......................... TRANSMISSIONREMOVAL-REFITTING 7 ..... -Removal 7 ............................. -Refitting 7 .............................. -Gearcontrolcheckandadjustment 8 ......... GEARCONTROL 10 ....................... -Flexiblecablereplacement 10 ................ -Removal 10 ............................. -Refitting 11 .............................. GEARSHIFTLEVERSUPPORT 11 ............. -Removal 11 ............................. -Refitting 11 .............................. 5S300TRANSMISSIONS 13 ................. 6S400O.D.TRANSMISSION. 49 ............. 6S400AO.D.TRANSMISSION. 91 ........... POWERTAKEOFF. 127 ......................

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2 TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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TRANSMISSION 3 D AILY E URO 4 Base-March2006 Print603.93.651 DIAGNOSTICS Maintransmissionoperationfaults: 1-Noisytransmission 2-Noisytransmissiononlyinreversespeed YES YES YES Insufficientlubricatingoillevel. Add TUTELA TRUCK GEARLITE oil up to properlevel. 3-Gearspontaneousdisengagement 4-Difficultspeedengagementorselection 5-Leakagesoflubricant. NO 1 Screwswhichfastenthetransmissiontothechassisare loose. Tightenloosescrewsproperly. NO Overhaultransmissionandreplaceworngears. YES NO Gears,bearings,synchronizerringsandslidingsleeves worn.Springsbroken. Replacewornordamagedcomponents. 2 Excessivebacklashbetweengears. NOISY TRANSMISSION ONLY IN REVERSE SPEED Reversespeedorconnectedgearsdamaged. Overhaultransmission. YES NOISY TRANSMISSION

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4 TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 Incorrectclutchdisengagement. YES YES YES YES YES Speed engagement/selection rod release ball spring yieldedorbroken. GEAR SPONTANEOUS DISENGAGEMENT Removethecapandreplacethespring. NO 3 Slidingsleevespositioningspringsyieldedorbroken. Removethetransmissionandreplacethesprings. Checkthecommandorreplaceclutch. NO 4 Wrongqualityofoilinthebox.Insufficientoillevel. Drain the oil and refill with TUTELA TRUCK GEARLITE oiluptoproperlevel. Movementofslidingsleeveshindered.Forks,sliding sleeves,synchronizerringsworn. Disassemblethegearboxandlookforthecauseand carryoutrepairsifnecessary. NO DIFFICULT SPEED ENGAGEMENT OR SELECTION YES Wrongassemblyofleversonselectionand/orgear engagementlevers. Checkand/ormounttheleversasdescribedunderthe relevantheading. NO

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TRANSMISSION 5 D AILY E URO 4 Base-March2006 Print603.93.651 YES YES YES YES Oilleveltoohigh. Restoreproperlevel NO 5 Breatherclogged Cleanbreather NO Inputand/oroutputshaftretainingringsworn. Replaceretainingrings. Loose screws and/or nuts which fasten: covers, support,boxes Remove the component; clean coupling surfaces. SpreadonthemsomeLOCTITE5206sealing,re-fit and tighten screws and/or nuts to the prescribed torque. NO LEAKAGES OF LUBRICANT

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6 TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 1 Removal Here we describe the removal-refitting operations for the 5 S 300 transmission that, unless specified otherwise, also hold for the 6 S 400 O.D. transmission. Position the vehicle over the pit or on a lift or on special stands. Act from inside the engine compartment to remove the screws securing the starting motor to the gearbox case front cover (the upper screw also secures the fuel pipe supporting bracket). Remove the starter motor and put it appropriately aside in the engine bay. Act from under the vehicle to: -remove screws (11) and take sound-proofing guards (12) off; -disconnect exhaust pipe (13) from the turboblower pipe. On 6 S 400 O:D. gearbox units: remove screws (17) securing exhaust pipe supporting bracket (16) to the gearbox unit. Remove the sealing from ring (25), then unscrew the same and disconnect the speed indicator control cable. Disconnect reversing light electric connection (22) (on 6 S 400 O.D. gearbox units, the reversing light switch is located on the left side of the gearbox unit). Remove bolts (23) securing propeller shaft (24) to the gearbox unit; if necessary, remove screws (19) securing elastic support (18) to the chassis, and properly secure the propeller shaft to the chassis. Disconnect the jointed heads: -of the selection cable: 4 (max. pull-out load: 250 N - max. pull-in load: 60 N); -of the engagement cable: 5 (max. pull-out load: 100 N - max. pull-in load: 80 N, from lever 6 and 7). Use a suitable screwdriver to open out flexible cable fins (3) so that the pawls are disengaged from the support (see detail A). Undo fastening screws (2), move clutch control cylinder (1) together with its bracket and properly secure it to the chassis. Use a hydraulic jack to place bracket 99370629 under the gearbox unit, then lay the chain onto the gearbox unit and fit a link of the chain into the bracket slot. Screw down the nut so as to firmly secure the gearbox unit to the bracket through the chain. Remove screws (20) securing the gearbox case to the engine base. Undo fastening screws (15) and elastic dowel fastening screw (21), then remove gearbox supporting crosspiece (14) together with its dowel. Move the gearbox back until the gearbox input shaft has come off the clutch disc hub. Then lower the hydraulic jack while simultaneously verifying that the gearbox unit does not, during the downward movement, hit or get stuck into a component. Refitting 108848 Gearbox unit reattachment is not particularly difficult and is carried out by properly reversing the order of the detachment operations. However, the following instructions shall be followed when coupling the clutch with the gearbox. Use suitable pliers to open safety snap ring (10) and take pressure plate bearing (9) out of clutch diaphragm spring (8). Fit the bearing onto the motion input shaft cover quill, by connecting the same to the clutch disengagement lever. Apply Molikote molybdenum disulfide grease to the gearbox input shaft. Engage a gear to allow the output shaft to rotate by turning the propeller shaft mount flange. Push the gear shift fully down so that pressure plate bearing (9) is properly engaged into the diaphragm spring. When connecting the propeller shaft, use new nuts for the fastening screws of the respective flanges. All the bolts and nuts shall be tightened to the prescribed torque values indicates in the relevant tables. Prior to assembling, lubricate the flexible cable (Bowden) jointed head connection points with MOLIKOTE 33 LIGHT or MOLIKOTE G72 grease. After the gearbox unit has been reattached, check for correct connection of electric cables. Verify that the gears are engaged correctly; otherwise, proceed as described in the ”Gear control check and adjustment” chapter. 6 TRANSMISSION 7 D AILY E URO 4 Base - March 2006 Print 603.93.651 TRANSMISSION REMOVAL - REFITTING

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Figure 2 Gear control check and adjustment Verify that the cable length as measured at the points shown in the figures corresponds with the values shown in the following table: 108849 Check, with the gears idling, the distance ”C” as measured between the outer side of support (16) and the centre of jointed head (11) of the selection cable. This distance shall be 146 + 1 mm; otherwise, proceed as follows: -disconnect jointed head (11) from lever (15) (pull-out load: 250 N), loosen nut (10) and properly rotate jointed head (11) until distance ” C ” is obtained, then tighten the nut (10) to the prescribed torque; -loosen nuts (22) and rotate tie-rod (23) until the same aforesaid distance ”C” is obtained between the ball pin (11) centre and the outer side of support (16), then tighten nuts (21) to the prescribed torque so that the vertical axes of the jointed heads are aligned with a maximum deviation of 30 ˚ ; -lubricate the jointed head (11) inside with MOLIKOTO 33 LIGHT or MOLIKOTO G 72 grease, then connect the head to lever (15) ball pin (pull-in load: 60 N). Check, with the gears idling, the distance F measured between the outer side of support (16) and the centre of jointed head (12) of engagement cable (4). This distance shall be 180 + 1 mm; otherwise, proceed as follows: -disconnect jointed head (12) from lever (13) (pull-out load: 100 N), loosen nut (14) and properly rotate jointed head (12) until distance ” F ” is obtained, then tighten the nut to the prescribed torque; -loosen nuts (17) and rotate tie-rod (18) until the same aforesaid distance ” F ” is obtained between the ball pin (12) centre and the outer side of support (16), then tighten nuts (17) to the prescribed torque so that the vertical axes of the jointed heads are aligned with a maximum deviation of 30 ˚ ; -lubricate jointed head (12) inside with MOLIKOTO 33 LIGHT or MOLIKOTO G 72 grease, then connect the head to lever (13) ball pin (pull-in load: 80 N). Verify that spring (21) ends come into contact with selection lever (15) or are at least 1 mm within the same. Otherwise, loosen screw (20) so that the spring is correctly positioned, due to plate (19) being released. 8 TRANSMISSION D AILY E URO 4 Base - March 2006 Print 603.93.651 Selection cable (8) A B C Left-hand drive 156 783 ± 2 146 ± 1 Right-hand drive 156 894 ± 2 146 1 Selection cable (4) D E F 150 790 ± 2 180 ± 1 150 859 ± 2 180 ± 1

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TRANSMISSION 9 D AILY E URO 4 Print 603.93.651 Base - March 2006 Act from inside the cab (see figure 2) to take off knob (1) and protection boot (2), then screw down knob (1) again and proceed as follows. 5-speed gearbox unit (detail A, figure 2) Selection cable adjustment (8): -put the gear shift lever in neutral; -open the adjusting device, by lifting the lock ring (6) selection cable (8); -position gear lever (9) in such a way that it is perpendicular to support (7) plane; -under the above conditions, release lock ring (6). Engagement cable adjustment (4). Engage the 5th speed, then move the lever forwards: under such condition, verify that the distance between knob (1) and the dashboard is ~ 70 mm. Otherwise, proceed as follows: -disconnect jointed head (4) from lever (3) (pull-out load: 100 N); -loosen nut (5); -properly rotate jointed head (4) until, at the aforesaid distance of 70 mm, jointed head (4) is aligned with the connecting ball pin; -lubricate the jointed head inside with MOLIKOTE 33 LIGHT or MOLIKOTE G 72 grease, then connect the head to lever (3) ball pin (pull-in load: 60 N); -tighten nut (5) to the prescribed torque so that the axis of jointed head (4) is aligned with the axis of lever (3) ball pin. Adjustment check Verify that all the gears are correctly engaged. In particular, the 1st and 2nd gears shall be engaged without control lever (9) coming into contact with the safety barrier. Otherwise, repeat selection cable (8) adjustment procedure, by positioning lever (9) slightly inclined to the left instead of perpendicular. Verify that, after engaging the 5th gear, the distance between knob (1) and the dashboard is close to the prescribed distance of 70 mm. 6-speed gearbox unit (detail B, figure 2) Selection cable adjustment (8): -engage the 2nd gear; -move control lever (9) fully to the left, then verify that the distance between restraint quill ( d ) and reverse gear safety barrier ( C ) is 2 P 3 mm. Otherwise, place a spacer of 2 P 3 mm in between the above parts, open the adjusting device by lifting lock ring (6), bring lever (9) into contact with the spacer, and release lock ring (6). Engagement cable adjustment (4): Engage the 5th speed, then move the lever (9) forwards: under such condition, verify that the distance between knob (1) and the dashboard is ~ 70 mm. Otherwise, proceed as follows: -disconnect jointed head (4) from lever (3) (pull-out load: 100 N); -loosen nut (5); -properly rotate jointed head (4) until, at the aforesaid distance of 70 mm, jointed head (4) is aligned with the connecting ball pin; -lubricate jointed head (4) inside with MOLIKOTE 33 LIGHT or MOLIKOTE G 72 grease, then connect the head to lever (3) ball pin (pull-in load: 60 N); -tighten nut (5) to the prescribed torque so that the axis of jointed head (4) is aligned with the axis of lever (3) ball pin. Adjustment check Verify that all the gears can be engaged with no crawling. In particular: -verify that the 1st and 2nd gears can be engaged without problems (by pressing the clutch pedal, if possible), also by trying to engage them while keeping lever (9) slightly moved away from safety barrier ( C ) or by lifting quill (6) while going slightly further. If the gears can be engaged more easily after the above procedure is performed, you will have to act on the selection cable adjustment: -if gear engagement proves to be better when moving over barrier ( C ), adjust the cable by allowing for a greater distance between lever (9) and barrier ( C ); -if, on the contrary, gear engagement proves to be better when moving away from barrier ( C ), adjust the cable by allowing for a smaller distance between lever (9) and barrier ( C ); -verify that, when the 5th gear is engaged, the distance from the dashboard is not too far from the prescribed dimension (70 mm).

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Flexible cable replacement Removal 108850 Figure 3 Figure 4 Place the vehicle on a pit or auto lift. Act from under the vehicle to disconnect the jointed heads of: -selection cable (2, max. pull-out load: 250 N - max. pull-in load: 60 N) from lever (1); -engagement cable (4, max. pull-out load: 100 N - max. pull-in load: 80 N) from lever (1). Proceed as follows, by acting from inside the cab (see figure 4): -unscrew and remove knob (1); -remove protection boot (2); -remove the fastening screws, then take covering (3) off; -remove glove compartment (4); -remove the fastening screws, then take lower central covering (5) off. 108851 Act from the upper part of the gearbox unit and use a suitable screwdriver to open out flexible cable fins (6 and 7) so that the pawls are disengaged from bracket (5). 10 TRANSMISSION D AILY E URO 4 Base - March 2006 Print 603.93.651 GEAR CONTROL

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Figure 5 Figure 6 Figure 7 Disconnect the jointed heads of: -selection cable (2, max. pull-out load: 250 N - max. pull-in load: 60 N); -engagement cable (6, max. pull-out load: 100 N - max. pull-in load: 80 N) from levers (1 and 5). Use a suitable screwdriver to open out flexible cable fins (3 and 7) so that the pawls are disengaged from support (4). Reattachment is carried out by reversing the order of the detachment operations. Moreover, the following instructions shall be observed: -prior to assembling, lubricate the flexible cable (Bowden) jointed head connection points with MOLIKOTE 33 LIGHT or MOLIKOTE G72 grease; -tighten the nuts and screws to the prescribed torque; -adjust the gear control, as described in the respective chapter. Remove nuts (3) securing flange (2) to the cab floor, then take flexible cable assembly (1) out. Refitting Proceed as described in figures 5 and 6, by acting from inside the cab. Remove fastening screws (2), then take gear shift lever support (1) off the cab. Refitting 108852 108854 108853 GEAR SHIFT LEVER SUPPORT Removal -prior to assembling, lubricate the flexible cable (Bowden) jointed head connection points with MOLIKOTE 33 LIGHT or MOLIKOTE G72 grease; -tighten the nuts and screws to the prescribed torque; -adjust the gear control, as described in the respective chapter. TRANSMISSION 11 D AILY E URO 4 Print 603.93.651 Base - March 2006

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12 TRANSMISSION D AILY E URO 4 Base - March 2006 Print 603.93.651

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5 S 300 TRANSMISSIONS 13 D AILY E URO 4 Base - March 2006 Print 603.93.651 5 S 300 Transmissions Page GENERAL 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR SELECTION AND ENGAGEMENT CONTROL 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY DEVICES 17 . . . . . . . . . . . . . . . . . . . . . . . . -Engagement locking device 17 . . . . . . . . . . . . . . . -Reverse gear anti-engagement device 17 . . . . . . . SPECIFICATIONS AND DATA 18 . . . . . . . . . . . . . TIGHTENING TORQUES 20 . . . . . . . . . . . . . . . . . -Gearbox uonit 20 . . . . . . . . . . . . . . . . . . . . . . . . . -Gearbox control 21 . . . . . . . . . . . . . . . . . . . . . . . TOOLS 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING THE TRANSMISSION 28 . . . . . . -Gear control box 28 . . . . . . . . . . . . . . . . . . . . . . . -Disassembly 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Assembly 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Selection and adjustment tie-rod assembling 30 . . -Disassembling the transmission 31 . . . . . . . . . . . . -Disassembling the rear cover bearings 33 . . . . . . . -Disassembling the transmission bearings 33 . . . . . -Disassembling the main shaft 34 . . . . . . . . . . . . . . -Drive input shaft 36 . . . . . . . . . . . . . . . . . . . . . . . -Disassembling the transmission shaft 36 . . . . . . . . CHECKS 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Transmission 39 . . . . . . . . . . . . . . . . . . . . . . . . . . -Hubs - sliding sleeves - forks 39 . . . . . . . . . . . . . . -Bearings 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Shafts - gears 39 . . . . . . . . . . . . . . . . . . . . . . . . . . -Synchronizing devices 39 . . . . . . . . . . . . . . . . . . . -Mounting the transmission shaft 40 . . . . . . . . . . . . -Mounting the main shaft 40 . . . . . . . . . . . . . . . . . -Rods - forks - selector - driver 43 . . . . . . . . . . . . .

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14 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 Page -Disassembly-assembly 43 .................. -Mountingthetransmission 43 ................ -Adjustingthetransmissionshaftbearing endfloat 43 .............................

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The5S300transmissionismechanicalwithsynchronized engagementofforwardgears. Itiscomposedofalightalloybox(whichalsoservesasaclutch cover),arearcover(wherethespeedengagementcontrols andgearingarehoused)andacontrolbox. Thereisanopeningonthesideofthetransmissiontoapply apowertake-off. Drivetransmissionisaccomplishedbyasetofhelical-toothed constantmeshgears,forbothforwardandreversegears. Thesplinedormachinedgearsareonfourshafts:input,main, transmissionandreversegear. Thegearssplinedonthemainandreversegearshaftsidleon straightrollerbearings. Theinputandmainshaftsaresupported,inthetransmission, bywatertight,non-adjustableballbearings. Thetransmissionshaftissupported,inthetransmission,by taperedrollerbearingsthatcanbeadjustedaxiallybymeans ofringshims. Gearengagementsynchronizationisaccomplishedbymeans offreeringsynchronizingdeviceswithasingleconefor5 th -4 th -3 rd gears-R.G.anddualconefor1 st -2 nd gears. Control inside the transmission isaccomplishedwithfour rods: -amainrodtoselectandengagegears; -threerodsequippedwithforksforengaginggears. Theexternalcontrolisachievedbymeansoftwolevers: (selectionandengagementlevers).Theleversareactuatedby tie-rodsthroughatransfercase,connectedtothegearshift leverlocatedinthecab,byanassemblymadeupoftwo flexiblecables(BOWDENcables). The external engagement lever features two opposed weights, used to dampen the flexible control cable (BOWDEN)engagementthrustand,asaresult,itsnoise. Figure 1 108637 5S300TRANSMISSIONS 15 D AILY E URO 4 Base-March2006 Print603.93.651 GENERAL

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1.Gearengagementlever-2.Gearselectionlever-3.Driver-4.Gearselection/engagementcontrolrod-5.Selector-6.Driver-7.Rodfor3 rd /4 th gearengagementfork-8.Rodfor1 st /2 nd gearengagementfork-9.Rodfor5 th /reversegearengagementfork. Thecombinedactionoftheselection(2)andengagement(1)leversbringabouttherotationand/oraxialshiftoftherod(4)intwo successivestages,engagingthedesiredgearbymeansofoneoftherods(9,8or7). First Stage Dependingontheangularpositionoftheselectionlever(2),thedriver(3)(integralwithit)turnstheselector(5)withtherod(4) (connectedtogether),settingtheselectorontherodofthechosengear. Second Stage Dependingonthemovementgiventotheengagementlever(1),thedriver(3)(integralwithit)shiftstheselector(5)(already prepared)axiallywiththerod(4)andconsequentlyalsotheengagementrodofthechosengear. SECTION A-A SECTION A-A Thisarrangementisaccomplishedbyshiftingtheselection lever (2) anticlockwise by 7.1 ° tothecontrol axis,which correspondstoaclockwisechangeintheangleoftherod(4) of10 ° . 49373 49372 Figure 2 Position of transmission in neutral and/or ready to select 3 rd /4 th gear Thepositionofthetransmissioninneutralcoincideswith beingreadytoselect3 rd /4 th gear. Inthiscasetheverticalaxisoftheselectionlever(2)isexactly 90 ° fromthehorizontalcontrolaxis,correspondingtono changeintheangleoftherod(4). Ready for 1 st /2 nd gear Figure 3 16 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 GEAR SELECTION AND ENGAGEMENT CONTROL

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Thisdeviceiscomposedofaplate(8)andaspring(7)housedinthetransmission.Whenpassingfromthe4 th gearposition(Figure A)tothe5 th gearposition(FigureB),thedriver(9),movinginthedirectionofthearrow,disengagestheplate(8),whichunderthe actionofthespring(7)movesontothedriver(9)preventingreversegearfromgettingengagedintheoppositemanoeuvre. SECTION A-A 1.Gearengagementlever-2.Gearselectionlever-3.Driver-4.Gearselection/engagementcontrolrod-5.Selector-6.Driver-7.Rodfor3 rd /4 th gear engagementfork-8.Rodfor1 st /2 nd gearengagementfork -9.Rodfor5 th /reversegearengagementfork. Thisdeviceiscomposedofaplate(1),housedintherear cover,operatedbythegearselection/engagementcontrolrod (2). When selecting/engaging a gear, the rod (2) simultaneouslyturnstheplate(1)inwhichitisinserted.Inthis way,theplate(1)willfreeitselffromtheslotoftherod involvedinengagingthegearandwilllocktheothertworods byinsertingitselfintotheirslots. Above presetting is implemented by moving selector (2) clockwiseby7.1ºwithrespecttocontrolverticalaxis,that correspondsto10ºanticlockwiseangulardisplacementofrod (4). 49374 51381 Figure 4 Figure 5 Figure 6 SAFETY DEVICES The transmission is equipped with two mechanical safety devices: Engagementlockingdevicetopreventmorethanonegear gettingengagedatthesametime. Reversegearanti-engagementdevicewhenpassingfrom5 th to4 th gear. Engagement locking device 49375 Reverse gear anti-engagement device 5S300TRANSMISSIONS 17 D AILY E URO 4 Base-March2006 Print603.93.651 Ready to select 5 th /reverse gear

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18 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 SPECIFICATIONS AND DATA TRANSMISSION 5S300 Type Mechanical Inputtorque Nm 300 Weight kg 44.6 Speeds 5forwardspeeds 1reversespeed Speedcontrol Mechanical Powertake-off Optional Speedengagement: Forwardspeeds -5 th /4 th/ 3 nd Single-conesynchronizer -2 nd /1 st Dual-conesynchronizer Reversespeed Rapidshift Speedretentionmechanism Slidingsleevesretainedbypawlsandsprings. Gears Helical-toothedconstantmeshgears Gearratio First 5.00 Second 2.62 Third 1.54 Fourth 1.00 Fifth 0.78 Reverse 4.58 Shaftbearings: Mainshaft Straightrollerbearing watertightballbearing taperedroller

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5S300TRANSMISSIONS 19 D AILY E URO 4 Base-March2006 Print603.93.651 TRANSMISSION 5S300 Transmissionshaftbearingendplay: 0 ÷ 0.05mm Transmissionshaftbearingendplayadjustment byshims Shimthicknessfortransmission shaftbearing endplayadjustment 2.00-2.30-2.45 mm with0.05mmprogressivesequence Main shaft Assembly temperatures: slidingsleevehubs 2 nd and3 rd speedgearbushingsandspacer 5 th speedgearspacer 150 o C 170ºC ÷ 160ºC 90ºC Secondary shaft Assembly temperatures: bearings 5 th speedgear 5 th speedgeardrivingload 5 th speedgearremovingload 80ºC(max120ºC) 140ºC ÷ 170ºC 31KN 50KN 50KN Input shaft Assembly temperatures: frontbearing* 80ºC(max120ºC) Gearaxialbacklash: 1 st -3 rd -4 th -R-5 th speed 2 nd speed 0.15 ÷ 0.3mm 0.25 ÷ 0.4mm 3 rd and4 th speedslidingsleevehubretaining circlipaxialbacklash 0 ÷ 0.05mm 3 rd and4 th speedslidingsleevehubretaining circlipthickness 2-2.85mmwithprogressionof0.05mm Transmissionshaftrearbearingretainingring endfloat 0 ÷ 0.05mm Transmissionshaftrearbearingretainingring thickness 2.05 ÷ 2.45mm withprogressionof0.05mm 242 LOCTITEsealant 510 5206 Typeofoil: TUTELA TRUCK GEARLITE 2lit Quantity 2litres 18k 1.8kg *=Donotusehotairequipmenttoheatbearing.

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108855 Figure 7 Gearbox unit 20 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 Clutchhousing,screwtofastenclutchhousingtochassis 80 8 2 Screwtofastenclutchhousingtobox 23 ± 15% 2.3 ± 15% 3 Constantmeshshaftcoverfasteningscrew 23 ± 15% 2.3 ± 15% 4 Springretainingplug 32 ± 10% 3.2 ± 10% 5 Grubscrewsecuringgearselectionsectortorod 60 ± 15% 6 ± 15% 6** Screwsecuringp.t.o.sidecover 46 ± 15% 4.6 ± 15% 7 Plug 28 ÷ 30 ± 15% 2.8 ÷ 3 ± 15% 8 Screwsecuringreversegearshaft 22 ± 15% 2.2 ± 15% 9 Screwsecuringrearcover 23 ± 15% 2.3 ± 15% 10 Screwlockingsleevefortransmissioncouplingonmainshaft 120 ± 15% 12 ± 15% 11 D Screwsecuringballbearingretainingring 9.5 ± 15% 0.9 ± 15% 12 Screwsecuringcontrolcablebracket 23 ± 15% 2.3 ± 15% 13 Screwsecuringgearcontrolmounting 23 ± 15% 2.3 ± 15% 14 Nutforscrewsecuringlevertocontrolrod 34 ± 15% 3.4 ± 15% 15 Nutsecuringarticulationpintocontrollever 23 ± 15% 2.3 ± 15% 16 Nutforscrewsecuringlevertocontrolrod 34 ± 15% 3.4 ± 15% 17 Oilvapourbreather 10 ± 15% 1 ± 15% 18 Nuttosecurearticulationpintocontrollever 23 ± 15% 2.3 ± 15% * SpreadLOCTITE5206sealantonthecontactsurfaces D SpreadLOCTITE242onthethread ** SpreadLOCTITE510onthethread

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108856 Figure 8 Gearbox control 5S300TRANSMISSIONS 21 D AILY E URO 4 Base-March2006 Print603.93.651 0, TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 M8screwforgearboxcontrolsupportfastening 14 ± 17 1.4 ± 1.7 2 Nutsecuringthejointedheadstothecable 4 ± 4.8 0.4 ± 0.48 3 M8screwsecuringthetransfercasetothegearbox 21 ± 25 2.1 ± 2.5 4 M8self-lockingnutsecuringtheflangetothecab 3.5 0.35 5 Nutsecuringthejointedheadtothetie-rod 4 ± 4.5 0.4 ± 0.5 6 Platefasteningscrew 7.8 ± 9.25 0.78 ± 0.95 Aftertighteningnuts(4),thejointedheadholeaxisshallbealignedwiththeaxisoftheballpintowhichitisconnected.Aftertightening nuts(5),theverticalaxesoftie-rod(5)jointedheadsshallbealigned,withamaximumdeviationoflessthan α < 30 ˚ (lower).

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22 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99322205 Assembliesoverhaulrevolvingstand 99322225 Unitsupport(tousewithstand99322205) 99340205 Percussionextractor 99341002 Single-actingscaffold 99341003 Single-actingscaffold 99341004 Single-actingscaffold

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5S300TRANSMISSIONS 23 D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99341012 Pairofbrackets 99341015 Press 99341017 Coupleofbracketswhithole 99341019 Pairoftierodswithgrips 99341025 Grips 99345003 Extractorforgearboxfronthalf-casing

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24 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOLNO. DESCRIPTION 99348001 Extractorwithlockingdevice 99348004 Universalmaleextractorfrom5to70mm 99360521 Tooltoextractandinsertmainshaft,transmissionshaftand rod-forkassembly 99370006 Handleforinterchangeabledrivers 99370007 Handleforinterchangeabledrivers 99370234 Toolforfittingmainshaftinrearbearingandfittingoutputflange onmainshaft

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5S300TRANSMISSIONS 25 D AILY E URO 4 Base-March2006 Print603.93.651 TOOL TOOLNO. DESCRIPTION 99370317 Reactionleverwithextensionforholdingflange 99370629 Transmissionsupportduringremovalfromandrefittingtovehicle 99371057 Bracketforsupportinggearboxduringoverhaul (usewith99322205-99322225) 99374091 Punchforfittingbearingexternalraces(dia.55 ÷ 69mm) (usewith99370007) 99374452 Keyingdevicetofitgasketontransmissionrearcover (usewith99370006) 99374453 Keyingdevicetofitgasketontransmission

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26 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 Figure 9 75420 LONGITUDINALSECTION Figure 10 TRANSVERSESECTIONONTHEGEAR SELECTION/ENGAGEMENTROD POSITIONINGPUSHROD 47369 Figure 11 TRANSVERSESECTIONONTHEREVERSEGEAR ANTI-ENGAGEMENTDEVICE 47371

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49368 49364 Figure 12 Figure 13 TRANSVERSESECTIONONINTERNALCONTROLBOX SECTIONONGEARENGAGEMENTRODPOSITIONINGPAWLS 5S300TRANSMISSIONS 27 D AILY E URO 4 Base-March2006 Print603.93.651

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Removethepluganddrainoffthelubricatingoil. 108638 Figure 14 Figure 15 530220 Gear control box Disassembly Fitthegearbox(1)withthebracket99371057(4)andsecure this to the brackets 99322225 (3) on the rotary stand 99322205(2). Theusedoilmustbedisposedofaccordingtothelaw inforce. 51384 51383 Takeoutthefixingscrews(1)andremovethegearcontrolbox (2). Loosenthenuts(3)fortheretainingscrews(6). Extractthelevers(2and7)fromtheshafts(1and8)and extractthesefromthebox(5).Takeoffthecaps(4). Figure 16 Figure 17 Withapunch(3),removethespringpin(4)andextractthe shaft(2)fromtheinternallever(1). Repeatthesestepsfortheothershaft. Figure 18 108857 Taketie-rod(3)offbydisconnectingjointedheads(1)from levers(4and7). Taketie-rod(8)offbydisconnectingjointedheads(9)from levers(10and2). Tie-rods(3and8)areinterchangeable. NOTE Removescrews(5),thentaketransfercase(6)offthegearbox unit. 51385 28 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 530210 OVERHAULING THE TRANSMISSION

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Thoroughlycleanthematingsurfacesofthegearcontrolbox (2)andapplyLOCTITE5206sealantonthem. Fitthebox(2)onthetransmission,takingcarethatthelevers andshaftsarepositionedcorrectlyintheirrespectiveseats. Tightenthescrews(1)totherequiredtorque. 51388 51390 87896 51391 Figure 21 Figure 22 Figure 23 Figure 24 Usingasuitablepunch,mounttheO-rings(1)inthebox(2), positioningthemattheheightshown. PackthegapbetweentheO-ringandrollerbearingwithgrease. Mount the selection and engagement levers (1) on their respectiveshafts(2)andfastenthemwiththespringpins(3). Lubricatetherollerbearings(1,Figure19)withTUTELAMR3 greaseandmounttheshafts(3and6)completewiththe internallevers(4and5)inthebox(2).Mountthecaps(8and 9)andlevers(1and10)ontheshafts(3and6)tighteningthe nutsforthefixingscrew(7). Thespringpin(3)mustbepositionedwiththecut horizontal. Fit spring peg (4), with cutting edge positionedat180 ° fromspringpeg(3)cuttingedge, inspringpeg(3)engagementlever. NOTE 51386 51387 Figure 19 Figure 20 Useapunchonthepointshownbythearrowandejectthe O-ringsandrollerbushes(2)fromthebox(1). Assembly Thoroughlycleantheoilvapourvent(3). Withasuitablepunch,mounttherollerbearings(1)inthebox (2). 5S300TRANSMISSIONS 29 D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 25 Figure 26 Figure 27 Figure 28 Fittransfercase(1)intoplace,bytighteningfasteningscrews (2)totheprescribedtorque. Selection and adjustment tie-rod assembling Verifythatthetie-rod(4)length”X”,asmeasuredbetween thejointedheadcentresisnotgreaterthan342mm. LubricatethejointedheadinsidewithMOLIKOTE33LIGHT orMOLIKOTEG72grease,thenconnectthejointedheads tolevers(1and5). Measurethedistance”y”betweentransfercase(3)outer surfaceandballpin(6)centre:itshallbe”y”=146±1mm. Otherwise,loosennuts(2)andproperlyrotatetie-rod(4) untiltheprescribeddistanceisobtained.Thentightennuts(2) totheprescribedtorque,sothattheverticalaxesofthe jointedheadsarealigned,withamaximumdeviationofless than30 ˚ (lower). Verifythatspring(3)endscomeintocontactwithselection lever(4)orareatleast1mmwithinthesame.Otherwise, loosenscrew(1)sothatspring(3)iscorrectlypositioned,due toplate(2)beingreleased. 108858 108859 108860 108861 Verifythatthetie-rod(4)length”X”,asmeasuredbetween thejointedheadcentresisnotgreaterthan342mm. LubricatethejointedheadinsidewithMOLIKOTE33LIGHT orMOLIKOTEG72grease,thenconnectthejointedheads tolevers(1and5). Measurethedistance”y”betweentransfercase(3)outer surfaceandballpin(6)centre:itshallbe”y”=180±1mm. Otherwise,loosennuts(2)andproperlyrotatetie-rod(4) untiltheprescribeddistanceisobtained.Thentightennuts(2) totheprescribedtorque,sothattheverticalaxesofthe jointedheadsarealigned,withamaximumdeviationofless than30 ˚ (lower). 30 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 51393 74956 74955 51396 51397 51398 Dismantle the gear control box as described under the relevantheading. Removethereversegearstopplate(2)andthespring(1). Block rotation of the sleeve (1) by applying the lever 99370317(3).Withthebushing(2)removethescrew(5) withthewasherbeneath(4). Takeoutthelever99370317(3). Applythebridge99341003(1)andclamps99341017(2) ontothesleeve(3). Extractthesleeve(3)fromthemainshaft. Removethescrews(1)andtakeoffthecover(2)protecting theinputshaft(3). DrilltheO-ring(2). Usingasuitablehookandextractor(1),removetheO-ring(2) fromthetransmission. Removethecirclip(2)retainingthefrontbearing(3)fromthe inputshaft(1). 5S300TRANSMISSIONS 31 D AILY E URO 4 Base-March2006 Print603.93.651 Disassembling the transmission

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Figure 35 Figure 37 Figure 38 Mountthetool99360521(3)ontotherods(4,5and6),on theinputshaft(1)andonthetransmissionshaft(10).Secure thetool99360521(3)ontheinputshaft(1)withtheretaining ring(2)andwiththescrew(9)tothetransmissionshaft(10). Hookthetool99360521(3)ontothelift.Applytheextractor composedofthebridge99341004(13)andties99341012 (12)ontotherearcover(7).Usethescrewofthebridge(13) andworkonthelifttoextractthemainshaft(11)fromthe rearbearing.Setthisassemblyontheworkbench.Removethe tool99360521(3)andseparatethetransmissionshaft(10), inputshaftwithrelativesynchronizingringandtherods(4,5 and6)fromthemainshaft. Takeouttheplugwiththewasher(1),extractthesprings(2 and3)andthepushrod(4).Removethescrew(6)securing thereversegearshafttothetransmission(5).Pushthetwo centring pins (7) downwards to free them from the transmission(5).Removethescrews(8)securingtherear cover(9)tothetransmission(5). 51399 74957 51402 74959 Fitthedriveinputshaft(1)withtool99345003(2)andsecure thistothegearbox(4)withscrews(3).Screwdownthescrew (5)ofthetool(2)toextractthegearboxfromthebearing(6). InsertanAllenwrench(2)intotheengagementlockingplate (5).TurntheAllenwrench(2)topositiontheengagement lockingplate(5)outsidetheslots( ⇒ )intheengagementrods (1,3and4). 74965 Takeoutthescrew(3)andextracttheshaft(1)fromtherear cover(4).Removethereversegear(2).Drillthecups(10) screwaspecialscrewintothem;withtheaidofthescrew, extractthecups(10)fromtherearcover(4).Removethe springs(9)andthepawls(8).Extracttherod(7)togetherwith theselector(5)anddriver(6). Figure 36 Figure 39 32 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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51404 51406 74960 74961 51409 Figure 40 Figure 41 Figure 42 Figure 44 Figure 45 Removethescrews(2)securingtheplates(3). Takeouttheplates(3)andtheengagementlockingplate(1). Usinguniversalextractor99348004(1),removetheouter ring(2)ofthetransmissionshaftbearing. Using the percussion extractor 99340205 (1) and part 99348004(2),extractthebushingwiththeballbearings(3). Turnovertherearcover(3).TakeouttheO-ring(1)andthe ”phonicwheel”(2).Usingasuitablepunch,removetheball bearing(4,Figure36).Removethetachographsensor(5)and thereversinglightswitch(4). Disassembling the transmission bearings Usinguniversalextractor99348004(1),removetheouter ring(2)ofthetransmissionshaftbearing. Using the percussion extractor 99340205 (1) and part 99348004(2),extractthebushingwiththeballbearings(3). 74962 Figure 43 5S300TRANSMISSIONS 33 D AILY E URO 4 Base-March2006 Print603.93.651 Disassembling the rear cover bearings

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51410 51412 51411 51413 51414 51415 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Removethescrews(1)securingtheplates(2). Takeouttheplates(2). Turnoverthetransmission. Usingasuitablepunch,removetheballbearing(1). Using the percussion extractor 99340205 (1) and part 99348004(2),extracttherollerbearing(3). Clampthemainshaft(1)inavice.Removetherollerbearing (2)andthesynchronizerring(3).Removetheslidingsleeve (6)forengaging3 rd -4 th gearfromthehub(5)and,takingcare astheplugs(8)comeoutwiththeirrelativeballs(9)and springs(7),recoverthem. Removetheretainingring(4,Figure44).Extractthehub(2) withtheextractor99348001(1). Removethesynchronizerring(1),3 rd gear(2)androller bearing(3). Disassembling the main shaft Markthe assembly positionof eachsynchronizing deviceontherespectivegears. NOTE 34 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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Usingthebridge99341003(1),ties99341012(2)andclamp 99341015(3),extractthe1 st gear(6),withthesynchronizer ring(7),middlering(8)andring(9),hub(5)andbushing(4). Removetherollerbearing(10). Usingbridge99341003(1),screwstays99341019(2),grips 99341025(4)andclamp99341015(3),takeoutthe2 nd gear (7),spacer(6)andbushing(5). 76010 51418 51417 51419 51420 51421 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Takeoutthesynchronizerring(4),middlering(3),ring(2)and rollerbearing(1). Removethesleeve(2)forengaging1 st -2 nd gearfromthehub (1)and,takingcareastheplugs(5)comeoutwiththeirrelative balls(3)andsprings(4),recoverthem. Turnoverthemainshaft(1).Takeoutthespacerring(2)and removethe5 th gear(3). Removethehalfrollerbearings(1),thesynchronizerring(3) andtheretainingring(4)holdingthehub(2). Forceofextractionofthebushing(4)40kN. NOTE Forceofextractionofthebushing(4)40kN. NOTE 5S300TRANSMISSIONS 35 D AILY E URO 4 Base-March2006 Print603.93.651

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Ifthecog-wheel(2)oftheinputshaftgear(1)showsanysign of damage, take out the retaining ring (3), replace the cog-wheel(2)andrefittheretainingring(3). Disassembling the transmission shaft Ifthecog-wheel(2)ofthe5 th gear(1)showsanysignof damage,takeouttheretainingring(3),replacethecog-wheel (2)andrefittheretainingring(3). Drive input shaft 75416 51424 51423 51425 51426 51427 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Usingthebridge99341003(1),ties99341012(2)andclamp 99341015 (3), extract the reverse gear (5) and the synchronizerassembly(4). Removetherollerbearing(1). Removetheslidingsleeve(2)forengagingreverse-5 th gear fromthehub(1),takingcareastheplugs(3)comeoutwith theirrelativeballs(4)andsprings(5),recoverthem. Takeouttheretainingring(1)andextracttheinternalring(2) oftherearbearing.Turnovertheshaft(3)andextractthe internalring(4)ofthefrontbearing. Shaft(3)gear(5)removal,ifrequired,shallbeperformedby hydraulicpress;50kNremovingload. 5 36 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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51428 76011 51430 Figure 64 Figure 65 Figure 66 INPUTSHAFTASSEMBLYDRAWING MAINSHAFTASSEMBLYDRAWING TRANSMISSIONSHAFTASSEMBLYDRAWING 5S300TRANSMISSIONS 37 D AILY E URO 4 Base-March2006 Print603.93.651

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51431 75414 Figure 67 Figure 68 1 st -2 nd GEARDUALCONESYNCHRONIZERASSEMBLY 3 rd -4 th -5 th GEARSINGLECONESYNCHRONIZERASSEMBLY 38 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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3 rd -4 th GEARSYNCHRONIZERS A.Synchronizationreserve 3 rd -4 th gear 1.15+0.2mm B.3 rd -4 th gearreleaseclearance1.40+0.65mm Transmission Thetransmissionandrelativecoversmustshownosignof cracking. Thematingsurfacesofthecoversandtransmissionmustnot bedamagedordeformed.Removeanyremainsofsealant fromthem. Theseatsofthebearings,reversegearshaftandgearcontrol rodsmustbeneitherdamagednortooworn. Hubs - sliding sleeves - forks Thegroovesonthehubsandrelativeslidingsleevesmustnot bedamaged.Theslidingsleevemustrunfreelyonthehub.The plugs and balls for positioning the sliding sleeve must be neitherdamagednorworn.Thetoothingoftheslidingsleeves mustnotbedamaged.Theforksmustbesoundwithanend float,intheradialgrooveofthesleeve,nogreaterthan1mm. Bearings Therollerbearingsmustbeinperfectconditionwithnosigns ofwearoroverheating.Theymustonlyberemovediftheyare tobereplaced. 87897 Figure 69 1 st -2 nd GEARSYNCHRONIZERS A.Synchronizationreserve 1 st -2 nd gear 1.4 mm B.1 st -2 nd gearreleaseclearance 0.9 mm 1.Slidingsleeve-2.1 st gearcog-wheel-3.Synchronizerring-4.Middlering-5.Ring-6.Hub-7.2 nd gearcog-wheel-8.3 rd gearcog-wheel-9.4 th gearcog-wheel-10.Reversegear-11.5 th gearcog-wheel Shafts - gears Theseatsontheshafts,forbearings,mustbeneitherdamaged norworn.Thetoothingofthegearsmustbeneitherdamaged norworn. Synchronizing devices Check the wear on the synchronizer rings (3, Figure70) proceedingasfollows: -position the synchronizer ring (3) on the respective cog-wheel(2,7,8,9and11,Figure70); -turnthesynchronizerringsoastoensurecorrectcoupling onthetaperedsurfaceofthecog-wheelofthegear. -With a feeler gauge, check the distance A on two diametricallyoppositepoints. Iftheaveragemeasuredvalue A islessthan0.5mm, replacethesynchronizerring. Forceofslidingofslidingsleeves80 ÷ 95Nm. Maximumadmittedwearonthesynchronizers,distance A -0,5mm 5 th GEARSYNCHRONIZER A.Synchronizationreserve 5 th gear 1.15+0.2mm B.5 th gearreleaseclearance 1.10+0.4mm After this check, the synchronizer rings must be markedontheirrespectivegearstoavoidswapping theirpositionsoverwhenassembling. NOTE +0,25 -0.35 +0,6 -0.35 5S300TRANSMISSIONS 39 D AILY E URO 4 Base-March2006 Print603.93.651 CHECKS

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Gear(5)fittingonshaft(3),ifrequired,shallbeperformedby hydraulicpressafterheatingthegearto140 ° C ÷ 170 ° C; 31kNdrivingload. Heattheinternalrings(2and4)ofthetaperedrollerbearings toatemperatureofapprox. ~ 80 ° Cand,withasuitable punch(1),mountthemonthetransmissionshaft(3). Mounttheretainingring(1)whosethicknessgivesanendfloat wheninitsseatof0 ÷ 0.05mm. Mountthesynchronizerringsontheirrespectivegears accordingtothemarksmadeduringdisassemblyor whencheckinginthecaseofreplacement. 51433 75417 51434 75418 51437 51438 Figure 70 Figure 71 Figure 72 Figure 73 Figure 74 Figure 75 Tightenthemainshaft(1)inaviceandmountonit:theroller cage(2),reversegear(4)andsynchronizerring(3). Heatthehub(2)forthe5 th -reversegearengagementsliding sleevetoatemperaturenohigherthan150 ° Candmountit onthemainshaftwithasuitablepunch(1). Mounttheretainingring(1)whosethicknessmakesfornull clearanceinitsseat. Checktheendfloatofthereversegear(2).Itshouldbe 0.15 ÷ 0.3 mm. Mounttheslidingsleeve(5)onthehub(4)facingasshown inthefigure. Putthesprings(3),plugs(1)andballs(2)intotheseatsofthe hub(4),settlingthemundertheslidingsleeve. Mounting the main shaft 5 Whenfitting,makesurethattheprojectingparts(3) ofthesynchronizerringgetpositionedinthehub(2) correctly. NOTE NOTE 40 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651 Mounting the transmission shaft

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Mountthe1 st gear(1). Lubricatethering(4),middlering(3),synchronizerring(2) withTUTELAMR3greaseandmountthemonthegear(1). Heatthehub(1)forthe1 st -2 nd gearslidingsleevetoa temperaturenohigherthan150 ° Candmountitonthemain shaftwithasuitablepunch. Makesurethetonguesoftherings(2and3)are positionedcorrectlyintheirrespectiveseats. 51439 51440 51420 51441 51442 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Positioning the synchronizer ring (2) and the half roller bearings(1). Installthe5 th speedgear(3). Heatspacerring(2)to90 ° Candinstallit. Upsetthemainshaft(1). Positiontherollerbearing(2)onthemainshaft(1). Whenassembling,makesurethetonguesoftherings (3 and 4, Figure79) and the projections of the synchronizerring(2)arepositionedcorrectlyinthe hub(1).Checkthattheendfloatofthe1 st gear(3) is0.15 ÷ 0.30mm. NOTE NOTE 5S300TRANSMISSIONS 41 D AILY E URO 4 Base-March2006 Print603.93.651

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51443 51417 51445 51446 Figure 81 Figure 82 Figure 83 Figure 84 Heatthebushing(2)toatemperaturenohigherthan170 ° C andmountitonthemainshaft(1). Mounttheslidingsleeve(4)onthehub(3). Put(3)thesprings(7),plugs(5)andballs(6)intotheseatsin thehub,settlingthemundertheslidingsleeve(4). Lubricatethesynchronizerring(4),middlering(3)andthering (2)withTUTELAMR3grease. Mounttherollerbearing(1). Mountthe2 nd gear(4). Heatthespacer(3)toatemperaturenohigherthan170 ° C andmountitonthemainshaft(1). Check the end float of the 2nd gear (4). It should be 0.15 ÷ 0.30mm. Heatthebushing(2)toatemperaturenohigherthan170 ° C andmountitonthemainshaft(1). Mounttherollerbearing(1)andthe3 rd gear(3).Positionthe synchronizerring(2)onthe3 rd gear(3). Makesurethetonguesoftherings(2-3)andthe projections of the synchronizer ring (4) are positionedcorrectlyintheirrespectiveseats. NOTE 42 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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Toreplacetheforksoftheselectoranddriverfromtheir respectivecontrolrodsitissufficienttoremovetheretaining springpinswithasuitablepunch. Forassembly,carryoutthesestepsinreverseorder,replacing thespringpins. Duringassembly,thegaskets,retainingrings,O-rings, springpins,safetyplatesandspringsmustalwaysbe replacedwithnewparts. 51447 51413 51449 Figure 85 Figure 86 Figure 87 Figure 88 Heatthehub(2)toatemperaturenohigherthan150 ° Cand mountitonthemainshaft(1)checkingthattheprojections (3) of the synchronizer ring are positioned in the compartmentsofthehub(2). Mounttheretainerring(4)whosethicknessdeterminesan endfloatinitsseatof0 ÷ 0.05mm. Check the end float of the 3 rd gear (5). It should be 0.15 ÷ 0.30mm. Mounttheslidingsleeve(6)onthehub(5).Putthesprings(7), plugs(8)andballs(9)intotheseatsinthehub(5),settling themundertheslidingsleeve(6). Greasetherollerbearing(2)andfititonthemainshaft(1). Positionthesynchronizerbearing(3)onthehub(5). Rods - forks - selector - driver Disassembly - assembly Determinethethickness S ofthering(1)foradjustingthe transmissionshaftbearing(2)endfloat,proceedingasfollows: -measure the distance A between the end of the transmission(3)andtheseatoftheringofthefront bearing(2); Adjusting the transmission shaft bearing end float 51450 Springpegsmustbepositionedwiththecuttingedge placedlevel. Mounting the transmission NOTE The nuts and screws must be tightened to the required torqueunlessspecifiedotherwise,withthethreaddryand greased. NOTE 5S300TRANSMISSIONS 43 D AILY E URO 4 Base-March2006 Print603.93.651

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-mounttheinternalrings(2-4)ofthetaperedroller bearingsonthetransmissionshaft(5); -positiontheexternalrings(1-3)ontheinternalones (2-4); -applyaload F of100 ÷ 120Nontheexternalrings(1-3). -Intheseconditions,measurethedistance C betweenthe endsoftherings(1-3). -Thethickness S ofthebearingendfloatadjustmentring isgivenby: 51451 51452A 41452 51453 Figure 89 Figure 90 Figure 91 Figure 92 -measurethedistance B betweentheendoftherear cover(1)andtheseatoftheringoftherearbearing; Position the adjustment ring (1, Figure88) of the thickness determinedwiththeabovemeasurementinthetransmission(1). Heatthebearingseatsofthebox(1)toatemperatureof approx.80 ° Candmount: -theexternalring(6)ofthefronttaperedrollerbearing withpunch99374091andgrip99370007; -theballbearing(7)withageneralpunch; -thebushingwithballbearing(4)andtherollerbearing(5) withageneralpunch. Positiontheretainingplates(3)andsecurethemtothebox, tighteningthescrews(2)totherequiredtorque. Heatthebearingseatsofthebox(1)toatemperatureof approx.80ºCandmount: -theexternalring(7)ofthetaperedrollerbearingwith punch99374091andgrip99370007; -theballbearing(4)andthebushingwithballbearings(2) withageneralpunch. Positiontheretainingplates(6)andtheengagementlocking plate(3)intheirseats. Securethesetothebox,tighteningthescrews(5)tothe requiredtorque. S = A + B − C − 0,10 Where: A-B-Carethemeasuredvalues 0.10 = constant value, including the deformation of the externalrings(1-3)afterdrivingthemintotheirseatsandthe endfloatofthebearingsof0.05mm. ApplyLOCTITE242ontothethreadofthescrews (2,Figure91and5,Figure92). NOTE 44 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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51454 74963 74964 74965 Figure 93 Figure 94 Figure 95 Figure 96 Clampthemainshaftinavice. Mounttheinputshaft(8)onthemainshaft(4)andcouplethis withthetransmissionshaft(5). Fittool99360521(6)onshafts(8and5)andtieittoinput shaft(8)bycirclip(9)andtosecondaryshaft(5)byscrew(7). Setforksandrodsthereof(1-2-3)onslidingsleevesandtie bytool99360521sleeves(6). Hookthehoistontotool99360521(1).Lifttheassembly(2) asputtogetherbeforehandandmountitintherearcover(3). Duringthisoperation,checkthattheoutputshaft(7)goesinto thesupportingballbearingandthecontrolrods(4-5-6)go intotheirrespectiveseats. Setproperlyclutchlockingplate(5)bysetscrewwrench(2)to avoidcontrolrods(1-3-4)interferencewithplateduringnext operation. Screwthepin(11)oftool99370234intotheholeintheoutput shaft(6).Mountthebushing(8)andspacer(9)onthetool 99370234. Screwonthenut(10)andatthesametimelowerthehoistso theoutputshaft(6)ispositionedontheballbearing(7). Removethetool99360521andtheparts(8-9-10-11)of thetool99370234. Mounttherod(7)completewithselector(5)anddriver(6). Putthepawls(8)andsprings(9)intotherearcover(4). Mountthecups(10). Mountthereversegearidler(2)withtheshaft(1)andsecure theshafttotherearcover(4)tighteningthescrew(3)tothe requiredtorque. ApplyLOCTITE5206sealanttothematingsurfacesofthe transmission. 5S300TRANSMISSIONS 45 D AILY E URO 4 Base-March2006 Print603.93.651

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74966 51459 51398 51461 51396 Figure 97 Figure 98 Figure 99 Figure 100 Figure 101 Warmuptherollerbearinginnerring( → )at80 ° Candfitthe gearbox(1)ontherearcoverandcheckthattheshaftsand thecontrolrodsfitcorrectlyintherespectiveseats. Insertthecentringpins( ⇒ )intherearcover(5). Screwonthescrews(11)fixingtherearcover(5)tothe transmission(3)andtightenthemtotherequiredtorque. Tightenthescrew(4)fixingthereversegearidlershafttothe transmission(3)totherequiredtorque. Insertthepushrod(6)andsprings(7-8)andtightentheplug (10)withanewgasket(9)totherequiredtorque. Ifthesidecover(1)hasbeenremoved,applyLOCTITE5206 sealantonthematingsurfaceandtightenthescrews(2)tothe requiredtighteningtorque. Mountthefrontbearing(3)retainingring(2)ontheinputshaft (1). MounttheO-ring(2)withthekey99374453(1). Mountinputshaft(3)protectioncover(2)andtightenscrews (1)totherequiredtorque. 46 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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Mountthewasher(3)andscrewonthescrew(4). Locktherotationoftheflange(1)withthelever99370317 (2)andtightenthescrew(4)totherequiredtorque. Mountthecontrolboxasdescribedundertherelevantheading. Fillthetransmissionwithlubricatingoilintherequiredquantity andgrade. 74967 74969 74968 74970 Figure 102 Figure 103 Figure 104 Figure 105 Mountthephonicwheel(2)ontothemainshaft(3). Mount the reversing light switch (4) and the tachograph sensor(1). MounttheO-ring(3)intherearcover(4)withthekey 99374452(1)andthegrip99370007(2). Mounttheoutputflange(1)onthemainshaftwiththetool 99370234(2). Removethetool99370234(2). 5S300TRANSMISSIONS 47 D AILY E URO 4 Base-March2006 Print603.93.651

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48 5S300TRANSMISSIONS D AILY E URO 4 Base-March2006 Print603.93.651

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6S400O.D.TRANSMISSION 49 D AILY E URO 4 Base-March2006 Print603.93.651 Print603.43.351 6 S 400 O.D. Transmission Page GENERAL 51 .............................. GEARSELECTIONANDENGAGEMENT 52 ..... SPECIFICATIONSANDDATA 54 ............. TIGHTENINGTORQUES 56 ................. -Gearcontrolbox 57 ....................... TOOLS 58 ................................ OVERHAULINGTHETRANSMISSION 66 ....... -Gearcontrolbox 66 ....................... -Disassembly 66 ........................... -Assembly 67 ............................. -Selectionandadjustmenttie-rodassembling 68 .. -Disassemblingthetransmission 69 ............ -Disassemblingtherearcoverbearings 72 ....... -Disassemblingthetransmissionbearings 73 ..... -Disassemblingthemainshaft 73 .............. -Disassemblingthedriveinputshaft 75 ......... -Disassemblingthetransmissionshaft 75 ........ CHECKS 79 ............................... -Transmission 79 .......................... -Hubs-slidingsleeves-forks 79 .............. -Bearings 79 .............................. -Shafts-gears 79 .......................... -Synchronizingdevices 79 ................... -Mountingthetransmissionshaft 81 ............ -Mountingthemainshaft 82 ................. -Rods-forks-selector-driver 85 ............. -Disassembly-assembly 85 .................. -Mountingthetransmission 85 ................ -Adjustingthetransmissionshaftbearing endfloat 85

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50 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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The6S400O.D.transmissionismechanicalwithsynchronized engagementofforwardgears. Itiscomposedofalightalloybox(whichalsoservesasaclutch cover),arearcover(wherethespeedengagementcontrols andgearingarehoused)andacontrolbox. Thereisanopeningonthesideofthetransmissiontoapply apowertake-off. Drivetransmissionisaccomplishedbyasetofhelical-toothed constantmeshgears,forbothforwardandreversegears. Thesplinedormachinedgearsareonfourshafts:input,main, transmissionandreversegear. Theinputandmainshaftsaresupported,inthetransmission, bywatertight,non-adjustableballbearings. Thetransmissionshaftissupported,inthetransmission,by rollerbearingsthatcanbeadjustedaxiallybymeansofring shims. 6 th ,5 th ,4 th ,3 rd andreversegears(newversiontransmissions) aresynchronisedbymeansofsingletaperfreesynchroniser rings;doubletaperwheelsareusedfor1 st and2 nd gear. Controlinsidethetransmissionisaccomplishedwithfiverods: amainrodtoselectandengagegears;fourrodsequippedwith forksforengaginggears. Theexternalcontrolisachievedbymeansoftwolevers: (selectionandengagementlevers).Theleversareactuatedby tie-rodsthroughatransfercase,connectedtothegearshift leverlocatedinthecab,byanassemblymadeupoftwo flexiblecables(BOWDENcables). The external engagement lever features two opposed weights, used to dampen the flexible control cable (BOWDEN)engagementthrustand,asaresult,itsnoise. Figure 1 108639 6S400O.D.TRANSMISSION 51 D AILY E URO 4 Base-March2006 Print603.93.651 GENERAL

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84147 84148 Thecombinedactionoftheselectorlever(2)andtheengagementlever(1)causetherotationandaxialmovementoftherod(4) intwosubsequentstepstoengagetherequiredgearbymeansoftherods(8-7-6and9). Neutral arrangement and/or 3 rd /4 th gear selection and engagement arrangement 3 rd /4 th gear selection Accordingtotheangularpositionoftheselectorlever(2),the slider(3)turnswiththerod(4)(whichisintegral)andthe selector(5)arrangestheslideronthe3 rd /4 th gearrod(9).At thesametime,theslider(3)movestherod(10)toprevent thesimultaneousengagementoftwogears,tokeepthe3 rd and 4 th gear engagement rod (9) free and to prevent movementoftheotherrodsbyengagingthegroovesinthe rods. 3 rd /4 th gear engagement Accordingtothemovementoftheengagementlever(1),the slider (3) axial movesthe rod(4) (whichisintegral),the selector (5) (previously arranged) and consequently the chosen3 rd and4 th gearengagementrod(9). Neutral position coincides with the 3 rd /4 th gear selection arrangement. Inthiscase,theverticalaxisoftheselectorlever(2)isexactly at 90 ° with respect to the horizontal axisof the control correspondingtonoangularvariationoftherod(4). Thisarrangementisobtainedbymovingtheselectorlever(2) anticlockwise.Inthisway,theselector(4)isinsertedinthe 1 st /2 nd gearengagementrod(5). Bymovingthelever(1),theslider(3)willaxiallymovethe 1 st /2 nd gearengagementrod(5). 1 st/ 3 rd gear selection election and engagement arrangement Figure 2 Figure 3 52 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 GEAR SELECTION AND ENGAGEMENT

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84149 84150 5 th /6 th gear selection and engagement arrangement Thisarrangementisobtainedbymovingtheselectorlever(2) clockwise.Inthisway,theselector(4)isinsertedinthe5 th /6 th gearengagementrod(5). Bymovingthelever(1),theslider(3)willaxiallymovethe 5 th /6 th gearengagementrod. Thisarrangementisobtainedbymovingtheselectorlever(2) anticlockwise.Inthisway,theselector(4)isinsertedinthere-versegearengagementrod(5). Bymovingthelever(1),theslider(3)willaxiallymovethere-versegearengagementrod(5). Safety device Thetransmissionisequippedwithadevicewhichpreventsthe simultaneousengagementoftwogears. Itconsistsofasuitablyshapedrod(6)fittedtransversallyinthe transmissionbox. Theslider(3),movestherod(6)undertheactionofthelever (2).Thiskeepstheselectedgearengagementrodfreeand prevents movement of the other gears by engaging their respectivegrooves. Reverse gear selection and engagement arrangement Figure 4 Figure 5 SECTION A-A SECTION A-A 6S400O.D.TRANSMISSION 53 D AILY E URO 4 Base-March2006 Print603.93.651

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54 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 Print603.43.351/D SPECIFICATIONS AND DATA TRANSMISSION 6S400O.D. Type Mechanical Inputtorque 400Nm Weight 63kg Speeds 6forwardspeeds 1reversespeed Speedcontrol Mechanical Powertake-off Optional Speedengagement: Forwardspeeds -5 th /6 th -3 rd /4 th Single-conesynchronizer -1 st /2 nd Dual-conesynchronizer Reversespeed clip-on,innewversiontransmissionwith singletapersynchroniserring Speedretentionmechanism Slidingsleevesretainedbypawlsandsprings. Gears Helical-toothedconstantmeshgears Gearratio First 5.375 Second 3.154 Third 2.041 Fourth 1.365 Fifth 1 Fifth 0.791 Reverse 4.838 Shaftbearings: Mainshaft Straightrollerbearing watertightballbearing taperedroller O.D..=OverDrive

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6S400O.D.TRANSMISSION 55 D AILY E URO 4 Base-March2006 Print603.93.651 SPECIFICATIONS AND DATA Transmissionshaftbearingendplay 0 ÷ -0.05mm Transmissionshaftbearingendplayadjustment byshims Shimthicknessfortransmission shaftbearing endplayadjustment -Main shaft Temperatureforfitting: -hubsforslidingsleeves 80 ° ÷ 110 o C -1 st -Rgearbushesandgear 110 ° ÷ 150 o C -frontbearing* 90 ° ÷ 110 o C Transmission shaft Temperatureforfitting: -bearings 80 ° C(max120 o C) -5 th -4 th gears 170 ° ÷ 160 o C Gearendfloat: 1 st -3 rd -4 th -R-5 th gear 2 nd gear 0.15 ÷ 0.40mm 0.25 ÷ 0.5mm 5 th -4 th gearslidingsleevehubretaining ringendfloat 0 ÷ -0.15mm 5 th -4 th gearslidingsleevehubretaining ringthickness -Retainingringendfloat: -transmissionshaftfrontbearing 0 ÷ -0.1mm -mainshaftrollerbearing 0 ÷ -0.1mm Transmissionshaftrearbearingretaining ringthickness -LOCTITE510 Sealant LOCTITE242 LOCTITE5206 Typeofoil: TUTELA TRUCK GEARLITE Quantity 2.2litres *=Donotusehotairequipmenttoheatbearing.

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108862 Figure 6 56 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 Plugretainingspringandreversegearhardeningpushrod 32 ± 10% 3.2 ± 10% 2 M22x1.5plug 50 5 3 D 3rdand4thgearforkarticulationpins 45 D 4.5 4 Plugsforrodpreventinggearengagement 32 3.2 5 Clutchhousing,screwtofastenclutchhousingtocrankcase 80 8 6 Constantmeshshaftcoverfasteningscrew 23 ± 15% 2.3 ± 15% 7 J Screwsecuringp.t.o.sidecover 46 ± 15% 4.6 ± 15% 8 Screwsecuringreversegearshaft 23 ± 15% 2.3 ± 15% 9 Sideplugonrearcover 35 3.5 10 Screwsecuringrearcover 23 ± 15% 2.3 ± 15% 11 Speedometertransmitterfixing 50 5 12 Screwlockingsleevefortransmissioncouplingonmainshaft 235 23.5 13 Fixingswitchesandreversinglights 40 4 14 D Screwsecuringballbearingretainingring 9.5 ± 15% 0.9 ± 15% 15 Nutforscrewsecuringlevertocontrolrod 34 ± 15% 3.4 ± 15% 16 Screwsecuringgearcontrolmounting 23 ± 15% 2.3 ± 15% 17 Oilvapourbreather 10 ± 15% 1 ± 15% 18 D Screwsecuringdrivertomainrod 9.5 D 0.9 19 D 5thand6thgearforkarticulationpins 45 4.5 : SpreadLOCTITE5206sealantonthecontactsurfaces F SpreadLOCTITE242onthethread J SpreadLOCTITE510onthethread

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108856 Figure 7 Gearbox control 6S400O.D.TRANSMISSION 57 D AILY E URO 4 Base-March2006 Print603.93.651 0, TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 M8screwforgearboxcontrolsupportfastening 14 ± 17 1,4 ± 1,7 2 Nutsecuringthejointedheadstothecable 4 ± 4,8 0,4 ± 0,48 3 M8screwsecuringthetransfercasetothegearbox 21 ± 25 2,1 ± 2,5 4 M8self-lockingnutsecuringtheflangetothecab 3,5 0,35 5 Nutsecuringthejointedheadtothetie-rod 4 ± 4,5 0,4 ± 0,5 6 Platefasteningscrew 2,3 ± 15% 0,78 ± 0,95 Aftertighteningnuts(4),thejointedheadholeaxisshallbealignedwiththeaxisoftheballpintowhichitisconnected.After tighteningnuts(5),theverticalaxesoftie-rod(5)jointedheadsshallbealigned,withamaximumdeviationoflessthan α 30 ˚ (lower).

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58 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 TOOL TOOLNO. DESCRIPTION 99322205 Assembliesoverhaulrevolvingstand 99322225 Unitsupport(tousewithstand99322205) 99340205 Percussionextractor 99341002 Single-actingscaffold 99341003 Single-actingbridge 99341004 Pairofbrackets

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6S400O.D.TRANSMISSION 59 D AILY E URO 4 Base-March2006 Print603.93.651 TOOL TOOL NO. DESCRIPTION 99341012 Pairofbrackets 99341015 Constrictor 99341017 Pairofbracketswithhole 99341019 Pairoftierodswithgrips 99341025 Grips 99345003 Extractorforgearboxfronthalf-casing

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60 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 TOOL TOOL NO. DESCRIPTION 99348001 Extractorwithlockingdevice 99348004 Universalmaleextractorfrom5to70mm 99360522 Tooltoextractandinsertmainshaft,transmissionshaft androd-forkassembly 99370006 Handleforinterchangeabledrivers 99370007 Handleforinterchangeabledrivers 99370234 Toolforfittingrearbearingandsleeveonmainshaft

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6S400O.D.TRANSMISSION 61 D AILY E URO 4 Base-March2006 Print603.93.651 TOOL TOOL NO. DESCRIPTION 99370317 Reactionleverwithextensionforholdingflange 99370629 Transmissionsupportduringremovalfromandrefittingtovehicle 99371057 Bracketforsupportinggearboxduringoverhaul (usewith99322205-99322225) 99374091 Punchforfittingbearingexternalraces (dia.55 ÷ 69mmusewith99370007) 99374452 Keyingdevicetofitgasketontransmissionrearcover (usewith99370006) 99374453 Keyingdevicetofitgasketontransmission

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62 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 LONGITUDINALSECTION Figure 8 Figure 9 87880 87881 C-C

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6S400O.D.TRANSMISSION 63 D AILY E URO 4 Base-March2006 Print603.93.651 LONGITUDINALSECTION Figure 10 Figure 11 Figure 12 87900 87901 87902 M-M G-G P-P

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64 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 TRANSMISSIONTRANSVERSALCROSS-SECTIONS Figure 13 Figure 14 Figure 15 87885 87886 87888 Figure 16 87887 E-E N-N R-R F-F

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6S400O.D.TRANSMISSION 65 D AILY E URO 4 Base-March2006 Print603.93.651 TRANSMISSIONTRANSVERSALCROSS-SECTIONS Figure 17 Figure 18 87889 87891 Figure 19 87890 A-A D-D

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Removetherevsensor(4). Fitthegearbox(1)withthebracket99371057(6)andsecure this to the brackets 99322225 (3) on the rotary stand 99322205(2). Removetheplug(5)anddrainoffthelubricatingoil. 85942 85941 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Shifttoneutral. Takeoutthefixingscrews(1)andremovethegearcontrolbox (2). Loosenthenuts(4)fortheretainingscrews(5). Extractthelevers(1and7)fromtheshafts(2and6)and extractthesefromthebox(8).Takeoffthecaps(4). Withapunch(3),removethespringpin(4)andextractthe shaft(2)fromtheinternallever(1). Repeatthesestepsfortheothershaft. 530220 Gear control box Disassembly Theusedoilmustbedisposedofaccordingtothelaw inforce. Thecouplingleverisboundtothestembytwosnap pins. NOTE 108857 Taketie-rod(3)offbydisconnectingjointedheads(1)from levers(4and7). Taketie-rod(8)offbydisconnectingjointedheads(9)from levers(10and7). Tie-rods(3and8)areinterchangeable. NOTE Removescrews(5),thentaketransfercase(6)offthegearbox unit. 51385 108640 66 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 Print603.43.351/D 530210 OVERHAULING THE TRANSMISSION

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Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Lubricatetherollerbearings(1,Figure27)withTUTELAMR3 greaseandmounttheshafts(3and6)completewiththe internallevers(4and5)inthebox(2).Mountthecaps(8and 9)andlevers(1and10)ontheshafts(3and6)andtightening thenutsforthefixingscrew(7). 51386 Useapunchonthepointshownbythearrowandejectthe O-ringsandrollerbushes(2)fromthebox(1). 51387 Thoroughlycleantheoilvapourvent(3). Withasuitablepunch,mounttherollerbearings(1)inthe box(2). Assembly 51388 Usingasuitablepunch,mounttheO-rings(1)inthebox(2), positioningthemattheheightshown. PackthegapbetweentheO-ringandrollerbearingwith grease. Mount the selection and engagement levers (1) on their respectiveshafts(2)andfastenthemwiththespringpins(3). 51390 87896 Thespringpin(3)mustbepositionedwiththecut horizontal. Fit spring peg (4), with cutting edge positionedat180 ° fromspringpeg(3)cuttingedge, inspringpeg(3)engagementlever. NOTE Thoroughlycleanthematingsurfacesofthegearcontrolbox (2)andapplyLOCTITE5706sealantonthem. Fitthebox(2)onthetransmission,takingcarethatthelevers andshaftsarepositionedcorrectlyintheirrespectiveseats. Tightenthescrews(1)totherequiredtorque. 85941 6S400O.D.TRANSMISSION 67 D AILY E URO 4 Base-March2006 Print603.93.651

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Figure 31 Figure 32 Figure 33 Figure 34 l Fittransfercase(1)intoplace,bytighteningfasteningscrews (2)totheprescribedtorque. Selection and adjustment tie-rod assembling Verifythatthetie-rod(4)length”X”,asmeasuredbetween thejointedheadcentresisnotgreaterthan342mm. LubricatethejointedheadinsidewithMOLIKOTE33LIGHT orMOLIKOTEG72grease,thenconnectthejointedheads tolevers(1and5). Measurethedistance”y”betweentransfercase(3)outer surfaceandballpin(6)centre:itshallbe”y”=146±1mm. Otherwise,loosennuts(2)andproperlyrotatetie-rod(4) untiltheprescribeddistanceisobtained.Thentightennuts(2) totheprescribedtorque,sothattheverticalaxesofthe jointedheadsarealigned,withamaximumdeviationofless than α <30 ˚ (lower). Verifythatspring(3)endscomeintocontactwithselection lever(4)orareatleast1mmwithinthesame.Otherwise, loosenscrew(1)sothatspring(3)iscorrectlypositioned,due toplate(2)beingreleased. 108858 108859 108860 108861 Verifythatthetie-rod(4)length”X”,asmeasuredbetween thejointedheadcentresisnotgreaterthan342mm. LubricatethejointedheadinsidewithMOLIKOTE33LIGHT orMOLIKOTEG72grease,thenconnectthejointedheads tolevers(1and5). Measurethedistance”y”betweentransfercase(3)outer surfaceandballpin(6)centre:itshallbe”y”=146±1mm. Otherwise,loosennuts(2)andproperlyrotatetie-rod(4) untiltheprescribeddistanceisobtained.Thentightennuts(2) totheprescribedtorque,sothattheverticalaxesofthe jointedheadsarealigned,withamaximumdeviationofless than<30 ˚ (lower). 68 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Block rotation of the sleeve (1) by applying the lever 99370317(3).Withthebushing(2)removethescrew(5) withthewasherbeneath(4). Takeoutthelever99370317(3). Extractthesleeve(3)fromthemainshaft. 51924 51926 51925 90250 51928 51829 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Shifttoneutral. Dismantle the gear control box as described under the relevantheading. Removethetwosideplugs(1-3).Removethescrew(2)and takeofftherod(5)draggingdevice(4). Mark the assembly position of the rod (1) preventing engagementofmorethanonegearatthesametimeand removeitfromthetransmission. Removethescrews(1)andtakeoffthecover(2)protecting theinputshaft(3). Ifdifficult,removethesleeve(3)withextractormade upoflink99341003(1)andgrips99341017(2)and block(4). Whenputtingawaythesleeve(1)takecarenotto damagethephonicwheel( → )obtainedbymachining. 1 1 1 1 NOTE NOTE Thescrewthreading(2)istreatedwithLOCTITE 242. NOTE 6S400O.D.TRANSMISSION 69 D AILY E URO 4 Base-March2006 Print603.93.651 Disassembling the transmission

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Fitthedriveinputshaft(1)withtool99345003(2)and securethisontothegearbox(4),withthescrews(3);screw downthescrew(5)oftool(2)toextractthegearboxfrom thebearing(6). Perforatetheo-ring(2)withasuitablehookandramextractor 99340205(1)andremovetheo-ringfromthetransmission box. 51930 51932 51931 51934 74957 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Removethecirclip(2)retainingthefrontbearing(3)fromthe inputshaft(1). Takeouttheplug(4)withthewasher(3),andextractthe spring(2)andthepushrod(1). Pushthetwolocatingpins(2)downwardsuntiltakingthem outoftherearcover(4). Removethescrews(3)securingtherearcover(4)tothe transmission(1). 90209 Removethetwoforkknucklepins(1)whichcontrolthe3 rd —4 th speedandthetwoforkknucklepins(2)whichcontrol the5 th —6 th speed. Figure 46 1 1 1 1 70 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Mountthetool99360522(3)ontotherods(4,5and6),on theinputshaft(1)andonthetransmissionshaft(9). Securethetool99360522(3)ontheinputshaft(1)withthe retainingring(2)andwiththescrew(8)tothetransmission shaft(9). Insertthepart(13)ofthebracket(11)intothereversegear (14)andtightenthescrew(12). Hookthetool99360522(3)ontothelift. Applytheextractorcomposedofthebridge99341004(16) andties99341012(15)ontotherearcover(7). 51936 90211 90210 90212 90213 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Drillthecups(2),screwaspecialscrewintothem. Usingthescrew,extractthecups(2)fromtherearcover(1). Removethesprings(3)andpawls(4). Removetherod(1)controllingthe3 rd /4 th gearandthemain rod(2)fromtherearcover(3). Takeoutthescrew(3)andremovethereversegearshaft(1) withthemounting(2)fromtherearcover(4). Removetherod(1)fromtherearcover(2). Usingtheextractorscrewandtheliftonthemainshaft(10), removethemainshaft(10)fromtherearballbearingandex-tracttheshaft-rodassemblyfromtherearcover(7). Inordernottodamagetherearcover(7),place specialprotectionsbetweenitandtheties(15). NOTE 1 6S400O.D.TRANSMISSION 71 D AILY E URO 4 Base-March2006 Print603.93.651

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Turnovertherearcover(4). TakeouttheO-ring(6). Usingasuitablepunch,removetheballbearing(5).Remove thetachographsensor(7)andthereversinglightswitch(1) withthewasher(2)andextractthepushrod(3). Removethescrews(1)securingtheplates(2). Takeouttheplates(2). Turnovertherearcover(4)andremovethebearing(3). 51951a 51944 Figure 52 Figure 53 Disassembling the rear cover bearings 51943 74960 Figure 54 Figure 55 Usinguniversalextractor99348004(1),removetheouter ring(2)ofthetransmissionshaftbearing. Using the percussion extractor 99340205 (1) and part 99348004(2),extractthebushingwiththeballbearings(3). Figure 56 Clamptheprimaryshaft(6)inavice. Removetherods(10and11)withtherelevantforks.Remove theforks(3and4)andthesmallblocks. RemovetheRMgear(4). Removethesnapring(8)andthetool9936522(9). Removetheinputshaft(7). Supportthesecondaryshaft(2),slackenthescrew(1) andremovethesecondaryshaft(2). 90214 1 1 72 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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51410 85945 Figure 57 Figure 58 Removethescrews(1)securingtheplates(2). Takeouttheplates(2). Turnoverthetransmission.Usingasuitablepunch,remove theballbearing(3). Removetheslidingsleeve(2)forengaging5 th -6 th gearfrom thehub(1)and,takingcareastheplugs(5)comeoutwiththe balls(4)andsprings(3),recoverthem. Using the percussion extractor 99340205 (1) and part 99348004(2),extracttherollerbearing(4-3). Marktheassemblypositionofeachsynchronizingde-viceontherespectivegear. 85944 Figure 59 Figure 60 Tighten the primary shaft (1) in a vice. Remove the synchroniserring(4)andthecirclip(2).Removethecirclip(3) fromitshousing. Disassembling the main shaft 51948 NOTE 51946 Figure 61 Figure 62 Usinguniversalextractor99348004(1),removetheouter ring(2)ofthetransmissionshaftbearing. Disassembling the transmission bearings Using the percussion extractor 99340205 (1) and part 99348004(2),extractthebushingwiththeballbearings(3). 74962 1 3 << 6S400O.D.TRANSMISSION 73 D AILY E URO 4 Base-March2006 Print603.93.651

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90215 108863 Figure 63 Figure 64 Usethehydraulicvicetoremovefromtheprimaryshaft(1): the1 st speedgear(8),thespacer(7),thebush(6),theroller cage (5), the R.M. gear (4) together with the coupling elements,thesynchronisingring(3)andtheserratedring(2). Take1st/2ndgearengagementslidingsleeve(2)anddowels (3),togetherwithballs(4)andsprings(5),offhub(1). Takeoutthesynchronizerring(4),middlering(3),ring(2)and rollerbearing(1). Usingahydraulicpress,removethe2 nd gear(10),ring(9), middlering(8),synchronizerring(7),synchronizerassembly (6)andthebushing(5).Takeouttherollerbearing(11). 51954 Figure 65 Figure 66 Removethereversegearengagementslidingsleeve(2)from thereversegear (1).Retrieve hub(1) andpads(3)with respectiveballs(4)andsprings(5). 85949 85946 85947 Figure 67 Figure 68 Useextractor99348001(6)asshowninthefiguretoextract theprimaryshaft(1),the5 th gear(7),thesynchroniserring(5), thehub(4),thecirclip(3)andtherollerbearing(2). Removetherollerhalfcages(1). 1 74 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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90216 51961 Figure 69 Figure 70 Usinggeneraltools,extracttheinternalring(2)oftherear taperedrollerbearingfromthetransmissionshaft(1). Removethe3rdgear(1)andtherollerbearing(2). Removethesynchronizerring(3).Removetheretainingring (5)securingthehub(4). 51960 51959 Figure 71 Figure 72 Usingahydraulic press, extract the 6th gear (2) andthe internal ring (1) of the tapered roller bearing from the transmissionshaft. Usingahydraulicpress,removethe5thgear(2)fromthe transmissionshaft(1). 51956 90217 Figure 73 Toreplacethecog-wheel(1),usethesamegeneraltoolsfor disassemblyasforassembly,heatittoatemperatureof80ºC. Takeouttheretainingring(1)holdingthe5 th gear(2). Disassembling the drive input shaft Disassembling the transmission shaft 1 Figure 74 1 1 1 6S400O.D.TRANSMISSION 75 D AILY E URO 4 Base-March2006 Print603.93.651

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TRANSMISSIONSHAFTASSEMBLYDRAWING 1.Transmissionshaftassembly-2.Taperedrollerbearing-3.Transmissionshaftwithreversegeartoothing(A),1stgear(B), 2ndgear(C)-4.Taperedbearing-5.4thgear-6.Synchronizerring-7.Slidingsleeve-8.Ball-9.Spring-10.Plug-11.Hub-12.Retainingring-13.Halfrollerbearings-14.3rdgear-15.6thgear-16.5thgear. 90218 Figure 75 Figure 76 51962 51424 Figure 77 Using a hydraulic press, remove the 4th gear (3), the synchronizerring(2)andthesynchronizerassembly(1). Removethehalfrollerbearings(4). 1 Removethesleeve(2)forengagingthe3rd-4thgearfromthe hub(1)and,takingcareovertheplugs(3)comingoutwith theirrelativeballs(4)andsprings(5),recoverthem. 1 1 76 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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PRIMARYSHAFTANDINPUTSHAFTASSEMBLY 1.Inputshaftwith5 th speedgear.-2.Retainingring-3.Rollerbearing-4.Singleconesynchronizerring-5.Slidingsleeve-6.Plug-7.Ball-8.Spring-9.Hub-10.6thgear-11.Mainshaftwith3rdgeartoothing(A),4thgeartoothing(B)-12.Rollerbearing-13.2ndgear-14.Dual-conesynchronizingunitfor1st/2ndspeed-15.Dowelswithbuilt-inballsprings for1st/2ndspeedhub-16.Bushing-17.1stgear-18.Spacerring-19.Reversegear -20.Synchroniserring-21.Gear. 108864 Figure 78 6S400O.D.TRANSMISSION 77 D AILY E URO 4 Base-March2006 Print603.93.651

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1ST-2NDGEARDUALCONESYNCHRONIZERASSEMBLY 85978 Figure 79 Figure 80 3RD-4TH-5TH -6THGEARSINGLECONESYNCHRONIZERASSEMBLY SINGLECONESYNCHRONIZERASSEMBLYREVERSEGEAR 86130 Figure 81 108865 78 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Transmission Thetransmissionandrelativecoversmustshownosignof cracking. Thematingsurfacesofthecoversandtransmissionmustnot bedamagedordeformed.Removeanyremainsofsealant fromthem. Theseatsofthebearings,reversegearshaftandgearcontrol rodsmustbeneitherdamagednortooworn. Hubs - sliding sleeves - forks Thegroovesonthehubsandrelativeslidingsleevesmustnot bedamaged.Theslidingsleevemustrunfreelyonthehub. Theplugsandballsforpositioningtheslidingsleevemustbe neitherdamagednorworn.Thetoothingoftheslidingsleeves mustnotbedamaged.Theforksmustbesoundwithanend float,intheradialgrooveofthesleeve,nogreaterthan1mm. Bearings Therollerbearingsmustbeinperfectconditionwithnosigns ofwearoroverheating.Theymustonlyberemovediftheyare tobereplaced. Shafts - gears Theseatsontheshafts,forbearings,mustbeneitherdamaged norworn.Thetoothingofthegearsmustbeneitherdamaged norworn. Synchronizing devices Checkthewearonthesynchronizerrings, proceedingas follows: -Seethatthefrictionsurfaceisnotundulated. 52510 52511 Figure 82 Figure 83 BK-type single cone synchronizers for 3rd/4th/5th/6th gears Arrangethesynchroniserring(1)ontherespectivegearor reversetaperring(2). Withafeelergauge,checkthedistance S ontwodiametrically oppositepoints. Ifthemeasuredvalue S islessthan0.8mm, replacethe synchronizerring. Turnthesynchronizerring(1)soastoensurecorrectcoupling onthecog-wheel. Position the internal ring (3), middle ring (2) and the synchronizerring(1)onthetaperedcog-wheel(4)ofthegear. Turnthesynchronizerring(1)soastoensurecorrectcoupling betweentheparts. Applyingauniformforceof50Nonthesynchronizerring(1), measurethedistance S ontwodiametricallyoppositepoints withafeelergauge. Iftheaveragemeasuredvalue S islessthan1.5mm,replace alltherings. ! After this check, the synchronizer rings must be markedontheirrespectivegearstoavoidswapping theirpositionsoverwhenassembling. D-type dual cone synchronizers for 1st/2nd gears 4 6S400O.D.TRANSMISSION 79 D AILY E URO 4 Base-March2006 Print603.93.651 CHECKS

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85918 85919 85917 5 TH -6 TH GEARSYNCHRONISERS A.synchronizationreserve6 th -5 th gear:1 ÷ 1,4mm B.5 th -6 th releaseclearance:0,3 ÷ 0,7mm 90220 3 TH /4 TH GEARSYNCHRONISERS A.synchronizationreserve1 st -2 nd gear:1 ÷ 1,4mm B.1 st -2 nd releaseclearance:0,3 ÷ 0,7mm 2 ND -1 ST GEARSYNCHRONISERS A.synchronizationreserve2 nd-1st gear:1,6 ÷ 2,0mm B.1 st -2 nd releaseclearance:0,9 ÷ 1,5mm REVERSEGEARSYNCHRONISER A.Synchronizationreserve:0.9 ÷ 1,4mm B.releaseclearance:0,35 ÷ 0,85mm 1.Hub-2.5 th gear-3.Synchronizerring-4.Slidingsleeve-5.6 th gearcog-wheel-6.3 rd gearcog-wheel-7.4 th gearcog-wheel-8.2 nd gearcog-wheel-9.1 st gearcog-wheel-10.Middlering-11.Ring-12.Reversegear-13.Reversegearring Figure 84 Figure 85 Figure 86 Figure 87 80 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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51966 51968 51967 51969 51970 51971 Figure 88 Figure 89 Figure 90 Figure 91 Figure 92 Figure 93 Clampthetransmissionshaft(1)inaviceandpositionthehalf rollerbearings(2)onit. Mountthe4thgear(2)andpositionthesynchronizerring(1) onthis. Heatthehub(2)toatemperatureof110 ° ÷ 150 ° Cand mountitonthetransmissionshaft(1),takingcarethatthe protrusions (3) of the synchronizer ring are positioned correctlyintheirseatsinthehub(2). Mounttheretainingring(1)whosethicknessproducesnull endfloatinitsseat. Check the end float of the 4th gear (2). It should be 0.15 ÷ 0.40mm. Mounttheslidingsleeve(1)onthehub(2).Putthesprings(5), plugs(3)andballs(4)intotheseatsinthehub(2),settling themundertheslidingsleeve(1). Positionthesynchronizerring(2)onthehub(3)sothatits protrusionsentertheseatsinthehub(3).Mounttheroller bearing(1). 1 1 1 1 1 1 6S400O.D.TRANSMISSION 81 D AILY E URO 4 Base-March2006 Print603.93.651 Mounting the transmission shaft

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51974 90221 51975 90222 90223 51973 Figure 94 Figure 95 Figure 96 Figure 97 Figure 98 Figure 99 Mountthe3rdgear(1). Withahydraulicpress,mountthe6 th gear(1)pre-heatedto approx.170 ° C. Checktheendfloatofthe3 rd gear(2).Itshouldbe0.15 ÷ 0.40 mm. Withahydraulicpress,mountthe5 th gear(1)pre-heatedto approx.170 ° C. Mounttheretainingring(1)whosethicknessproducesnull endfloatinitsseat. Heattheinternalrings(1-3)ofthetaperedrollerbearingsto atemperatureofapprox.80 ° Cand,withasuitablepunch(1), mountthemonthetransmissionshaft(2). Tightenthemainshaft(1)andpositiontherollerbearing(2) onit. Mounting the main shaft Mountthesynchronizerringsontheirrespectivegears accordingtothemarksmadeduringdisassemblyor whencheckinginthecaseofreplacement. 1 1 NOTE 82 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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51980 51981 51983 51984 Figure 100 Figure 101 Figure 102 Figure 103 Figure 104 Mountthe2ndgear(4)andpositionthering(3),middlering (2)andsynchronizerring(1)onit,takingcarethatthetongues ( → )ofthemiddlering(2)entertheslots( → )inthegear(4). Heatthehub(2)toatemperatureof80 ° ÷ 110 ° Candmount itonthemainshaft(1),takingcarethattheprojections(3)of thesynchronizerringandthetongues( → )ofthering(3, Figure100)arepositionedcorrectlyintheseatsinthehub(2). Check the end float of the gear (4). It should be 0.25 ÷ 0.5mm. Fitslidingsleeve(2)ontohub(1).Fitdowels(4)withbuilt-in springs(5)andballs(3)intohub(1)housings. Positionthesynchronizerring(3),middlering(2)andring(1) onthehub(4),takingcarethatthetongues( → )ofthering (1)andtheprojections( → )ofthering(3)entertheseatsin thehub(4). Positiontherollerbearing(2).Mountthe1stgear(1)taking carethatthetongues(3)ofthemiddleringentertheslotsin thegear(1). 108866 6S400O.D.TRANSMISSION 83 D AILY E URO 4 Base-March2006 Print603.93.651

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85961 51952 Figure 105 Heatthespacerring(2)toatemperatureofapprox. ~ 80 ° ÷ 110 ° Candmountitonthemainshaft(1).Checktheend floatofthegear(4);thisshouldbe0.15 ÷ 0.3mm. Heatthebushing(3)toatemperatureofapprox.80 °÷ 110 ° C andmountitonthemainshaft(1). Mounttherollerbearing(5). Turnthemainshaftoverandpositionthehalfrollerbearings (3)onit. Mountthe6thgear(2)andpositionthesynchronizerring(1) onit. 1 Fitreversegear(1). Fitslidingsleeve(2)onreversegearhub(1). Insertthesprings(5),thepads(3)andtheballs(4)inthehub seats(1)andarrangethemwithrespecttotheslidingsleeve (2). 85950 85951 Figure 106 Figure 107 Fitthesynchroniserring(2). Heatthegearring(3)to110 ° ÷ 150 ° andfitonprimaryshaft (1). Checkreversegearplay(4)whichmustbe0.15 ÷ 0.4mm. Heatthehub(2)toatemperatureofapprox. ~ 80 °÷ 110 ° C andmountitonthemainshaft(1)takingcarethattheprojec-tions(3)ofthesynchronizerringarepositionedintheseats inthehub(2). Mounttheretainingring(4)whosethicknessproducesnull endfloatinitsseat. 51990 51991 Figure 108 Figure 109 Mounttheslidingsleeve(2). Putthesprings(3),plugs(5)andballs(4)intotheseatsinthe hub(1)andpositionthemundertheslidingsleeve(2). 1 Figure 110 84 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Duringassembly,thegaskets,retainingrings,O-rings, springpins,safetyplatesandspringsmustalwaysbe replacedwithnewparts. Thenutsandscrewsmustbetightenedtothere-quiredtorqueunlessspecifiedotherwise,withthe threaddryanddegreased. 85952 Figure 111 Heatthebearing(2)to80 ÷ 110 ° Candfitonprimaryshaft(1). Fitthecirclip(4)andsynchroniserring(3). Mounting the transmission Adjusting the transmission shaft bearing end float Thetransmissionshaftbearingendfloatisonlyad-justedifthebearings,transmissionshaftgears,trans-missionshaft,transmissionorrearcoverhavebeen replacedoriftoomuchclearancehasbeenfound. 1.Rodwithreversegearengagementfork-2.Mainrod-3.Rodwith1 st -2 nd gearengagementfork.-4.Forkcontrol rod(5).-5.3 rd -4 th gearengagementfork-6.Forkcontrol rod(7)-7.5 th -6 th gearengagementfork Rods - forks - selector - driver 90224 Figure 112 Disassembly - assembly Springpegsmustbepositionedwiththecuttingedge placedlevel. NOTE NOTE NOTE 51993 Figure 113 Determinethethickness S ofthering(1)foradjustingthe transmissionshaftbearingendfloat,proceedingasfollows: -positionthethinneradjustmentring(1)1.65mmthickin theseatinthetransmission(3); -heattheseatofthebearing(2)toapprox.60 ° C.Mount the external ring of the bearing (2) with the punch 99374091andgrip99370007,seeFigure115; -mountthetransmissionshaftcompletewiththeinternal ringsofthetaperedrollerbearings; -mounttheexternalringoftherearbearingintherear cover in a similar manner to the front one (see Figure115); -mounttherearcoveronthetransmission; -screwonthe8fixingscrewssothatbetweenonescrew andanotherthereisaholeforafreescrewandtighten themtotherequiredtorque; -turnthetransmissionshafttosettlethebearings; Checkthestateoftheplugs(2)ofthe3 rd -4 th -5 th-6 th gearen-gagementforkandreplacethemiftheyareworn. Toreplacetheforksoftheselectoranddriverfromtheirre-spectivecontrolrodsitissufficienttoremovetheretaining springpinswithasuitablepunch. Forassembly,carryoutthesestepsinreverseorder,replacing thespringpins. 6S400O.D.TRANSMISSION 85 D AILY E URO 4 Base-March2006 Print603.93.651

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52512 Figure 114 Figure 115 -usingacomparator(2)zeroedonthe5thgeartoothing ofthetransmissionshaft(1)measure itsendfloat A throughtheopeningforthepowertake-offconnection andnoteitdown. Thethickness S isgivenby: S = A + B + C Where: A =measuredendfloat,e.g.0.18mm; B =averagebearingpre-load,e.g.0.02mm; C =adjustmentvalueusedforthemeasurement1.65mm; Positiontheadjustmentring(1,Figure119)ofthethickness determinedwiththeabovemeasurement.Heatthebearing seatsoftheboxtoatemperatureofapprox.80 ° Cand mount: -theexternalring(3)ofthefronttaperedrollerbearing withpunch99374091(2)andgrip99370007(1); -theballbearing(6)withageneralpunch; -thebushingwithballbearing(9)andtherollerbearings (4-5)withageneralpunch. Positiontheretainingplates(7)andsecurethemtothebox, tighteningthescrews(8)totherequiredtorque. 51996 S = 0, 18 + 0, 02 + 1, 65 = 1, 85 Thenmounttherearcover,transmissionshaftandexternal ringofthefrontbearing. Heatthebearingseatsoftherearcover(1)toatemperature ofapprox. ~ 80 ° Candmount: -theexternalring(3)ofthetaperedrollerbearingwith punch99374091(2)andgrip99370007(1); -theballbearing(4)andthebushingwithballbearings(7) withageneralpunch. Positiontheretainingplates(6).Securethesetotherear cover,tighteningthescrews(5)totherequiredtorque. 51997 Figure 116 Clamptheprimaryshaft(13)inavice,fitonitthesynchronis-ingringandtheinputshaft(8). Fittool99360522(10)ontheinputtransmissionshaft(8)and fastenwiththecirclip(9). Couplethesecondaryshaft(2)totheprimaryshaft(13)and fastenbytighteningthescrew(1)onthetool(10). Fittheclutchforks:3 rd —4 th speed(4)and5 th —6 th speed(3) ontherelevantslidingsleeves. Coupletherods(11and13),fittherelevantforksontheslid-ing sleeves and clamp the rods with the sleeves of tool 99360522(10). Couplethereversegear(7)withtheshafts(2and13)and fastenittothemwiththepartofthebracket(5)tightenthe screw(6). 90225 Figure 117 86 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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90226 Figure 118 Figure 119 Placetherollerbearings(2)inthereversegear(1). Fitthestem(2)andthesupport(3)sothattherespective holesforthefasteningscrewarealignedwiththerelevanthole ontherearcover(5). Driveinthefasteningscrew(6)ofthestem(3)andthe support (4) on the rear cover (5) and tighten it to the prescribedtorque. Fittherod(3)intherearcover(4). Hookhoisttotool99360522(1),lifttheunit(2)aspreviously mounted,andpartiallyinsertitintotherearcover(4). Duringthisoperation,checkthattheoutputshaftgoesintothe supportingballbearingandthecontrolrods(5-6)gointotheir respectiveseats. Screwtool99370234pin(7)intooutputshafthole(2)and fitbushing(4)andspacer(5)ontool. Screwonthenut(6)andatthesametimelowerthehoistso theoutputshaft(2)ispositionedontherearballbearing(3). Removetools99360522(1)and99370234(4-5-6-7). 52000 Figure 120 Figure 121 90210 Fitthecontrolrod(1)ofthe3 rd —4 th speedandthemainrod (2)intherearcover(3). 90227 eft 6S400O.D.TRANSMISSION 87 D AILY E URO 4 Base-March2006 Print603.93.651

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Screwonthescrews(2)securingtherearcover(3)tothe transmission(1)withoutfullytighteningthem. Mountthecentringpins(4)intherearcover(3)andinthe transmission(1). Tightenthescrews(2)totherequiredtorque. 90229 90230 51936 90231 Figure 122 Figure 123 Figure 124 Figure 125 Applysomegreaseonthepinofthedraggingdevice(2)and fittheclutchfork(1)forthe3 rd —4 th speedonthisdevice. Putthepawls(4)andsprings(3)intherearcover(1)anddrive intheretainingcups(2)withasuitablepunch. ApplyLOCTITE5206ongearboxattachment. Warmupthefrontbearinginnerring(2)at90 ÷ 110 ° Candfit thegearbox(1)ontherearcover. Whenfittingthegearbox,checkthattheshaftsand thecontrolrodsfitcorrectlyintherespectiveseatand thatthefork(1,Figure117)doesnotdisconnectfrom theclutchrod(2,Figure122)forthe3 rd —4 th speed. 1 NOTE 51931 Figure 126 Fitanewretainingring(2)securingthefrontbearing(3)onto theinputshaft(1). 1 88 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Mountthecover(1)protectingtheinputshaftandtightenthe screws(2)totherequiredtorque. 51932 52006 52007 Figure 127 Figure 128 Figure 129 Mountthepushrod(1)andthespring(2).Screwontheplug (4)withanewwasher(3),tighteningittotherequiredtorque. MounttheO-ring(2)intherearcover(1)withthekey 99374454(4)andthegrip9937006(3). 1 52005 Figure 130 Usingthekey9937455(3),mounttheO-ring(2)inthetrans-mission(1). ApplyLOCTITE242tothethreadofthepins(1). Screwthepins(1)intothebox,checkingthattheirendsgo intotheholeofthe3rd/4thgearengagementforklink(1, Figure122)andthentightenthemtotherequiredtorque. Driveinthepins(2)andcheckthattheirendsfitintheknuckle holeoftheclutchforkforthe5 th —6 th speedandtightenitto theprescribedtorque. 90209 Figure 131 If during these assembly operations the fork (1, Figure122.)comesfreeofthecontrolrod,itwillnot bepossibletomountthepins(1)untiltheyhavebeen reconnected. NOTE Makesurethattheclutchcontrolrodsareallin neutralposition. NOTE 6S400O.D.TRANSMISSION 89 D AILY E URO 4 Base-March2006 Print603.93.651

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Mountthewasher(3)andscrewonthescrew(4). Locktherotationoftheflange(1)withthelever99370317 (5)andtightenthescrew(4)totherequiredtorque. Mount the tachograph sensor (2) and the reversing light switch. Fitanewgasket(1)ontothetransmission. ApplyLOCTITE510onthescrewthreading(2). Mountthesidecover(3)andtightenthefixingscrews(2)to therequiredtorque. Mountthecontrolboxasdescribedundertherelevanthea-ding. Mounttheoildrainageplug,tighteningittotherequiredtorque. Fillthetransmissionwithlubricatingoilintherequiredquantity andgrade. Mounttheoilfillerandlevelindicatorcap,tighteningittothe requiredtorque. 52009 51924 51925 52118 Figure 132 Figure 133 Figure 134 Figure 135 Mounttherod(1)preventingengagementofmorethanone gearatthesametime,inthepositionmarkedduringdisas-sembly. Applysealanttothethreadoftheplugs(1-3),screwthem intothebox,tighteningthemtotherequiredtorque. Positionthedriver(4)ontherod(5). Secureitwiththescrew(2)afterapplyingLOCTITE242onto itsthread. 1 1 52008 Figure 136 Fitthetransmissionshaftcoupling(1)ontotheoutputshaft. Ifthereisanyinterference,usethetool99370234(2)foras-semblywiththelever99370317(3)tolockthecoupling. 90 6S400O.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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6S400AO.D.TRANSMISSION 91 D AILY E URO 4 Base-March2006 Print603.93.651 6 S 400 A O.D. Transmission Page GENERAL 93 .............................. MAINCOMPONENTSLOCATION 94 ......... MAINSYSTEMFUNCTIONS 95 ............... -Startup/startprocedure 95 .................. -Checkprocedures 95 ...................... -LimpHome 96 ........................... -Buzzer 96 ............................... -Startupwithtow 96 ...................... HILLHOLDER(FUNCTIONONLYAVAILABLETO VEHICLESWITHESP8BRAKINGSYSTEM) 97 . -Functionalfeatures 97 ..................... SYSTEMSTRUCTURE 98 .................... -Systemcentralunit 98 ..................... -Clutchactuator 99 ........................ -Gearsactuator 99 ........................ -Acceleratorpedal 100 ...................... -Displayunit 100 ........................... -Gearselector 101 ......................... GEARSELECTIONANDENGAGEMENT 102 .... -Neutralarrangementand/or3rd/4thgearselection andengagementarrangement 102 ............. -1st/3rdgearselectionelectionandengagement arrangement 102 .......................... -5th/6thgearselectionandengagement arrangement 103 .......................... -Reversegearselectionandengagement arrangement 103 .......................... -Safetydevice 103 .......................... SPECIFICATIONSANDDATA 104 ............. TIGHTENINGTORQUES 106 .................

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92 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 Page TOOLS 107 .................................. DIAGNOSIS 108 .............................. -Diagnosisinstruments 108 ................... MODUS-IT2000-E.A.SY.CONNECTION 109 .... GEARBOXREMOVAL/REFITTING 110 ............ -Removal 110 ............................. -Refitting 113 .............................. GEARBOXUNITOVERHAULING 117 ............ CONTROLUNIT 117 .......................... -Removal 117 ............................. -Refitting 118 .............................. CLUTCHACTUATOR 119 ...................... -Removal 119 ............................. -Refitting 120 .............................. GEARBOXACTUATOR 120 .................... -Removal 120 ............................. -Refitting 121 .............................. CHASSISWIRINGGEARBOX 121 ................ -Removal 121 ............................. -Refitting 122 .............................. GEARBOXWRING-GEARBOX 122 ............. -Removal 122 ............................. -Refitting 123 .............................. CALIBRATION 124 ............................

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Gearboxes 6 S 400 A O.D are made up of an electronic/mechanicalsystemcontrollingandmanagingthe gearboxinthedifferentconditionsofvehicleuse. Thisistheautomaticversionofthe6S400gearboxunit. Driver’s intervention is just limited to using the gear selection/engagement control lever and the accelerator pedal, so making clutch control pedal application not necessaryanymore. Thesystemisequippedwith: -Safetydevicepreventingvehicleenginestartupunder determinedsituations(gearboxcentralunitmanaging theignition). -Sound and visual signalling device drawing driver’s attentiononsystemoperationorfaults. -Diagnosisdevice. -Provideddisplayunitacquaintingabout: SelectedA/Mmode; Gear; Faultsstatus. ThesysteminterfacestoEDCsystemandABS8/ESP8device viaCANline. 1.Productionseriesnumber-2.1st/6thgearsratio-3.Dryoilquantity-4.Oilrules-5.Tachographreport-6.IVECOnumber-7.ZFseriesnumber. 108867 Figure 1 On the rear cover there is the speed selection and engagementcontrolsupport. Onasideofthemaincasingthereisaslotwhereitispossible toapplyapowertake-off. Motiontransmissioniscarriedoutbyasetofhelical-toothed constantmeshgearsbothforforwardspeedsandforreverse speed. Splinedormachinedgearsareplacedonfourshafts:input, main,transmissionandreverseshaft. Gearssplinedonmainandonreverseshaft,idleonstraight rollerbearings. Input and main shaft are supported, in the gearbox, by four-contactballbearings. Transmissionshaftissupported,inthegearbox,byroller bearingswhichcanbeadjusted,axially,bymeansofring shims. Thesynchronizationofthespeedengagementiscarriedout by means of free synchronizer rings having the same dimension for:first,fourth,andfifth speedandagreater dimensionforsecondandthirdspeed. Speedengagementslidingsleevecontrolforks,arecontrolled byoneshaftonly,thesamewhichsupportsthem. 6S400AO.D.TRANSMISSION 93 D AILY E URO 4 Base-March2006 Print603.93.651 GENERAL

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94 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 MAIN COMPONENTS LOCATION Figure 2 1.Gearsactuator -2.Electroniccentralunit-3.Gearboxcable -4.Clutchactuator-5.Fork-6.Flywheel-7.Clutchdisk 108868

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6S400AO.D.TRANSMISSION 95 D AILY E URO 4 Base-March2006 Print603.93.651 MAIN SYSTEM FUNCTIONS Startup/start procedure Inordertohavecorrectsignallingonthedisplayunit,”keyingoff”andthen”keyingon”mustbecarriedoutwithin atimenotshorterthan4seconds,asintheotherelectronicsystemsaboardthevehicle.If,afterwriting”BRAKE”has appeared,thebrakeisnotpressed,theclutchremainsshut. NOTE (FOR MARKET AUSTRALIA ONLY) Thesystemonlyenablesenginestartupwiththegearboxinneutralposition.If,duringenginestartup,thegearboxisin1stor reversegearposition,thenthesystemdisablestheenginefrombeingstartedupbutwarnsbyan”N”blinkingonthedisplay unitthatthegearboxhastobeputintoneutralpositioninorderthatstartupisenabled. Check procedures Figure 3 107203 Onstartingupagaintheengineafterswitchingoffwiththegearboxinneutralposition,thesystemcarriesoutaboveindicated checkprocedure. Figure 4 107203 Onstartingupagaintheengineafterswitchingoffwiththegearboxin1stgearposition,thesystemcarriesoutaboveindicated checkprocedure. NOTE START Gearbox initialisation step ”Brake” appearson display unit Brakepedal pressed? Enablingon displayunit(OK) for2sec.Itis possibletostart (~1000rpm) STOP NO SI

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96 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 Limp Home LimpHomefunctionallowstoremovethevehiclewhensystemfaultsaresoseriousthattheycannotbeautomaticallymanaged bythesystem. Informationlossingearboxcentralunitallowstodriveinmanualmode.Gearsalloweddependonfaulttype: 1. driving with gears from first to fourth plus reverse gear: e.g.whenB7speedsignalislost; 2. driving with first, second and reverse gears: whenacceleratorpedalfailureispresent; 3. driving with first and second gears: whengearselectorfailureispresent; 4. driving with first gear only: whenafailureispresenteitherinselectionactuatorelectricalmotororintheactuatorwith agearentered; 5. locked clutch: e.g.whenclutchactuatorisfaulty;inthiscase,thesystemremainsinitscurrent condition. Buzzer Thebuzzerisactivatedinfollowingsituations: -Towarnaboutfaultssuchasclutchslipping.Throughacalculationalgorithm,thresholdtemperatureoverflowissignalled byanintermittingBeepsound. -Toshowreversegearbeingentered(intermittingBeepsound)orwarnaboutdriver’sdoorbeingopenedwithagear enteredandengineon(intermittingBeepsound). -Towarnaboutparkingbrakenotoperatedwiththeengineoff(KEYON)andthegearboxinneutralposition.Itwarnsabout thedangerthatthevehiclemightskid(intermittingBeepsound). Start up with tow -Select1stgear(clutchisopen) -starttowingthevehicle -onceaspeedof12km/hhasbeenreached,theclutchshutsengagingthegearandstartinguptheengine. ifyouaretowed,useneutralgearpositionbeforeusingacceleratorpedal.Onthecontrary,ifyouareskiddingonsloping down,drivenormally. Startingup withreversegearisnotsuggested. NOTE NOTE

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6S400AO.D.TRANSMISSION 97 D AILY E URO 4 Base-March2006 Print603.93.651 HILL HOLDER (FUNCTION ONLY AVAILABLE TO VEHICLES WITH ESP8 BRAKING SYSTEM) Functional features Figure 5 108869 -Itpreventsthevehiclefrommovingeitheruphillwith1stgearordownhillwithreversegearafterreleasingbrakepedal. -Itkeepsthatbrakespressurewhichwasappliedbydriver’sfoot. -Brakespressureiskeptupto2s. Thistimeissufficienttodrivertodisplacehis/herfootfrom brakepedaltoaccelerator pedalinordertoperformstartoperationinaneasierway. -2-secondsafetyconceptisappliedinordertopreventdriverfromgoingoutofthevehicleasifitwasparked. -Ifthevehicleisskiddingwithitswheelslocked,thebrakesarereleasedinordertomaintainitsstability. Activation: -Stoppeduphill/downhill(>2%slope) -Pressbrakepedal -1stgear(uphill)reversegear(downhill) Deactivation: -Start -shiftingfrom1sttoreversegear(uphill)orfrom reversegeartoneutral(downhill) -clutchshutting -2sec.afterreleasingbrakepedal -withhandbrakeengaged(signalfromESP8central unit).

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98 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 SYSTEM STRUCTURE System central unit Theelectroniccentralunitreceivessignalsfromsensors/switches;onthesesignals,itbasesmanagementandcontrolofthe systeminthedifferentoperationconditionsofthegearbox. Itisinterfacedwithotherelectronicsystemsonboard,suchasEDCandABS,throughCANcommunicationlines. A-Gearboxsideconnector B-Vehiclesideconnector Figure 6 90135 FromtheconnectiontoEDC16system,gearboxcentralunitisabletodetectacceleratorpedalpositionandenginerpm’s. ConnectionwithABS8/ESP8centralunitisusedtopreventgearshift”UP”onbendingandmanagesthedriveinlowadhesion conditionsincaseofdriveinmode”A”(automaticmode). NewABSsystemmanages”intelligent”warninglampsintegratedintoboardpanel.Theirgoingonshowsafailureinbraking system. Signal”Brake”,atstartup,isdirectlycomingfrom EDCcentralunit. Reversegearsignalisdirect. NOTE Figure 7 90136 Centralunitlocation

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6S400AO.D.TRANSMISSION 99 D AILY E URO 4 Base-March2006 Print603.93.651 Gearengagementelectricalmotor-2.Gearselectionelectricalmotor Figure 8 107211 Gearsactuatorhasthetaskofcontinuouslyexchanginggearsselectionandengagementinformationwithelectroniccentralunit. Itismadeupoftwoelectricalmotors,drivecylinders,andtheirsensors. Clutch actuator Figure 9 90138 1.Actuatorcylinder-2.Electricalmotor-3.Vehicleelectricalwiringharnessjunctionblock Itismadeupof: -Onecylinderoperatingonclutchengaging/disengaginglever. -Onepositionsensordetectingclutchlevertravelandacquaintingtheelectroniccentralunitof actuatorcylinderposition andclutchdiskwear. Gears actuator

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100 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 Accelerator pedal Todetectengineidlingpositionandenableclutchenteringatvehiclestart,N.O.switchisusedwithpedalreleased;theswitch isintegratedinpositionsensor. ThissignalcomestoEDCcentralunitandissenttogearboxcentralunitthroughVDB(VehicleDataBase)CANline. Duringride,”kickdown”functioncanbeactivatedinautomaticmode. Inconditionswherethepedalis98%pressed,e.g.onovertaking,thesystemautomaticallyshiftsdownbyonegear,soallowing tobestexploitthedrivetorque. Inpractice,ifacceleratorpedalisfullypressed,adrivewithanenginerotationspeedwithhighergearshiftischosen. Display unit Figure 10 112601 Thedisplayunit,positionedoninstrumentpanelallowstodisplayallinformationneededforsystemcorrectuse,e.g.: -Mode:manualorautomated,and,inbothcases,gearratioentered; -Reverse/neutral(R/N)position; -Faultssignalling: - SERVICE:gearboxfailure - SERVICE:seriousgearboxfailure(associatedtoacousticwarningsignal) - SERVICE:excessiveclutchtemperature(associatedtoacousticwarningsignal) - Gearboxfailurein”SERVICE”mode(thismessageisdisplayedonlyattheDealershipCentres) -Failurecodeatpage50canonlybedisplayedthroughdiagnosistool. -Vehiclestatus:gearentered.

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6S400AO.D.TRANSMISSION 101 D AILY E URO 4 Base-March2006 Print603.93.651 -Capabilitytoswitchfromautomatedtomanualmodeselectionandfrommanualtoautomatedmodeselectionbyoperating theleverleftwards.Inthisway,enteredgear/rpmisnotlostonshifting. -Capabilitytoskipgears:byrepeatedlyoperatingthelever,agearwhichiscorrectandsuitabletothespeedisentered(3-4 gearscanbeskipped,too). -Central”N” - Neutral-positionand”R” - reversepositionsarestable. -Thegearboxshowsthatgearwithwhichyoustopped.Shouldthegearbeentered,thesystemopenstheclutchinorder toenableenginestartup. -Thesystemoptimisestheperformancesbyidentifyingadrivestyledependingonhowacceleratorpedalisoperated.If acceleratorpedalisfullypressed,adrivewithanenginerotationspeedwithhighergearshift(~3900rpm)ischosen. -Completesignallingonthedisplayunitshowing: mode(manualorautomated) reverse/neutralposition failure/misusewithsoundwarning(e.g.clutchoverheating). -Onbending,shifting”UP”isinhibited.Thisfunctionpersistsforsomemetresaftertheexitfromthebend. Gear shitting -Itiseitherinmanualmodebyoperatingongearsleverorinautomatedmode.Gearshiftingiswithoutreleasingthe acceleratorpedal.Thesystemopenstheclutch,entersthegearandshutstheclutch. -Clutchpedalisnotpresent. Vehicle parking Onvehicleputtingoffoperation,thesystemautomaticallyopenstheclutch,thenshutsitback,withouttheneedofpositioning thelevertoneutralposition.Intheseconditions,theclutchisshutandparkingwiththegearenteredisenabled. Figure 11 108873 Gear selector

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Thecombinedactionoftheselectorlever(2)andtheengagementlever(1)causetherotationandaxialmovementoftherod (4)intwosubsequentstepstoengagetherequiredgearbymeansoftherods(8-7-6and9). Themotionofspeedselection/engagementleversoccursthroughtheactionoftwoelectricmotors(M)manageddirectlybythe gearboxelectroniccontrolunit. Neutral arrangement and/or 3 rd /4 th gear selection and engagement arrangement 3 rd /4 th gear selection Accordingtotheangularpositionoftheselectorlever(2), theslider(3)turnswiththerod(4)(whichisintegral)andthe selector(5)arrangestheslideronthe3 rd /4 th gearrod(9).At thesametime,theslider(3)movestherod(10)toprevent thesimultaneousengagementoftwogears,tokeepthe3 rd and 4 th gear engagement rod (9) free and to prevent movementoftheotherrodsbyengagingthegroovesinthe rods. 3 rd /4 th gear engagement Accordingtothemovementoftheengagementlever(1),the slider(3)axialmovestherod(4)(whichisintegral),the selector (5) (previously arranged) and consequently the chosen3 rd and4 th gearengagementrod(9). Neutralpositioncoincideswiththe3 rd /4 th gearselection arrangement. Inthiscase,theverticalaxisoftheselectorlever(2)isexactly at90 ° withrespecttothehorizontalaxisofthecontrol correspondingtonoangularvariationoftherod(4). Thisarrangementisobtainedbymovingtheselectorlever(2) anticlockwise.Inthisway,theselector(4)isinsertedinthe 1 st /2 nd gearengagementrod(5). Bymovingthelever(1),theslider(3)willaxiallymovethe 1 st /2 nd gearengagementrod(5). 1 st/ 3 rd gear selection election and engagement arrangement Figure 12 Figure 13 101935 101936 SECTIONA-A SECTIONA-A 102 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 GEAR SELECTION AND ENGAGEMENT

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5 th /6 th gear selection and engagement arrangement Thisarrangementisobtainedbymovingtheselectorlever(2) clockwise.Inthisway,theselector(4)isinsertedinthe5 th /6 th gearengagementrod(5). Bymovingthelever(1),theslider(3)willaxiallymovethe 5 th /6 th gearengagementrod. Thisarrangementisobtainedbymovingtheselectorlever(2) anticlockwise.Inthisway,theselector(4)isinsertedinthere-versegearengagementrod(5). Bymovingthelever(1),theslider(3)willaxiallymovethere-versegearengagementrod(5). Safety device Thetransmissionisequippedwithadevicewhichpreventsthe simultaneousengagementoftwogears. Itconsistsofasuitablyshapedrod(6)fittedtransversallyinthe transmissionbox. Theslider(3),movestherod(6)undertheactionofthelever (2).Thiskeepstheselectedgearengagementrodfreeand prevents movement of the other gears by engaging their respectivegrooves. Reverse gear selection and engagement arrangement Figure 14 101937 101938 Figure 15 SECTION A-A SECTION A-A 6S400AO.D.TRANSMISSION 103 D AILY E URO 4 Base-March2006 Print603.93.651

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104 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 SPECIFICATIONS AND DATA TRANSMISSION 6S400AO.D. Type Mechanical Inputtorque 400Nm Weight 72kg Speeds 6forwardspeeds 1reversespeed Speedcontrol Electronic Powertake-off Optional (HYDROCARtypeonly) Speedengagement: Forwardspeeds -5 th /6 th -3 rd /4 th Single-conesynchronizer -1 st /2 nd Dual-conesynchronizer Reversespeed Quick-connect(non-synchronized)type Speedretentionmechanism Slidingsleevesretainedbypawlsandsprings. Gears Helical-toothedconstantmeshgears Gearratio First 6.727 Second 3.947 Third 2.555 Fourth 1.776 Fifth 1.289 Fifth 1.000 Reverse 6.055 Shaftbearings: Mainshaft Transmissionshaft watertightballbearing taperedroller

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6S400AO.D.TRANSMISSION 105 D AILY E URO 4 Base-March2006 Print603.93.651 SPECIFICATIONS AND DATA Transmissionshaftbearingendplay 0 ÷ -0.05mm Transmissionshaftbearingendplayadjustment byshims Shimthicknessfortransmission shaftbearing endplayadjustment -Main shaft Temperatureforfitting: -hubsforslidingsleeves 80 ° ÷ 110 o C -1 st -Rgearbushesandspacerring 80 ° ÷ 110 o C -frontbearing* 90 ° ÷ 110 o C Transmission shaft Temperatureforfitting: -bearings 80 ° C(max120 o C) -5 th -4 th gears 170 °÷ 160 o C Gearendfloat: 1 st -3 rd -4 th -R-5 th gear 2 nd gear 0.15 ÷ 0.40mm 0.25 ÷ 0.5mm 5 th -4 th gearslidingsleevehubretaining ringendfloat 0 ÷ 0.15mm 5 th -4 th gearslidingsleevehubretaining ringthickness -Retainingringendfloat: -transmissionshaftfrontbearing 0 ÷ 0.1mm -mainshaftrollerbearing 0 ÷ 0.1mm Transmissionshaftrearbearingretaining ringthickness -LOCTITE510 Sealant LOCTITE242 LOCTITE5206 Typeofoil: TUTELA TRUCK GEARLITE Quantity 2.7litres 2.43kg *=Donotusehotairequipmenttoheatbearing.

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Figure 16 101948 : SpreadLOCTITE5206sealantonthecontactsurfaces F SpreadLOCTITE242onthethread J SpreadLOCTITE510onthethread 106 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 D Screwsecuringdrivertomainrod 9.5 0.9 2 Gearboxactuatorsupportfasteningscrew 23 2.3 3 Clutchhousing,screwtofastenclutchhousingtocrankcase 80 8 4 Constantmeshshaftcoverfasteningscrew 23 ± 15% 2.3 ± 15% 5 J Screwsecuringp.t.o.sidecover 46 ± 15% 4.6 ± 15% 6 Plugsforrodpreventinggearengagement 32 3.2 7 Clutchactuatorfasteningscrews 23 2.3 8 Screwsecuringreversegearshaft 23 ± 15% 2.3 ± 15% 9* Screwsecuringrearcover 23 ± 15% 2.3 ± 15% 10 Electroniccontrolunitfasteningscrews 9.5 0.9 11 Sideplugonrearcover 35 3.5 12 Speedometertransmitterfixing 50 5 13 Screwlockingsleevefortransmissioncouplingonmainshaft 235 23.5 14 Cap 32 3.2 15 D Screwsecuringballbearingretainingring 9.5 ± 15% 0,. ± 15% 16 Gearboxactuatorfasteningscrews 23 3.2 17 Electricmotorfasteningscrews --

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6S400AO.D.TRANSMISSION 107 D AILY E URO 4 Base-March2006 Print603.93.651 TOOLS TOOL NO. DESCRIPTION 99327010 E.A.SY. 99327001 Modusstation

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108 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 s 108872 DIAGNOSIS Diagnosis instruments DISPLAY Computer-assisteddiagnosisstationintendedfordiagnosisofelectronically-controlledbrakingsystems,pneumaticsuspensions, enginesandsystems. Thisstationisequippedwithauxiliaryfunctionssuchaselectroniccontrolunitprogramming,sparepartcataloguereferencing, time-charts,etc. MODUS IT 2000 IT2000isadiagnosisinstrumentforallElectronicSystemsfittedtoIVECOvehicles.Itallowsyoutopromptlyoperateonavehicle byrecognizingthelatterbymeansofthechassisnumber. Itstorestheresultsofthediagnosticworkcarriedout. ItcanalsobeusedasalaptopPCandissetforremotediagnosis. UsingMODUSasamotherstationallowsyoutoupdateandconfigureIT2000. E.A.SY. TheE.A.SY.systemallowsyoutoeasilydiagnoseandprogramthevariouselectroniccontrolsunitfittedtothevehicle.Itismade upofanECImoduleforcommunicationwiththeelectroniccontrolunitsandaPanasonicPC. TheECImoduleallowsyou,bytakingadvantageofthePanasonicPC,toeasilycarryoutworkontheroad;inparticular,diagnostic workcanbeassistedbyaspecializedremotecentre,thankstothewirelesstechnologyincorporatedintothePanasonicPC(e.g. GPRS). Figure 17 Systemfaultdisplayedwithsymbolsindicatedinfigure.

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6S400AO.D.TRANSMISSION 109 D AILY E URO 4 Base-March2006 Print603.93.651 108874 The38-poleconnectionmakesitpossibletoperformthefollowingoperations: -Gearboxcontrolunitdatareading -Error(ifany)detectionandclearing -Clutchengagement/releasecontrol -Controlunitconfiguring A.IT2000-B.E.A.SY.-C.MODUS-D.Bodycomputer-E.Diagnosissocket. MODUS - IT 2000 - E.A.SY. CONNECTION Figure 18

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Removethestraps(shownbyarrows)thatsecuretheelectric cabletothegearbox. Removereversegearlightconnectors(1)andrevsnumber sensor(2). Removethepowertake-offelectricconnections(ifany)from theothersideofthegearbox. Push the safety retainer downwards, then remove the connectorformthecontrolunit(seearrow). Remove electric cable fastening strap (1) on the clutch actuatorside. Pressclutchactuatorconnectorpull-backspring(1),asshown bythearrow Removeconnector(1)fromclutchactuator(2). 102134 102137 102135 102136 102138 102139 Disconnectthebatterycableinengineopening. Placethevehicleinapit,oronanautoliftorspecialsupporting stands. Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 24 110 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 530210 GEARBOX REMOVAL/REFITTING Removal

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Removethefourclutchactuatorfasteningscrews(1). Takeoffactuator(2). Removescrews(1)securingthestartingmotortothegearbox case front cover. Then, place it carefully in the engine compartment. Unscrewthefourscrews(2)securingdriveshaft(1)tothe gearbox. Properlysecuredriveshaft(1)tothechassis. Removethetwohexagonalscrews(1),thentakeoffthe enginelowercover(oppositetheaxle). 102140 102143 102141 102163 102144 102145 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Priortoremovingtheactuator,verifythattheclutch isclosed.Thiscanbedoneeitherbymeansofthe diagnosis instrument or by visually inspecting the positionoftheforkwhichmustbeperpendicularto thegearboxaxis. Intheeventthattheclutchhasbeenleftopen,due toamechanicorelectricfault,theforkwillbeloaded bytheactuatorinternalspring Therefore,avoidtouchingtheengagingtipstraight withyourhands. 6S400AO.D.TRANSMISSION 111 D AILY E URO 4 Base-March2006 Print603.93.651

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Useahydraulicjacktopositionbracket99370629(1)under thegearbox;then,putthechainontothegearboxandplace aringofthesameintothebracketslottedhole. Screwdownthenutsoastotightlysecure,throughthechain, thegearboxtothebracket. Removescrew(1)centrallysecuringtherearcrossbartothe gearbox. Removethecrossbarfasteningscrews(1)ontheleftside. Removethecrossbarfasteningscrews(1)ontherightside, thenremovethecrossbar,takingcarenottodropitonthe floor. Removeboot(1)fromitshousing. Thisoperationisnecessarytomaketheforktravelthefull disengagementstrokewhendetachingthegearbox Removetheremainingscrewssecuringthegearboxtothe clutchbell. 102146 102149 102147 102148 102150 102151 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Beforemountingbracket99372069,removeanumberof screwssecuringgearboxtoblock. 112 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Useplierstoactontheretainingringtodisassemblebearing(1). Removebearing(1). Pressthepressureplatebearingontotheshaftandthefork againstthebearing,asshowninthefigure.ApplygreaseMRM2 totheforkatthebearingpressurepoint. Putrubberboot(1)intoitshousing. Couplegearbox(2)withclutch(1). 102152 102155 102153 102154 102156 102157 Movethegearboxbackwardsuntilthemotioninputshafthas comeoutoftheclutchdischub.Fullytakeoutthegearbox, takingcarenottohititorgetitcaughtinsomecomponent. Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 After the detachment operation has been completed, pressureplatebearing(1)shallremainfittedintotheclutch(as showninthefigure). Refitting Gearboxisprovidedbysparesinsecondgearin order to enable primary shaft rotation through transmissionshaftconnectionflangerotation. NOTE Inordertofacilitatecoupling,twoguidingpins,fitted ontotwooftheholesusedtosecurethegearbox tothebaseunit,canbeused. NOTE 6S400AO.D.TRANSMISSION 113 D AILY E URO 4 Base-March2006 Print603.93.651

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Securethecabletothegearboxbymeansofthespecial fasteners(1). Screwdowngearboxfasteningscrews(1)bytighteningthem totorque. Screwdownscrews(1),thenfittheenginelowercover. 102158 102160 102159 102161 102145 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Manuallyscrewdownscrews(1)securingthegearboxcaseto thebaseunitpriortotighteningthemtotorque. Pullthefork(3)towardsthecontrolunit,sothat pressureplatebearing(2)iscorrectlyengagedinto diaphragmspring(1). NOTE 114 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Securecrossbar(1)tothegearboxandtothechassisby tighteningthescrewstothespecifiedtorque. Fittheclutchactuator(1)engagingtipintothespecialforkslot, takingcarenottotouchitstraightwithyourhands. Secureclutchactuator(1)tothegearboxbymeansofthefour screws(2),thentightentothespecifiedtorque. Connectconnector(1)totheclutchactuator. Securethegearboxcablebymeansofstrap(1). 102163 102141 102149 102165 102167 102168 Figure 48 Figure 49 Figure 50 Figure 51 Re-attachthestartingmotortothegearboxcasefrontcover bytighteningthescrews(1)tothespecifiedtorque. Figure 52 Figure 53 6S400AO.D.TRANSMISSION 115 D AILY E URO 4 Base-March2006 Print603.93.651

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Properlysecuretheconnectoruntilthepull-backspringclicks intoposition(seearrow). Connectthereverselight(1)andrevsnumbersensor(2) connectors. Connecttheelectricalconnectionsofthepowertake-off,if present,fromtheothersideofgearbox. Securethewiringtothegearbox,asshownbythearrowsin thefigure. 102169 102172 102170 102171 102143 Figure 54 Figure 55 Figure 56 Figure 57 Connectconnectors(1)tothecontrolunit. Securedriveshaft(1)tothegearboxbytighteningfastening screws(2)totorque. Afterthegearboxhasbeenre-attachedcompletely,checkfor correctconnectionofelectriccables. Figure 58 Afterre-attachmenthasbeencompleted,perform thespecificcalibrationprocedurebymeansofthe diagnosisinstrumentdescribedonpage122/30. NOTE 116 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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102162 Placethevehicleinapitoronanautolift. Disconnectthebatterycableintheenginecompartment. Asfarasgearboxunitoverhaulingisconcerned, followtheinstructionsandillustrationsrelativeto the6S400O.D.gearboxunit. Belowarethedescriptionsandillustrationsrelative to the replacement of the gearbox unit electric/electroniccomponentssuppliedwithspare parts. 66136114 CONTROL UNIT Removal Removeconnector(4)fromcontrolunit(1)bypullingthesafetyretainerdownwards,asshownbythearrow. Removestrap(6).Unscrewscrews(2,3). Removescrew(5)whileholdingthecontrolunitandtakingcaretorecoverspacer(7)placedbehindscrew(3).Takeoffcontrol unit(1). Figure 59 NOTE 6S400AO.D.TRANSMISSION 117 D AILY E URO 4 Base-March2006 Print603.93.651 GEARBOX UNIT OVERHAULING

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102164 Screwdownscrew(5),yetwithouttighteningittotorque. Fitspacer(7),betweenthecontrolunitandthegearbox, behindscrew(3),thenscrewdownthelatter. Screwdownscrews(2). Screwdownallscrews(2,3&5)tothespecifiedtorque. Insertcontrolunitconnector(4)bysecuringitwiththesafety hook,asshownbythearrow. Connectthebatterycable. Figure 60 Afterre-attachmenthasbeencompleted,perform thespecificcalibrationprocedurebymeansofthe diagnosisinstrumentdescribedonpage122/30. NOTE 118 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 Refitting

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102166 Placethevehicleinapit,oronanautoliftorspecialsupporting stands. Disconnectthebatterycableintheenginecompartment. Removestrap(1). Takeoffconnector(5)bypressingontothefasteningsprings, asshownbythearrows. Removal Removethefourfasteningscrews(3). Takeoffclutchactuator(2). 505279104 CLUTCH ACTUATOR Priortoremovingtheclutchactuator,makesure thattheclutchisclosed. Engaginglever(4)mustbeinthepositionshownin boxA(perpendiculartothegearboxaxle). Iftheleverisnotfoundinthatposition,theclutch willbeopen. Thisconditioncanbeinspectedbothvisuallyandby gettingconnectedtothevehiclebymeansofthe diagnosisinstrumentandsubsequentlyreadingthe datamemory.Intheeventthattheclutchis Intheeventthattheactuatorhasbeentakenoff withtheclutchopen,releaselever(4),previously engaged,withtheutmostcare. Avoidtouchingtheleverstraightwithyourhands, owingtotheleverbeingloaded. open,itisrequiredthattheactionoftheleveris forcedback,sincetheleverisloadedbytheclutch diaphragmspring.Properlylockthemotionoflever (4), and avoid, during the subsequent actuator releasing phase, getting your hands near the engagingtiparea. Figure 61 6S400AO.D.TRANSMISSION 119 D AILY E URO 4 Base-March2006 Print603.93.651

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Positionclutchactuatortip(1)intoforkaperture(3). Tightenthefourfasteningscrews(2)tothespecifiedtorque. Fitconnector(2)bypressingituntilitgetsengaged. Securethecablebymeansofstrap(1). Connectthebatterycable. Placeapitlift(2)undergearbox(1).Unscrewthegearbox crossbarfasteningscrews.Lowertheliftsoastoobtaina distance“A”of12-13cmbetweentheactuatorandthecabin floor. 102173 102189 102190 Refitting Figure 62 Figure 63 530520100 GEARBOX ACTUATOR Placethevehicleinapit,oronanautoliftorspecialsupporting stands. Disconnectthebatterycableintheenginecompartment. Takeofftheclutchactuator,asdescribedonpage119. Removal Theactuator,positionedintheupperpartofthe gearbox, cannotbeaccessed, owingto thevery narrow space between the cabin floor and the actuatoritself. NOTE Proceedasitfollows: Thisoperationmustbecarriedoutwiththegreatest care,avoidinghittingthefrontpartofthepowerunit. Figure 64 Afterre-attachmenthasbeencompleted,perform thespecificcalibrationprocedurebymeansofthe diagnosisinstrumentdescribedonpage125. NOTE NOTE 120 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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-Apply an even coat of LOCTITE 574 sealant on the gearboxactuatorsupportingsurface. -Positiontheactuatorintoitsseatwiththegreatestcare. -Tightenthenutsorscrewstothespecifiedtorque. Opentheenginehood. Unscrewscrew(1),disconnectthebatterycablesandtakeoff battery(2).Takeconnector(3)offEDCcentralunit. 102191 102192 102193 Figure 65 Figure 66 Takeelectricconnectors(2)offtheactuator. Unscrewelectricmotorsupportfasteningscrew(4).Takeoff supports(3). Useasuitabletool(5)toremovetheeightfasteningscrews (1),thentakeoffgearboxactuator(6). Cleanthesupportingsurfaceoftheactuatoronthe gearboxcase. NOTE Refitting Re-attachment is carried out by reversing the order of detachmentoperations.Alsofollowtheadvicebelow: Afterre-attachmenthasbeencompleted,perform thespecificcalibrationprocedurebymeansofthe diagnosisinstrumentdescribedonpage125. NOTE 769152104 CHASSIS WIRING GEARBOX Removal Placethevehicleinapit,oronanautoliftorspecialsupporting stands. Figure 67 6S400AO.D.TRANSMISSION 121 D AILY E URO 4 Base-March2006 Print603.93.651

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Removethestraps(shownbyarrows)thatsecurethecable tothegearbox. 102194 102196 Figure 68 Disconnectwiring(1)fromthegearboxcontrolunit,taking carethatitisnothitordoesnotgetcaught. After the re-attachment operation has been completed, verify, by getting connected to the vehiclebymeansofthediagnosisinstrument,thatno error is found in the gearbox control unit fault memory. NOTE Refitting Re-attachment is carried out by reversing the order of detachmentoperations.Alsotightenthenutsorscrewstothe specifiedtorque. 769152104 GEARBOX WIRING -GEARBOX Removal Placethevehicleinapit,oronanautoliftorspecialsupporting stands. Disconnectthebatterycableintheenginecompartment. 102195 Figure 69 Takefullwiring(1)offthevehicle. Figure 70 122 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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Pressconnectorsprings(2)inwards(seearrows). Removetheconnectorfromclutchactuator(1). 102198 102199 Figure 71 Removeconnector(1)fromcontrolunit(2),byreleasingthe pull-backspringdownwards,asshownbythearrow. Figure 72 Re-attachment is carried out by reversing the order of detachmentoperations.Alsofollowtheadvicebelow: - Laythewiringontothegearboxbyfittingthesamewith bracketsatthespecifiedpoints,thenplaceitontheengine, takingcarethatitdoesnotgetpinched. - Checkforcorrectinsertionofconnectors,whichcanbefelt whenthelockingbrackethasbeencloset. Refitting After the re-attachment operation has been completed, verify, by getting connected to the vehiclebymeansofthediagnosisinstrument,thatno error is found in the gearbox control unit fault memory. NOTE Remove the connectors (1) from the gearbox actuator electricmotorsbypressingthefasteningsprings,asshownby thearrows. 102200 Figure 73 6S400AO.D.TRANSMISSION 123 D AILY E URO 4 Base-March2006 Print603.93.651

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124 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651 CALIBRATION SomemodificationsorrepairsthataffecttheESV1systemcomponents,automatictransmission,requireacalibrationprocedure. Therepairsthatrequirethisoperationaredetailedasfollows: - Replacingthegearboxkit+controlunit - Replacingthecontrolunitonly - Replacingtheclutchactuator - Replacingthegearboxactuator - Replacinganelectricmotorofthegearboxactuator - Replacingtheengagingfork Replacingthegearboxwiringrequiresnocalibrationprocedure. NOTE Calibration in case of replacement of the gearbox kit + control unit Thecontrolunitmustbeprogrammed(noerrorinthememory)byprovidingthesamewiththevehicledata,e.g.axleratio,rolling radius,strengthcurve,etc. Getconnectedtothevehiclebymeansofthediagnosisinstrument,withthevehiclestationary,engineOFFandgearshiftlever inneutral. Carryouttheoperationsindicatedbytheinstrument:keyON(engineON),thenthededicatedcalibrationprocedurewillbe started → ” Adaptation of touch Point. Message“service”willappearonthedisplay;thesysteminautomaticmodewillcarryoutthefollowingoperations: -openingtheclutch; -engagingthe5 th or6 th speed; -heclutchclosesthreetimessearchingforthepointofinitialslip(thevehiclewillpickupthreetimes); -puttingtheleverinneutral; -closingtheclutch. Theprocedureisinterruptedwhentheengineisswitchedoff. Wait10secondspriortothenextKEYON. NOTE Whentheprocedurehasbeencompleted,checkthecontrolunitmemoryandverifythatnoerrorisfound. Calibration in case of replacement of the control unit Thecontrolunitmustbeprogrammedbyprovidingthesamewiththevehicledata,e.g.axleratio,rollingradius,strengthcurve, etc. Getconnectedtothevehiclebymeansofthediagnosisinstrument,withthevehiclestationary,engineOFFandgearshiftlever inneutral. Carryouttheoperationsindicatedbytheinstrument:keyON(engineOFF),thenthededicatedcalibrationprocedureswillbe started → Measurement of Maximum Clutch Travel Transmission Self Adaptation Message“service”willappearonthedisplay;thesysteminautomaticmodewillcarryouttheaforesaidprocedures.Upon completionofthisstep,theenginewillbestartedandthe → Adaptation of touch Point calibrationprocedurewillbestarted. Message“service”willappearonthedisplay;thesysteminautomaticmodewillcarryoutthefollowingoperations: -openingtheclutch; -engagingthe5 th or6 th speed; -heclutchclosesthreetimessearchingforthepointofinitialslip(thevehiclewillpickupthreetimes); -puttingtheleverinneutral; -closingtheclutch. Theprocedureisinterruptedwhentheengineisswitchedoff.

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6S400AO.D.TRANSMISSION 125 D AILY E URO 4 Base-March2006 Print603.93.651 Wait10secondspriortothenextKEYON. NOTE Whentheprocedurehasbeencompleted,checkthecontrolunitmemoryandverifythatnoerrorisfound. Calibration in case of replacement of the clutch actuator Clearthecontroluniterrormemory. Getconnectedtothevehiclebymeansofthediagnosisinstrument,withthevehiclestationary,engineOFFandgearshiftlever inneutral. Carryouttheoperationsindicatedbytheinstrument:keyON(engineOFF),thenthededicatedcalibrationprocedurewillbe started → Measurement of Maximum Clutch Travel. Message“service”willappearonthedisplay;thesysteminautomaticmodewillcarryoutthenecessaryoperations.Theprocedure willbeinterruptedwhentheengineisswitchedoff. Wait10secondspriortothenextKEYON. NOTE Whentheprocedurehasbeencompleted,checkthecontrolunitmemoryandverifythatnoerrorisfound. Calibration in case of replacement of the gearbox actuator or an electric motor of the gearbox actuator Clearthecontroluniterrormemory. Getconnectedtothevehiclebymeansofthediagnosisinstrument,withthevehiclestationary,engineOFFandgearshiftlever inneutral. Carryouttheoperationsindicatedbytheinstrument:keyON(engineOFF),thenthededicatedcalibrationprocedurewillbe started → Transmission Self Adaptation. Message“service”willappearonthedisplay;thesysteminautomaticmodewillcarryoutthenecessaryoperations.Theprocedure willbeinterruptedwhentheengineisswitchedoff. Wait10secondspriortothenextKEYON. NOTE Whentheprocedurehasbeencompleted,checkthecontrolunitmemoryandverifythatnoerrorisfound. Calibration in case of replacement of the clutch engaging/release fork Clearthecontroluniterrormemory. Getconnectedtothevehiclebymeansofthediagnosisinstrument,withthevehiclestationary,engineOFFandgearshiftlever inneutral. Carryouttheoperationsindicatedbytheinstrument:keyON(engineON),thenthededicatedcalibrationprocedurewillbe started → Adaptation of Touch Point. Message“service”willappearonthedisplay;thesysteminautomaticmodewillcarryoutthefollowingoperations: -openingtheclutch; -engagingthe5 th or6 th speed; -theclutchclosesthreetimessearchingforthepointofinitialslip(thevehiclewillpickupthreetimes); -puttingtheleverinneutral; -closingtheclutch. Theprocedureisinterruptedwhentheengineisswitchedoff. Wait10secondspriortothenextKEYON. NOTE Whentheprocedurehasbeencompleted,checkthecontrolunitmemoryandverifythatnoerrorisfound.

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126 6S400AO.D.TRANSMISSION D AILY E URO 4 Base-March2006 Print603.93.651

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POWERTAKEOFF 127 D AILY E URO 4 Base-March2006 Print603.93.651 TRANSMISSION Power take off Page SPECIFICATIONSANDDATA 129 ............. TIGHTENINGTORQUES 130 ................. ASSEMBLYSTANDARDS 131 ................. POWERTAKEOFFELECTRICACTUATOR 132 .. -Description 132 ........................... -Operation 132 ............................

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62092 Figure 1 Powertakeoffsareappliedtosecondaryshaftongearboxleftsideinsteadofcover(1). Fillandcheckgearboxoillevel. NOTE POWERTAKEOFF 129 D AILY E URO 4 Base-March2006 Print603.93.651 SPECIFICATIONS AND DATA TYPE Hidrocar 20Z1 Hidrocar 20 Z2 Application 5 S 300 6 S 400 A O.D. GearratioI,PTO(*)outputrevs.,normalPTO(*)inputrevs. 1 0.910 PTO(*)outputratedtorqueat1500rpm(Nm) 120 180 Expecteddurationatratedtorqueandat1500rpm hours 500 Rotationdirection(withrespecttoengine) Opposite Control Electric Assemblyside(withrespecttorunningdirection) Leftside Torqueobtainablefromgearbox(Nm) 175 303 Oilcapacity(litres) ~0.6 ÷ 0.4 (*)=PowerTakeOff Drivegeartaperrollerbearingaxialbacklash 0-0.1mm Drivegeartaperrollerbearingaxialbacklash adjustment byshims Drivegeartaperrollerbearingaxialbacklash adjustingringthickness 0.1-0.2-0.3-0.5mm

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62181 Figure 2 130 POWERTAKEOFF D AILY E URO 4 Base-March2006 Print603.93.651 TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 M16x1.5actuatorfixingtang 50 5 2 Switchfixing 50 5 3* Flangefixingscrew 25 2,5 M10nutsforfixingPTOtogearbox 35 ÷ 39 3.5 ÷ 3.9 *SmearscrewthreadwithLOCTITE242

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62094 62093 Figure 3 Figure 4 POWERTAKEOFFCOMPONENTS ASSEMBLY STANDARDS Parts(*):sealingringsandbearingsshallbesmearedwith greasePOLIMER400. Adjusting ring ( ♦ ) thickness shall guarantee taper roller bearingaxialbacklashequalto0 ÷ 0.1mm. Screwthread( • )shallbesmearedwithLoctite242. Sealingring(1)shallbefittedwith6mmsinkingfrompower takeoffhousing(2)surface. POWERTAKEOFF 131 D AILY E URO 4 Base-March2006 Print603.93.651

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62095 Figure 5 Thelinearactuator(1)providesmotiontocontrolrod(5) controllingpowertakeoffconnectionanddisconnection. Itisfixedtopowertakeoffthroughthebottomside(2), screwingitonthepowertakeoffbox. Controlrodmotionisgeneratedbyasystemcomposedof electricmotorandwormscrew(7)which,beingblockedin rotation,linearly moves along twodirections enablingto connectanddisconnectthePTO. Axialpowerloadiscontrolledbyaspring,setinsideactuator (1),providingapprox.350Nforceonpowertakeoffcontrol rod(5). Operation POWER TAKEOFF CONNECTION PTO connection (Figure5) is divided into two different phases: Thefirstphaseconsistsinmovingforwardwormscrew(7), rod(5)andsleeve(3),which,comingintocontactwithshaft toothing(4),createsaxialbackstopoftherodandworm screwinanintermediatepositionastothewholestroke. Theaxialbackstopofwormscrew(7)preloadsthespring insidetheactuatorandswitchestheelectricmotoroff;the pretensionedspringexertsenergisescontrolrod(5)and keepstheaxialloadevenafterelectricmotorswitchingoff. Thesecondphaseconsistsinstrokecontinuationifsleeve(3) toothing sustains a relative rotation as to the shaft (4) toothingandthereforestopstheaxialbackstoppreviously setbythetwotoothingcontrast. Description 132 POWERTAKEOFF D AILY E URO 4 Base-March2006 Print603.93.651 POWER TAKE OFF ELECTRIC ACTUATOR

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62096 Figure 6 In this case, the spring inside the actuator, previously preloaded,providesafirstmotiontotheelements(7,5and 3)andcausestheelectricmotor,previouslystopped,starting. Subsequently,thestrokestartsagainuntilitmeetsanew obstacle,representedbyrod(5)limitstoponthepower takeoffbox. Atthispoint,anotheraxialbackstopconditioniscreatedand theabove-mentionedoperationisrepeated:rod(5)tension andelectricmotorswitchingoff. AslongasthePTOengagementtoothingsstayoncontact witheachother,theelectricmotorisswitchedoffbecause thepressureonthetoothings(3and4)iskeptbythespring, insidetheactuator. Theaxialloadontheengagementtoothingsiscalibrated (about 350 N) andgradually appliedbecause the action spring(insidetheactuator)carriesoutadeterminedstroke beforebeingcompletelyloaded.Toothingmouths(3and4) shallthereforebeprotectedagainstviolentimpactsassuring, as to traditional mechanical or pneumatic system, less engagement element wear and consequently, an higher number of turns to be implemented before component deterioration. Thefunctionalityismoreserviceablesincetheengagement issofterandmoresilentastothetraditionalsystems. Wormscrew(7)limitstopisdeterminedbyaxialloadand distancecoveredbycontrolrod(5). ItisthereforepossibletoinstallonPTOhavingdifferent stroke values without modifyingor addingcompensation elements. POWER TAKEOFF DISCONNECTION ThePTOdisconnectionphase(Figure6)isdividedintotwo motions: The first motion consists in the wormscrew return (7) throughthereversalcarriedoutontheelectricmotor. Thesecondmotionconsistsinthecontrolrodretrocession (5)throughspring(6)andconsequentshaft(4)sleeve(3) disengagement. Theretrocessionmotionofthewormscrew(7)do notdependonthemovementcarriedoutbythe controlrod(5);thisguarantees,ifthe sleeve(3) cannotbedisengaged,theimmediatebackingofthe wormscrew(7)withoutcausingoverloadstothe electricmotor. ThePTOwillbedisconnectedwhenthebackstop conditionisover. Thiseventcanoccurifduringthedisengagement request the shaft (4) is still in rotation or pretensionedbyaresidualtorque. NOTE POWERTAKEOFF 133 D AILY E URO 4 Base-March2006 Print603.93.651

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134 POWERTAKEOFF D AILY E URO 4 Base-March2006 Print603.93.651

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PROPELLER SHAFTS 1 D AILY E URO 4 Print 603.93.651 Base - March 2006 SECTION 5 5056 Propeller shafts Page CHARACTERISTICS AND DATA 3 . . . . . . . . . . . . . DIAGNOSTICS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 10 . . . . . . . . . . . . . . . . . . . TOOLS 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER SHAFT REMOVAL AND REFITTING 11 . -Removal 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING PROPELLER SHAFTS ON VEHICLE 11 . .

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62123 50826 Figure 1 Figure 2 GKN-TYPEARTICULATEDPROPELLERSHAFT DANA-TYPEARTICULATEDPROPELLERSHAFT 4x2 Vehicles PROPELLERSHAFTS 3 D AILY E URO 4 Print603.93.651 Base-March2006 CHARACTERISTICS AND DATA Name mm Completespiderassembly(radial)intheforkhousings 0,03 Transmissionshaftmax.off-centring -measuredatcentre 0,4 -measuredatextremities 0,25 -measuredontang 0,15 Max.workingangle 20º

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GKN-TYPECONNECTINGSHAFT 62122 50827 Figure 3 Figure 4 DANA-TYPECONNECTINGSHAFT 4x2 Vehicles Figure 5 GKN-TYPECONNECTINGSHAFT 75213 4 PROPELLERSHAFTS D AILY E URO 4 Base-March2006 Print603.93.651

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PROPELLERSHAFTS 5 D AILY E URO 4 Print603.93.651 Base-March2006 PITCH Propellershaftlength(mm)SENZACODICE-2 MODEL VERSION PITCH (mm) L 1 L (mm) L 1 GKNsupply DANAsupply VAN 2120 ÷ 2205 29L-35S10/12 29L35S14 CHASSI CAB 3000 813 2120 ÷ 2210 2120 ÷ 2205 2130 ÷ 2215* 29L-35S14 VAN 3450 1134 2565 ÷ 2655 -VAN 3450 1135 -2580 ÷ 2665 35S10/12/15/18 VAN 3000 763 2075 ÷ 2165 2075 ÷ 2160 2085 ÷ 2170* 35S10/12/15/18 CHASSI CAB 3450 1085 2520 ÷ 2610 2520 ÷ 2605 35C-40C10/12 VAN 2080 ÷ 2165 35C-40C10/12 35C14 CHASSI CAB 3000 652 2080 ÷ 2170 2080 ÷ 2165 2090 ÷ 2175* 35C10/12/18 VAN 35C-40C 10/12/15/18 CHASSI CAB 3000 602 2035 ÷ 2125 2035 ÷ 2120 (*) Powertrainsextendedby10mm.

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6 PROPELLERSHAFTS D AILY E URO 4 Base-March2006 Print603.93.651 Propellershaftlength(mm) MODEL VERSION PITCH FrontshaftSENZACODICE-4 RearshaftSENZACODICE-2 MODEL VERSION (mm) L L 1 L L L 1 GKNsupply DANAsupply VAN 3300 891 343 1540 ÷ 1630 1540 ÷ 1625 VAN 3300 891 343 1540 ÷ 1630 1540 ÷ 1625 29L.10/12/14 CHASSI 3750 891 666 1980 ÷ 2070 1980 ÷ 2065 35S10/12/14 CHASSI CAB 3750 891 666 1980 ÷ 2070 1980 2065 1990 ÷ 2075* VAN 3950 891 866 2180 ÷ 2270 2180 ÷ 2265 VAN 3950 891 866 2180 ÷ 2270 2180 2265 2190 ÷ 2275* VAN 3300 841 343 1540 ÷ 1630 1540 ÷ 1625 35S10/12/14 /15/18 CHASSI CAB 3750 841 666 1980 ÷ 2070 1980 ÷ 2065 1990 ÷ 2075* VAN 3950 841 866 2180 ÷ 2270 2180 ÷ 2265 2190 ÷ 2275* VAN 3300 730 608 1650 ÷ 1740 1650 ÷ 1735 1660 ÷ 1745* CHASSI CAB 3450 730 607 1815 ÷ 1905 1815 ÷ 1900 35C-40C10/12 35C14 CHASSI CAB 3750 730 652 2090 ÷ 2180 2090 ÷ 2175 2110 ÷ 2195* VAN 3950 730 986 2315 ÷ 2405 2315 ÷ 2400 CHASSI CAB 4100 730 1024 2450 ÷ 2540 2450 ÷ 2530 2460 ÷ 2540* CHASSI CAB 3450 680 607 1800 ÷ 1905 1815 ÷ 1900 35C-50C15 45C-50C10/12 14/15/18 CHASSI CAB 3750 680 652 2090 ÷ 2180 2090 ÷ 2175 2110 ÷ 2195* VAN 3950 680 986 2295 ÷ 2385 2315 ÷ 2400 (*) Powertrainsextendedby10mm.

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PROPELLERSHAFTS 7 D AILY E URO 4 Print603.93.651 Base-March2006 Propellershaftlengthinmm. MODEL VERSION PITCH FrontshaftSENZACODICE-4(*) RearshaftSENZACODICE-2-(*)5 MODEL VERSION (mm) L L 1 L L L 1 GKNsupply DANAsupply 35C 40C VAN 4100 680 1024 2450 ÷ 2540 2460 ÷ 2545 35C-40C 10/12/14/15/18 CHASSI CAB 3300 680 607 1650 ÷ 1740 1650 ÷ 1735 1660 ÷ 1745* 45C-50C15/18 VAN 3300 (*)680 (*)690 ÷ 790 35C-50C 45C-50C 10/12/15/18 VAN 3950 680 986 2295 ÷ 2405 2315 ÷ 2400 Propellershaftlengthinmm. MODEL VERSION PITCH (mm) Frontshaft SENZACODIC Centralshaft SENZACODICE-4-( S )5 RearshaftSENZACODICE-2-( S )5 MODEL VERSION (mm) SENZACODIC -4 L L 1 L L GKNsupply DANAsupply L 1 GKNsupply DANAsupply CHASSIS COWL 3750 ( S )680 ( S )755 ÷ 855 ( S )755 ÷ 855 -( S )1080 ÷ 2180 ( S )1080 ÷ 1190 CHASSICAB 746 722 1950 ÷ 2040 1965 ÷ 2050 45-50C15/18 CHASSIS COWL ( S ) 4350 680 ( S )755 ÷ 855 ( S )755 ÷ 865 ( S )440 ( S )1630 ÷ 1720 ( S )1630 ÷ 1715 45-50C15/18 CHASSICAB 730 1056 2380 ÷ 2470 2380 ÷ 2465 CHASSIS COWL ( S ) 4750 680 ( S )755 ÷ 855 ( S )755 ÷ 865 ( S )781 ( S )2100 ÷ 2190 ( S )2100 ÷ 2185 VAN 3950 (*)680 ( S )1120 ÷ 1220 -( S ) 900 ÷ 1000 -( S )VehicleswithTelmaretarder (*) Powertrainsextendedby10mm.

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8 PROPELLERSHAFTS D AILY E URO 4 Base-March2006 Print603.93.651 Propellershaftlengthinmm. MODEL VERSION PITCH FrontshaftSENZACODICE-4 RearshaftSENZACODICE-2 MODEL VERSION (mm) L L 1 L L L 1 GKNsupply DANAsupply VAN 3300 670 614 1630 ÷ 1720 1630 ÷ 1715 60C-65C15/18 CHASSI CAB 3450 670 626 1780 ÷ 1870 1790 ÷ 1875 60C-65C15/18 CHASSI CAB 3750 670 660 2075 ÷ 2165 2085 ÷ 2170 VAN 3950 670 995 2280 ÷ 2370 2280 ÷ 2365 Propellershaftlengthinmm. MODEL VERSION PITCH Frontshaft SENZACODIC Centralshaft Rearshaft MODEL VERSION PITCH (mm) SENZACODIC -4 Centralshaft SENZACODICE-4 L 1 L L L L 1 GKNsupply DANAsupply 60C-65C15/18 CHASSI CAB 4350 670 801 724 1885 ÷ 1975 1885 ÷ 1970 60C-65C15/18 CHASSI CAB 4750 670 730 1065 2350 ÷ 2440 2350 ÷ 2435 Propellershaftlengthinmm. MODEL VERSION PITCH Frontshaft SENZACODIC CentralshaftSENZACODICE RearshaftFigure5.1.2 MODEL VERSION PITCH (mm) SENZACODIC -4 L L 1 L L GKNsupply DANAsupply L 1 GKNsupply DANAsupply CHASSIS COWL 3750 670 ( S )970 ÷ 1070 --( S )825 ÷ 925 -60C-65C15/18 CHASSIS COWL 4350 670 ( S )970 ÷ 1070 --( S )1395 ÷ 1495 -CHASSIS COWL 4750 670 ( S )1080 ÷ 1180 -408 -( S )1705 ÷ 1790 ( S )VehicleswithTelmaretarder

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PROPELLERSHAFTS 9 D AILY E URO 4 Print603.93.651 Base-March2006 1 Themainoperatingfaultsofthepropellershaftareasfollows: 1. Noiseandvibrations DIAGNOSTICS YES NO Deformationofshaft. Replaceshaft. Shaftunbalanced. Checkbalancingofshaftanddeterminethepoints wheretoweldthecounterweights. Excessiveplaybetweenthesplinedprofiles. Replacetheshaft. Nutsandboltsfasteningshafttoeithertransmissionor rearaxlesleevesloose. Afteracarefulcheck,tightenuptheloosescrewsand nuts,andeventuallyreplaceanydamagedones. Universaljointsseized-uporexcessivelyworn. Overhaulorreplacetheuniversaljoints. Insufficientlubricationoftheparts. Lubricatethepartsattheappropriatenipples. YES NO YES NO YES NO YES NO YES YES NO Elasticsupportfixingscrewsloose. Tightenthescrewstotherequireddrivingtorque. NOISE AND VIBRATIONS (Continues)

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10 PROPELLERSHAFTS D AILY E URO 4 Base-March2006 Print603.93.651 PART TORQUE PART Nm kgm Ringnutforfixingtoconnectingshaft 250 ± 25 25,4 ± 2,5 Nutforscrewforfixingflangestopropellershaft M10x1,5 M12x1,25 63,5 ± 6,5 116,5 ± 11,5 6,5 ± 0,6 11,8 ± 1,2 Nut,linkageshafttochassissidememberfixingscrew 62,5 ± 6,5 6,3 ± 0,6 TOOLS TOOLNO. DESCRIPTION 99370618 Supportforremoval-refittingpropellershaft YES NO Elasticdowelofcentralsupportinbadcondition. Replacethesupport. Centralelasticsupportbearinginbadconditionor excessiveplay. Replacethesupport. Flangefixingscrewsorringnutsonpropellershafttang loose. Tightenthescrewsortheringnutstorequireddriving torque. YES NO YES TIGHTENING TORQUES

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Arrangethesupport99370618onthehydraulicjackand applythesupporttothepropellershaft. Removethefixingboltsfromtheflangeandremovetheshaft; fortheintermediateandfrontaxles,alsoremovethechassis shaftsupport. Refitting 52123 52124 Figure 6 Figure 7 Theplatesweldedtothepropellershaftsarecounterweights. Iftheplatesaremissingtheshaftmustbere-balanced. Byoperatingonthepropellershaftandatthesametime,in theoppositedirection,ontheslidingsleeve,checkthatthere isnottoomuchslackbetweenthesplines. Byoperatingonthesleeveforks.checkthatthespidersare notworn;iftheyare,replacethem. Removal Whenoverhaulingthepropellershaft,alwaysbegin byremovingtherearshaft. CHECKING PROPELLER SHAFTS ON VEHICLE Repeatthesameoperationsforremovalintheopposite orderandobservethefollowing: -Makesurethatthearrowsshownonthemovingpart andontheshaftarealigned. -Makesurethattheholesofthefrontflangearealigned withthoseoftherearflange; -thenutsfortheflangecouplingscrewsmustbereplaced andneverreused; -theflangecouplingscrewsmustbeinsertedintothe holesoftheflangefromthesideoftheuniversaljoint; -thenutsandscrewsmustbetightenedtotherequired drivingtorque; -theflangeofthemovingpartofthepropellershaftmust beconnectedtotheoutputshaftflange. NOTE PROPELLERSHAFTS 11 D AILY E URO 4 Print603.93.651 Base-March2006 505620 PROPELLER SHAFT REMOVAL AND REFITTING

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12 PROPELLERSHAFTS D AILY E URO 4 Base-March2006 Print603.93.651

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REAR AXLES 1 D AILY E URO 4 Base - March 2006 Print 603.93.651 SECTION 6 5250 Rear axles Page DIAGNOSTICS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE NDA RS 5 . . . . . . . . . . . . . . . . . . . . . REAR AXLES NDA RG 35 . . . . . . . . . . . . . . . . . . . . REAR AXLE 450511 53 . . . . . . . . . . . . . . . . . . . . . . REAR AXLE 450517/2 83 . . . . . . . . . . . . . . . . . . . .

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2 REAR AXLES D AILY E URO 4 Base - March 2006 Print 603.93.651

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REAR AXLES 3 D AILY E URO 4 Base - March 2006 Print 603.93.651 DIAGNOSTICS YES The main rear axle operating faults are as follows: 1. -Wheel hubs noise; 2. -Rear axles noise; 3. -Noise at release; 4. -Noise during acceleration; 5. -Cornering noise. 1 WHEEL HUBS NOISE YES Insufficient lubrication. Check that there are no leaks from gaskets or the rear axle casing and top up oil to correct level. YES NO Wheel hub bearings inefficient. Remove the hub and replace inefficient parts. Wheel hub bearings out of adjustment. Adjust bearings. YES 2 REAR AXLES NOISE NO Lubricating oil level low. Check that there are no leaks from gaskets or the rear axle casing and top up oil to correct level. YES NO Drive shaft splines to fit the differential crown wheels damaged. Overhaul the rear axle and replace worn or damaged parts. YES Wheel hub bearings inefficient. Adjust the bearings clearance. NO

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YES YES 3 NOISE AT RELEASE Improper fitting clearance between pinion and ring bevel gear. Remove the gear housing inspection cover and adjust clearance between pinion and ring bevel gear. NO Insufficient lubrication. Check that there are no leaks from gaskets or the rear axle casing and top up oil to correct level. 4 NOISE DURING ACCELERATION YES Bad adjustment or wear on differential gears or bearings. Locate the trouble and overhaul the unit. YES NO Gear housing bearings badly set or deteriorated. Overhaul the unit. YES Bad tooth contact between pinion and ring bevel gear. Adjust the contact. 5 YES Improper clearance between planetary gears and crown wheels. Overhaul or replace the unit. CORNERING NOISE 4 REAR AXLES D AILY E URO 4 Base - March 2006 Print 603.93.651

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REAR AXLE NDA RS 5 D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear axle NDA RS Page DESCRIPTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA 8 . . . . . . . . . . . . . TIGHTENING TORQUES 10 . . . . . . . . . . . . . . . . . TOOLS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE NDA - RS REMOVAL - REFITTING 17 -Removal 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING THE REAR AXLE ASSEMBLY 19 . -Air breather disassembly - assembly 19 . . . . . . . . -Wheel hub overhaul 19 . . . . . . . . . . . . . . . . . . . . -Disassembly 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Assembly 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIRING THE DIFFERENTIAL 22 . . . . . . . . . . . . -Disassembling the differential unit 22 . . . . . . . . . . -Gear housing removal 23 . . . . . . . . . . . . . . . . . . . -Dismounting bevel pinion 24 . . . . . . . . . . . . . . . . -Checking the parts comprising the differential 25 -Assembly of gear housing 26 . . . . . . . . . . . . . . . . -Assembling the bevel pinion assembly 27 . . . . . . -Assembly of differential unit 30 . . . . . . . . . . . . . .

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6 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

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107834 Figure 1 DESCRIPTION The rear axle is the load-bearing type with a single reduction using a hypoid crown wheel and pinion. The axle housing is made of pressed sheet steel with hot pressed arms. The bevel pinion is supported by two pre-lapped tapered roller bearings to hold the bearing pre-load better. The bearings are factory lubricated by the manufacturer with rustproof protective oil. The rolling torque of the bearings of the bevel pinion is adjusted by changing the thickness of the adjustment ring between the two tapered roller bearings. In addition, it is possible to adjust the position of the bevel pinion with respect to the ring bevel gear by changing the thickness of the ring between the axle housing and the bevel pinion rear bearing external ring. The gear housing is supported by two tapered roller bearings, also pre-lapped and lubricated with rustproof protective oil. The adjustment of bearing rolling torque is through adjusting rings put in between box and stop rings. The clearance between pinion and crown wheel is adjusted by changing the thickness and/or position of the adjustment rings, though the total thickness must be the same as that of the adjustment rings removed. Differential wheelwork assembly is made up of two planetary and two crown wheel gears. The drive shafts are supported inside the arms of the axle housing by UNIT BEARINGS lubricated for life, which require no adjustment. The brakes are disc brakes with floating brake calipers. The disc brakes are splined onto the end of the drive shafts and secured with pins that also serve as centring for the wheel rims. The brake calipers are secured with flanges welded onto the end of the arms of the axle housing. The brake calipers are equipped with the parking brake device. REAR AXLE NDA RS 7 D AILY E URO 4 Base - March 2006 Print 603.93.651

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8 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651 SPECIFICATIONS AND DATA Type of rear axle: NDA RS Simple reduction type NDA RS DIFFERENTIAL UNIT Reduction bevel gear pair ratio (No. of teeth: pinion/crown) 1/3,154 (13/41) - 1/3,416 (12/41) - 1/3,727 (11/41) - 1/3,916 (12/47) - 1/4,182 (11/46) - 1/4,444 (9/40) - 1/4,889(9/44) -1/5,111 (9/46) Bevel pinion bearings 2 with taper rollers Bevel pinion bearings rolling torque (bearings lubricated and without gasket) Nm New bearings kgm 2.3 ÷ 3.3 0.23 ÷ 0.33 Adjustment of pre-load of bevel pinion bearings By means of adjustment rings > Bevel pinion bearings pre-load adjustment rings 0.545 ÷ 1.070 mm with progression of 0.025 mm. Temperature at assembly of inner bearing ring on bevel pinion -Position of bevel pinion with respect to differential casing By means of adjustment spacers > Thickness of adjustment rings placed between bevel pinion and differential casing 3.585 ÷ 4.235 mm with progression of 0.025 mm. Bearings for gear housing 2 with taper rollers Differential casing bearings rolling torque (bearings lubricated and without gasket) -15/44 - 13/41- 12/41 - 12/43 - 12/47 - 10/41: Nm 2.7 ÷ 3.9 kgm 0.27 ÷ 0.39 -11/49 - 9/40 - 9/44 - 8/41 - 8/45: Nm 2.6 ÷ 3.7 kgm 0.26 ÷ 0.37 Adjustment of differential casing bearings rolling torque By means of adjustment rings > Thickness of adjustment rings of differential casing bearings rolling torque 1 ÷ 1,95 mm with progression of 0.05 mm.

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REAR AXLE NDA RS 9 D AILY E URO 4 Base - March 2006 Print 603.93.651 Type of rear axle: NDA RS Simple reduction type NDA RS Clearance between pinion and ring bevel gear with reduction ratios -1/3.916 - 1/4.182 - 1/4.444 -1/5.111: 0.13 ÷ 0.18 mm -1/3.154 - 1/3.416 - 1/3.727 -1/4.889: 0.15 ÷ 0.20 mm Adjustment of clearance between pinion and ring bevel gear By means of adjustment rings Clearance between planetary and crown wheels 0.05 ÷ 0.15 mm WHEEL HUBS Wheel hub bearings UNIT-BEARING Wheel hub bearings end play -Wheel hub bearings rolling torque Nm kgm --Adjustment of wheel hub bearings end play Not adjustable Tighten fixing ring nut to torque Rear axle oil Quantity Litres TUTELA W90/M-DA (SAE 80 W 90) 1,35 Dry rear axle weight : -With ABS kg -Without ABS kg -Max capacity (GAW) kg 112.1 110.6 2240

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Figure 2 NDA RS REAR AXLE DIFFERENTIAL SECTION 107835 10 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651 TIGHTENING TORQUES PART TORQUE PART Nm Kgm 1 Bevel pinion retaining nut 400 ÷ 500 40 ÷ 50 2 Screw securing half-housing and ring bevel gear 89 ÷ 108 8.9 ÷ 10.8 3** Oil filler plug 49 ÷ 62 4.9 ÷ 6.2 4 Screw securing caps to differential housing 100 ÷ 120 10 ÷ 12 5 Screw securing gearing inspection cover to the axle housing 80 ÷ 95 8 ÷ 9.5 *** Oil drainage plug 49 ÷ 62 4.9 ÷ 6.2 * = Apply LOCTITE 5910 on the housing ** = Apply LOCTITE 577 on the plug thread *** = Apply LOCTITE 573 on both sides of the gasket

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107836 Figure 3 NDA RS REAR AXLE DIFFERENTIAL SECTION REAR AXLE NDA RS 11 D AILY E URO 4 Base - March 2006 Print 603.93.651

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12 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651 PART TORQUE PART Nm Kgm 1 Wheel securing screw 160 16,3 2 M8x1.25 brake disk securing screw 13 ÷ 21 1,3 ÷ 2,1 3 M52x3 half shaft bearing securing ring nut 559 ÷ 677 57,0 ÷ 69,0 4 M12 rear axle arm - bearing support securing screw 125 ÷ 135 12,7 ÷ 13,8 5 M14x1.5 brake caliper securing screw 176 ÷ 217 17,9 ÷ 22,1 -M6 metal sheet guard securing screws 10 ÷ 16 1,0 ÷ 1,6 NDA RS REAR AXLE WHEEL HUB SECTION 107837 Figure 4

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REAR AXLE NDA RS 13 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99305121 Hot air drier 99322215 Front and rear axle overhaul stand 99341003 Single-acting rear axle 99341009 Pair of brackets 99341011 Pair of brackets 99341015 Clamp

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14 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99345057 Extractor reaction block 99348001 Extractor with locking device 99355184 Shaft bearing ring nut wrench 99370006 Handle, interchangeable drift 99370007 Grip for interchangeable punches 99370239 Tool to determine thickness of adjustment of bevel pinion (use with 99395728)

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REAR AXLE NDA RS 15 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99370241 Tool for fitting drive shaft bearing 99370317 Reaction lever with extension for flange retaining 99370617 Universal mounting to support axles during removal and refitting 99372236 Tool to move brake caliper piston back 99374022 Key to fit differential bevel pinion gasket (use with 99370007) 99374091 Punch to fit external races of bearings (diameter 55 ÷ 69 mm use with 99370007)

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16 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99374092 Punch to fit external races of bearings (diameter 69 ÷ 91 mm use with 99370007) 99389819 Dynamometric wrench (0 ÷ 10 Nm) with 1/4” square connection 99395728 Dial gauge with mounting to be used with the tools to determine the thickness of adjustment of the bevel pinion

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Figure 5 525010 REAR AXLE NDA - RS REMOVAL -REFITTING Removal Refitting For refitting, carry out the operations described for removal in reverse order, taking the following precautions: -Check the thread of the brackets joining the leaf springs to the axle. If there are any irregularities, rectify the thread (operation 500412) or replace the brackets. -Bleed the air from the brake hydraulic system as described under the relevant heading (operation 784010). -Adjust the handbrake control ties as described under the relevant heading (operation 502710). -Lock the nuts or screws to the required tightening torque. -The self-locking nuts must not be reused. -The lubricating oil in the axle housing should be at the right level. -Check the state of the flexible pads (19) and replace them if they have deteriorated (operation 500417). 108434 Position the vehicle on level ground and stop front wheels. Loosen rear wheels securing screws. Lift the vehicle from its rear side and position it on support stands. Position hydraulic truck under rear wheels. Remove wheels securing screws and take them off the vehicle. Unscrew nut (2) adjusting hand brake linkage. Release the cables from the chassis by uncoupling check springs (1). Unscrew screws (7) securing transmission shaft (8). Disconnect electrical cables (15) of the sensors of brake pad wear and phonic wheel rpm’s (6). Unscrew nuts (12) securing shock absorbers (11). Take hydraulic pipes (16) of brake system off the fitting on the chassis. Such pipes will be removed together with real axle in the end step of the disconnection from the vehicle. ! In disconnecting the hydraulic pipes of brake circuit and vapours breather, pay attention to any oil losses. Prearrange suitable collectors in such a way that brake liquid is not spread out into environment. Avoid contact of liquid with skin and eyes. In case of contact, wash abundantly with water. Unscrew screws (3) securing rods (4) supporting stabilising bar (5). Disconnect rear axle oil vapours breather pipe (20). Properly position a hydraulic jack provided with support 99370617 under rear axle. Unscrew nut (17) securing leaf spring (9) to rod (18). Unscrew nuts (13) of brackets (14) securing rear axle to leaf springs (9). Lower hydraulic jack and take out rear axle. REAR AXLE NDA RS 17 D AILY E URO 4 Base - March 2006 Print 603.93.651

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18 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Check that the air breather (1) is not clogged; otherwise, disassemble and clean it thoroughly before refitting. Set the entire rear axle assembly on stand 99322215. 107854 107853 107985 107855 Figure 6 Figure 7 Figure 8 Figure 9 Take out the screws (1) and remove the brake caliper (2) with its brake linings from the mounting. Remove pin (1) centering/securing brake disk (2) to half shaft (3). Take off brake disk (2). Before positioning the rear axle assembly on the stand for overhauling, drain off the oil by unscrewing the side plug of the axle housing. 525010 OVERHAULING THE REAR AXLE ASSEMBLY ! The drive shafts, brake disc and calipers, air breather and differential can all be removed and refitted even with the unit mounted on the vehicle. ! The identification data of the rear axle unit are given on the plate (1) fixed near to the leaf spring attachment support. 525013 Air breather disassembly - assembly 525030 Wheel hub overhaul Disassembly ! The caliper must not be violently knocked or dropped. Prevent the rubber caps coming into contact with sharp metal tools. Do not dirty or wet the rubber caps with mineral grease or oil. Do not dirty the pads with liquids or grease. Do not operate the parking brake lever before mounting on the disc: this makes the piston come out, decreasing the gap between the two brake linings and jeopardizing wearability on the disc. Should this be done unexpectedly, it is necessary to take down the brake linings and move the piston back with tool 99372236, taking the precautions given in the BRAKES section. Check brake disk as described in Brakes section.On putting away the brake disk, do not damage phonic wheel toothing. NOTE REAR AXLE NDA RS 19 D AILY E URO 4 Base - March 2006 Print 603.93.651

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107986 107988 107987 107989 107990 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Unscrew securing screws (2) and take out half shaft comprehensive of unit-bearing support (1), bearing, ring nut and metal sheet guard (3). Tighten half shaft (1) in a vice. Remove denting ( → ) of ring (2) engaging in ring nut (3). Using wrench 99355184 (1), unscrew ring nut (2) checking bearing (3) to half shaft (4). Properly arrange half shaft (1) on hydraulic press and take out bearing (2) together with support (3). Using extractor 99348001 (4). Unscrew screws (2) securing metal sheet guard (1) to support (3). Pull guard apart from support. 20 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

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108040 108041 108042 107855 Figure 15 Figure 16 Figure 17 Figure 18 Arrange tool 99370241 (4) on the press and position bearing (3) and support (2) comprehensive of metal sheet guard on the tool. Put in half shaft (1) and, by the press (driving load 3300÷18000 N), put it into up to ledge. Mount the assembly on a vice. Thread washer (2) and ring nut (1). Using wrench 99355184 (3), tighten ring nut (1) at prescribed torque. Dent washer (2) on milled portion of ring nut (1) as indicated in figure. Put assembled half shaft into rear axle box. Tighten screws (1), securing half shaft to rear axle arm, at prescribed torque. Mount brake disk (2) on half shaft (3) and tighten securing pin (1) at prescribed torque. The bearing (3) must not be heated. NOTE Assembly REAR AXLE NDA RS 21 D AILY E URO 4 Base - March 2006 Print 603.93.651

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107985 107838 108043 Figure 19 Figure 20 Figure 21 Rest the brake caliper (2) with the brake linings on the mounting. Tighten the screws (1) securing the caliper (2) to the required torque. After assembly, fill the axle housing with TUTELA W90/M -DA oil in the required quantity and grade. Unscrew screws (1) complete with safety washers and take off wheelwork inspection cover (2). Mark the position of the caps (1 and 2), take out the screws (3) and remove them. 526210 REPAIRING THE DIFFERENTIAL Disassembling the differential unit Figure 22 Take differential box (1), comprehensive of ring gear, wheelwork, bearings (2-5), adjusting shims (4) and rib rings (3), out of rear axle box. The brake lining with the wear indicator must be mounted on the piston side of the brake caliper. NOTE Should brake calliper piston be moved backward, use tool 99372236 and follow the recommendations set out in the BRAKES section. NOTE Before repairing the differential it is necessary to drain off the oil and dismantle the drive shafts, as described under the heading of overhauling the wheel hub (operation 525030). NOTE Write down the positions of adjusting shims, rib rings and bearing outer rings in order to be able to arrange them according to original configuration on mounting step. NOTE 108044 22 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

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51818 Figure 23 Figure 24 Figure 25 Use tool 99341003 (1), brackets 99341009 (2), clamp 99341015 (3) and reaction block 99345057 (4) to remove taper roller bearing inner rings (5 - 7) from gear housing (6). Gear housing removal 108045 108046 Unscrew screws (3) and remove bevel wheel (1) from differential box (2). Using a proper beater, remove spring peg (1) and unthread planetary gear holder pin (9). Rotate crown wheels (6 and 10) in such a way as to have planetary gears (3 and 7) matching the slits on differential box (4). Remove planetary gears (3 and 7) and relating thrust blocks (2 and 8) from differential box (4). Remove crown wheels (6 and 10) and relating rib thrust blocks (5 and 11). REAR AXLE NDA RS 23 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Lift denting (1) checking nut (2). Using tool 99370317, stop the rotation of flange (3). Unscrew and remove nut (2). 108047 108049 108048 108050 107839 74727 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Take flange (1) out of bevel pinion (2). Should flange (2) be too difficult to remove, single-acting rear axle 99341003 coupled to bracket pair 99341009 can be used as an extracting assembly. Using a proper beater, beat according to direction indicated by the arrow until bevel pinion (1) complete with rear bearing, fixed spacer and adjusting nut is ejected from rear axle box (2). Remove the seal (1) and the internal ring (2) of the front bearing. Use a punch to remove the external rings (3 - 4) of the tapered roller bearings from the axle housing (1) and take out the adjustment shim (2). With axle 99341003 (2), brackets 99341011 (1), press 99341015 (5) extract the internal ring (3) on the bevel pinion (4). Dismounting bevel pinion 24 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Check planetary gears with relating rib thrust blocks, pin and crown wheels with rib thrust blocks. Replace all the sealing elements, the bevel pinion retaining nut and the gear housing bearing adjustment ring nut with new parts. Carefully clean the single components of the differential locking. Lubricate the bearings and rotate the roller cage freely; rotation must be even and without signs of stiffness. Check the support surfaces of the ring bevel gear and the striking surface of the half-casing so that the ring bevel gear fits perfectly. Deformations of such parts, could determine vibration of the ring bevel gear fastening screws, thus compromising the perfect operation of the unit. DIFFERENTIAL UNIT COMPONENTS 1. Nut - 2. Transmission connection flange - 3. Gasket - 4. Front bearing - 5. Bearing adjusting shim - 6. Spacer - 7. Ledge ring -8. Rear bearing - 9. Bevel pinion - 10. Ring bevel gear - 11. Rib ring -12. Adjusting ring - 13. Taper roller bearing -14. Differential box - 15. Crown wheel rib thrust block - 16. Crown wheel - 17. Planetary gear rib thrust block - 18. Planetary gear - 19. Pin - 20. Screw securing ring gear / differential box 107840 Figure 32 Check for grooved section for keying the flange on the pinion not being excessively worn out. Otherwise, replace the pinion. Checking the parts comprising the differential Carefully clean all the threads in order to obtain exact adjustments and accurate tightening torque. If it is necessary to replace the ring bevel gear or pinion, replace both parts since they are supplied in pairs. NOTE The tapered roller bearings are supplied as spare parts, lubricated with rustproof oil. They must not be washed or heated for assembly. The differential housing support bearings must both be from the same supplier. NOTE NOTE REAR AXLE NDA RS 25 D AILY E URO 4 Base - March 2006 Print 603.93.651

Page 538

Tighten screws (3), for matching between bevel wheel (1) and the box of differential (2), at prescribed torque. Put crown wheels (6) and (10), complete with rib rings (5) and (11), into seats inside differential box (4). Through the slits on box (4), position planetary gears (3) and (7), complete with rib thrust blocks (2) and (8), in order them to contact crown wheels (6) and (10). Rotate crown wheels in such a way that the holes of planetary gears are aligned to guide holes for pin (9) that are present on the box of differential (4). Thread pin (9) aligning the hole for spring peg (1) to the hole that is present on the box of differential (4). Using a proper beater, put spring peg (1) into its seat. 108046 108045 Figure 33 Figure 34 Assembly of gear housing Figure 35 108404 Using a proper beater, mount inner ring (1) on wheelwork box (2). Repeat operation for outer ring (3). 26 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

Page 539

On a surface plate (2), zero a dial gauge (1) set on the mounting 99395728 (3) and pre-load it slightly. 108405 18241 108406 101977 108409 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Using the punch 99374091 (3) and grip99370006 (4),mount the external ring (2) of the tapered roller bearing in the axle housing (1). Set adjusting ring (4), removed at disassembling, into rear axle casing (5). Using the punch 99374092 (2) and grip99370007 (1),mount the external ring (3) of the tapered roller bearing. Mount provided washer (3) and inner ring (2) of taper roller bearing on dummy pinion 99370239 (1). Position dummy pinion 99370239 (1), assembled as in Figure 39, on the outer ring of taper roller bearing (2). On the opposite side, fit the taper bearing internal ring (3) on the dummy pinion (1) and the transmission shaft flange (4) . Screw nut (5) until dummy pinion is freely rotating without axial clearance. Assembling the bevel pinion assembly New bearings are lubricated with rustproof oil and must therefore not be washed or heated for assembly. NOTE REAR AXLE NDA RS 27 D AILY E URO 4 Base - March 2006 Print 603.93.651 v

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Fit the mounting 99395728 (2) with the dial gauge (1) on the dummy pinion 99370239 (3). Orientate the, previously zeroed, dial gauge so as to position the rod on the lowest portion of the seat of the bearing supporting the gear housing and note the difference A1 . Repeat the same operation on the seat of the other bearing and note the difference A2 . Thickness S to be added to adjusting ring thickness (4, Figure 43) used for measuring, for pinion positioning is obtained by the following formula: 108407 18246 108406 A1 indicates the value measured on the right-hand seat. A2 indicates the value measured on the left-hand seat. B indicates the value marked on the bevel pinion (see Figure 42). For example: Unscrew check nut and transmission connection flange. Unthread flange and bearing from dummy pinion. Remove the dummy pinion with the mounting 99395728, dial gauge and rear bearing from the axle housing. If required, replace adjusting ring (4) with a new one having the calculated thickness, after removing bearing outer ring (3) from rear axle casing (5) by beater. Then fit the new adjusting ring (4) into rear axle casing (5). Using the punch 99374092 (2) and grip99370007 (1),mount the external ring (3) of the tapered roller bearing. = A1 + A2 2 − (  B) = 1,05 + 1, 10 2 − ( − 0, 05) = 2, 15 2 + 0, 05 = S S Figure 41 Figure 42 Figure 43 If the value marked on the pinion is preceded by a positive sign (+), it must be subtracted from the value of the sum divided by two for both seats, whereas it has to be added if it is preceded by a negative sign (-). NOTE The result of the formula must be added algebraically to the value of the adjusting ring used to make the measurements. Example: if the value of the adjusting ring used is 3.00 mm, replace with one measuring 4.125 mm (3.00 + 1.125). 1,125 28 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651 .

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Position fixed spacer (3) and adjusting ring (2)on bevelpinion (1). 18251 18252 108408 Figure 44 Figure 45 Figure 46 Using a suitable punch (1) and a hydraulic, press mount the internal ring (2) of the tapered roller bearing on the bevel pinion (3). Position the axle casing as indicated in the figure. Fit the taper bearing internal ring (1) and the transmission shaft flange (2). Position a suitable pipe (3) on the stand so that the flange (2) and the taper bearing internal ring (1) are correctly supported. Use tool 99370317 (2) to prevent the flange (1) from rotating. Tighten the bevel pinion retainer nut to the required torque with a torque wrench (3). Mount the bevel pinion (1) in the axle housing so as to enter the internal ring (2) of the tapered roller bearing. Beat on the top of pinion (1) until nut securing flange (3) can be mounted. 108410 108421 Figure 47 Figure 48 REAR AXLE NDA RS 29 D AILY E URO 4 Base - March 2006 Print 603.93.651

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108423 Figure 49 Using torque meter 99389819 (1), detect bevel pinion rolling torque. If the reading differs from the prescribed value, disassemble the pinion (1, Figure 47), replace the adjuster ring (2, Figure 45) with a ring of the correct thickness. Refit the pinion and repeat the rolling torque check. Figure 50 Assembly of differential unit Fit the differential (1) unit and support (6) bearings in the axle casing. Mount spacers and adjusting rings in same quantity, thickness and position as detecting on dismounting, according to following sequence: stop ring (2), adjusting rings (3 and 5) and stop ring (4). Figure 51 108424 Screw on the screws (1) and tighten them to the required torque with the dynamometric wrench (3). 108423 Figure 52 Check total rolling torque using torque meter 99389819 (1). If the value of the measurement is not as required, replace the adjustment rings (3 and 5, Figure 50) with another one of a suitable thickness. Rolling torque must be detected at 25 ºC ambient temperature having the pinion rotating at 50 rpm speed, after the pinion has run 10 revolutions. NOTE Position the caps (2) making the marks made during disassembly coincide. NOTE The rolling torque must be measured at an ambient temperature of 25 ° C, making the pinion turn at a speed of 50 rpm after it has made 10 turns. NOTE When fitting the differential unit, carefully comply with the tightening torque values specified, and make use of a torque wrench. NOTE 108422 30 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Position the dial gauge 99395728 (1) with a magnetic base and measure the clearance between the pinion and crown wheel on four opposite teeth of the crown wheel (2). The average of the measurements must equal the required value. If a different clearance is found, remove the caps (3) again and swap over the assembly position of the adjustment rings (1 and 3, Figure 50). Should this not be sufficient, replace adjusting rings by other rings having different thickness, on condition that total thickness must be equal to the total thickness of the adjusting rings that were dismounted. This is so as not to change the total rolling torque. Using a brush, apply a thin layer of Prussian blue on ring gear teeth. Turn the pinion and measure the impression of the contact of the pinion toothing on the crown wheel toothing. Here we illustrate the possible contacts with the corrections to obtain precise coupling of the crown wheel and pinion. 108427 44603 Figure 53 Figure 54 A = Coupling depth B = Crest C = Side D = Play E = Greater base F = Heel G = Top land H = Contact surface I = Lateral surface Figure 55 Figure 56 44604 Correct contact. 44605 Excessive contact on tooth bottom or flank. Move pinion away from ring gear, then move ring gear close to pinion in order to adjust clearance. Figure 57 Excessive contact on heel of tooth . Move the ring bevel gear towards the pinion and then move the pinion away from the ring bevel gear to adjust clearance. 44606 REAR AXLE NDA RS 31 D AILY E URO 4 Base - March 2006 Print 603.93.651

Page 544

Excessive contact on the top land of the tooth Move the ring bevel gear away from the pinion them move the pinion towards the ring bevel gear to adjust clearance. 44608 Figure 58 Figure 59 44607 Excessive contact in the upper part or crest of the tooth Move pinion close to ring gear, then move ring gear away from pinion in order to adjust clearance. 108426 108421 Lubricate the internal lip of the seal (1). With the key 99374022 (2) and grip 99370007 (3), mount the seal in the axle housing. Mount flange (1). Stop the rotation of flange (1) using tool 99370317 (2). Using torque wrench (3), tighten nut checking bevel pinion at prescribed torque. After prescribed coupling clearance has been completed, stop the rotation of flange (1) using tool 99370317 (2). Unscrew the retaining nut and extract the flange (1) from the bevel pinion. 108425 Figure 60 Figure 61 Figure 62 108428 Figure 63 Deform the collar of the nut (1) as shown in the figure at the milling of the bevel pinion (2). 32 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

Page 545

Thoroughly clean the flange of the axle housing. Apply LOCTITE 5910 sealant on the flange of the axle housing to form a bead of approx. 5 mm diameter. It must be uniform (no lumps), without any air bubbles, thin areas or gaps. Any flaws must be corrected in as short a time as possible. Avoid using too much material to seal the joint. Too much sealant would tend to come out on both sides of the joint. After applying the sealant, the joints need to be assembled immediately (10 - 20 minutes). To seal at a later date, there is product 21623 capable of softening or liquefying the above-mentioned sealant. It is essential to clean the surface to be sealed in order to achieve good future sealing. 108429 108430 Figure 64 Figure 65 Mount the cover (1) and screw on the screws (2). -Flanged screws (for solution without gasket). -Screws with washer (for solution with gasket). 107856 Figure 66 According to sequence indicated in figure, tighten the screws at prescribed torque. Complete mounting operation observing the following: -Mount the drive shafts as described under the heading: ”525030 overhauling hubs”. -Apply LOCTITE 577 thread-locking oil on the oil drain plug thread, screw it into the axle housing, tightening it to the required torque. -Add lubricating oil in the required quantity and grade through the hole. -Apply LOCTITE 577 thread-locking oil on the inspection plug thread, screw it into the axle housing, tightening it to the required torque. -Take the assembly off the stand. α The assembly should be put back on its mounting to prevent the dust guards and/or brake discs from getting damaged. NOTE REAR AXLE NDA RS 33 D AILY E URO 4 Base - March 2006 Print 603.93.651

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34 REAR AXLE NDA RS D AILY E URO 4 Base - March 2006 Print 603.93.651

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REAR AXLE NDA RG 35 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear axles NDA RG Page DESCRIPTION 37 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA 38 . . . . . . . . . . . . . TIGHTENING TORQUES 40 . . . . . . . . . . . . . . . . . TOOLS 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING THE REAR AXLE ASSEMBLY 49 . -Air breather disassembly - assembly 48 . . . . . . . . -Wheel hub overhaul 48 . . . . . . . . . . . . . . . . . . . . -Replacing the wheel hub bearing 49 . . . . . . . . . . -Disassembly 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Assembly 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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36 REAR AXLE NDA RG D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 1 DESCRIPTION The rear axle is the load-bearing type with a single reduction using a hypoid crown wheel and pinion. The axle housing is made of pressed sheet steel with hot pressed arms. The bevel pinion is supported by two pre-lapped tapered roller bearings to hold the bearing pre-load better. The rolling torque of the bearings of the bevel pinion is adjusted by changing the thickness of the adjustment ring between the two tapered roller bearings. In addition, it is possible to adjust the position of the bevel pinion with respect to the ring bevel gear by changing the thickness of the ring between the axle housing and the bevel pinion rear bearing external ring. The gear housing is supported by two tapered roller bearings. The rolling torque of the bearings is adjusted with adjustment rings between the spacer rings and the external rings of the bearings. The clearance between pinion and crown wheel is adjusted by changing the thickness and/or position of the adjustment rings, though the total thickness must be the same as that of the adjustment rings removed. The gearing of the differential is composed of two planetary gears and two crown wheels. The wheel hubs are keyed, with UNIT BEARINGS lubricated for life, onto the arms of the axle housing. The bearings UNIT BEARINGS need no adjustment. The brakes are disc brakes with floating brake calipers. The disc brakes are keyed onto the wheel hubs. The brake calipers are secured with flanges fixed onto the arms of the axle housing. Brake caliper is equipped with parking brake device. 107857 REAR AXLE NDA RG 37 D AILY E URO 4 Print 603.93.651 Base - March 2006

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38 REAR AXLE NDA RG D AILY E URO 4 Base - March 2006 Print 603.93.651 SPECIFICATIONS AND DATA Type of rear axle: NDA RG Simple reduction type with mech-anical control differential locking NDA RG DIFFERENTIAL UNIT Reduction bevel gear pair ratio (No. of teeth: pinion/crown) 1/4.182 (11/46) - 1/4.444 (9/40) - 1/4.889 (9/44)- 1/3.416 (12/41) - 1/3.916 (12/47) - 1/3.154 (13/41) - 1/3.615 (13/47) -1/3.308 (13/43) - 1/3.727 (11/41) Bevel pinion bearings 2 with taper rollers Bevel pinion bearings rolling torque (without seal ring) Nm 2.3 ÷ 3.3 kgm 0.23 ÷ 0.33 Adjustment of pre-load of bevel pinion bearings By means of adjustment rings > Bevel pinion bearings pre-load ad-justment rings 0.545 ÷ 1.070 mm with progression of 0.025 mm. Temperature at assembly of inner bearing ring on bevel pinion -Position of bevel pinion with re-spect to differential casing By means of adjustment spacers > Thickness of adjustment rings placed between bevel pinion and differential casing 3.585 ÷ 4.235 mm with progression of 0.025 mm. Bearings for gear housing 2 with taper rollers Differential casing bearings rolling torque Nm 2.7 ÷ 3.9 kgm 0.27 ÷ 0.39 Adjustment of differential casing bearings rolling torque By means of adjustment rings > Thickness of adjustment rings of dif-ferential casing bearings rolling torque 1.00 ÷ 1.95 mm with progression of 0.05 mm. Clearance between pinion and ring bevel gear -1/3,615 - 1/3,727 - 1/3,916 -1/4,182 - 1/4,444: 0.13 ÷ 0.18 -1/3,154 - 1/3,308 - 1/3,417 -1/4,889: 0.15 ÷ 0.20

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REAR AXLE NDA RG 39 D AILY E URO 4 Print 603.93.651 Base - March 2006 Type of rear axle: NDA RG Simple reduction type NDA RG Adjustment of clearance between pinion and ring bevel gear By means of adjustment rings Clearance between planetary and crown wheels 0.05 ÷ 0.15 mm WHEEL HUBS Wheel hub bearings UNIT-BEARING Wheel hub bearings end play --Wheel hub bearings rolling torque Nm kgm ----Adjustment of wheel hub bearings end play By means of nut Torquing the securing nut Rear axle oil Quantity Litres TUTELA W90/M-DA (SAE 80 W 90) 1.35 Max capacity (GAW) kg 2240

Page 552

Figure 2 NDA RG REAR AXLE DIFFERENTIAL SECTION 107858 40 REAR AXLE NDA RG D AILY E URO 4 Base - March 2006 Print 603.93.651 TIGHTENING TORQUES PART TORQUE PART Nm Kgm 1 M26x1.5 bevel pinion securing nut 400 ÷ 500 40.8 ÷ 51.0 2 M12x1.5 ring bevel gear wheelwork box securing screw 89 ÷ 108 9.0 ÷ 11.0 3 M22x1.5 oil filling plug** 49 ÷ 62 5.0 ÷ 6.32 4 Screw securing caps to differential box 100 ÷ 120 10.2 ÷ 12.2 5 M8x1.25 rear axle box rear cover securing screw 80 ÷ 95 8.2 ÷ 9.7 -M22x1.5 oil draining magnetic plug** 49 ÷ 62 5.0 ÷ 6.3 * Apply Loctite 5910 on the housing ** Apply Loctite 577 on the plug thread

Page 553

NDA RG REAR AXLE DIFFERENTIAL SECTION 107859 Figure 3 REAR AXLE NDA RG 41 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Figure 4 108433 NDA RG REAR AXLE WHEEL HUB SECTION 42 REAR AXLE NDA RG D AILY E URO 4 Base - March 2006 Print 603.93.651 PART TORQUE PART Nm kgm 1 Wheel securing screw -2 M10x1.25 screw securing half shaft to wheel hub 63 ÷ 76 6.4 ÷ 7.7 3 M52x1.5 ring nut checking wheel hub bearing 545 ÷ 565 55.5 ÷ 57.6 4 M10x1.25 screw securing brake disk to wheel hub 69 ÷ 76 7.0 ÷ 7.7 5 M14x1.5 screw securing shoes support to caliper support 177 ÷ 217 18.0 ÷ 22.1 6 M10x1.5 screw securing brake caliper support to rear axle arm 85 ÷ 97 8.7 ÷ 9.8

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REAR AXLE NDA RG 43 D AILY E URO 4 Print 603.93.651 Base - March 2006 TOOLS TOOL NO. DESCRIPTION 99305121 Hot air drier 99321024 Hydraulic trolley for removing and refitting wheels 99322215 Driving and steering axle overhaul stand 99341001 Double effect bridge 99341003 Single-acting rear axle 99341005 Reaction bridge

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44 REAR AXLE NDA RG D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99341009 Pair of retainers 99341010 Pair of retainers 99341011 Pair of retainers 99341015 Clamp 99345057 Extractor reaction block 99355087 65 mm. diam. box wrench for disassembly - assembly wheel hub locking ring

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REAR AXLE NDA RG 45 D AILY E URO 4 Print 603.93.651 Base - March 2006 TOOLS TOOL NO. DESCRIPTION 99370006 Handle, interchangeable drift 99370007 Grip for interchangeable punches 99370239 Tool for measuring thickness of bevel pinion adjustment rings (to be used with 99395728) 99370317 Lever and relevant extension bar to retain flanges 99370497 Tool for assembly of wheel hub 99370498 Tool for assembly of wheel hub bearing and phonic wheel

Page 558

46 REAR AXLE NDA RG D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99370617 Axle universal support during removal/installation 99372236 Tool to move brake caliper piston back 99374022 Keying tool for assembly of differential bevel pinion gasket (to be used with 99370006) 99374091 Punch to fit external races of bearings (diameter 55 ÷ 69 mm use with 99370007) 99374092 Punch to fit external races of bearings (diameter 69 ÷ 91 mm use with 99370007) 99389819 Torque wrench (0 to 10 mm) with 1/4” square attachment

Page 559

REAR AXLE NDA RG 47 D AILY E URO 4 Print 603.93.651 Base - March 2006 TOOLS TOOL NO. DESCRIPTION 99395728 Dial gauge with support to be used with the tools to determine the adjustment thickness of the bevel pinion

Page 560

525010 OVERHAULING THE REAR AXLE ASSEMBLYOVERHAULING THE REAR AXLE ASSEMBLY For differential assembly repair operations, refer to what described in chapter ” NDA-RS rear axle” on pages 22 to 34. NOTE Before positioning the rear axle assembly on the stand for overhauling, drain oil by loosening rear axle casing plug. The drive shafts, brake disc and calipers, air breather and differential can all be removed and refitted even with the unit mounted on the vehicle. NOTE Figure 5 Figure 6 Set the entire rear axle assembly on stand 99322215. Take out the screws (1) and remove the brake caliper with its brake linings from the mounting. 525013 Air breather disassembly - assembly The identification data of the rear axle unit are given on the plate (1) fixed near to the leaf spring attachment support. NOTE 107860 107854 525030 Wheel hub overhaul Figure 7 Take out the screws (1) and remove the brake caliper (2) with its brake linings from the mounting. ! The caliper must not be violently knocked or dropped. Prevent the rubber caps coming into contact with sharp metal tools. Do not dirty or wet the rubber caps with mineral grease or oil. Do not dirty the pads with liquids or grease. Do not operate the parking brake lever before mounting on the disc. This makes the piston come out, decreasing the gap between the two brake linings and jeopardizing wearability on the disc. Should this be done unexpectedly, it is necessary to take down the brake linings and move the piston back with tool 99372236, taking the precautions given in the BRAKES section. 108435 Figure 8 Take out the screws (1) and remove the drive shaft (2). 101967 48 REAR AXLE NDA RG D AILY E URO 4 Base - March 2006 Print 603.93.651

Page 561

Figure 9 Lift up the notch ( ⇒ ) of the ring nut (1). Using the wrench 99355087 (2) remove the ring nut (1), take out the washer and extract the wheel hubs (3). 525031 Replacing the wheel hub bearing Disassembly 44613 44616 Figure 10 Figure 11 Remove bearing protection ring. Take out the screws (2) and remove the brake disc (1) from the wheel hub. Check the brake disc as described under the Brakes heading. The bearing (1) is removed from the wheel hub with the aid of an ordinary punch. Bearing (1) driving load is 2100 ÷ 5000 kg. NOTE 101969 Figure 12 45164 The new bearing should be mounted in the wheel hub with a press and tool 99370498. 1 2 Figure 13 Mount the brake disc (1) on the wheel hub (2) and tighten the fixing screws (3) to the required torque. 101970 Assembly In resting the hubs on the bench, pay attention that phonic wheel is not being damaged. NOTE REAR AXLE NDA RG 49 D AILY E URO 4 Print 603.93.651 Base - March 2006

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44618 Figure 14 Figure 15 If it is necessary to replace the pins of the wheel hub (1), before mounting the new ones, check that the mating surface of the pin head is free from burrs, dross and blisters. The pins should be driven in by applying a load on their head no greater than 2000 kg. After driving them home, check that the pins are perfectly in touch with the hub: maximum orthogonal tolerance 0.2 mm. Figure 16 44619 Stand the bearing of the wheel hub (2) on a special mounting that permits rotation. With a magnetic dial gauge (1) check the off-centring of the brake disc on both sides. Centering error must not exceed 0.1 mm. 44621 Mount the inserter 99370497 (2) on the sleeve. Lubricate the sleeve with TUTELA W90/M-DA oil and key the wheel hub (1). 50 REAR AXLE NDA RG D AILY E URO 4 Base - March 2006 Print 603.93.651

Page 563

Figure 17 Figure 18 Figure 19 44622 Mount new washer (1), ring nut (2) and, using wrench 99355087 (3), tighten ring nut (2) at prescribed torque. Notch the fixing ring nut (2) on the milling of the axle housing arm. 108435 Mount brake caliper support on rear axle arm observing prescribed tightening torques. Thread braking gaskets. Apply brake caliper (2) to the support and tighten securing screws (1) at prescribed torque using a torque wrench. Where brake caliper plunger must be withdrawn, observe what indicated in section Brakes. Apply IVECO 1905685 sealant on the contact surfaces of the drive shaft (2) with the wheel hub (1). Mount the drive shaft (2) in the sleeve. Tighten the screws (3) securing the drive shaft (2) to the hub (1) to the required torque. After the assembling operation has been completed, fill the rear axle case with TUTELA W90/M - DA oil to the prescribed amount and grade. 44626 On each brake caliper remounting operation, replace screws (1): these screws cannot be reused once they have been unscrewed. NOTE REAR AXLE NDA RG 51 D AILY E URO 4 Print 603.93.651 Base - March 2006

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REAR AXLE 450511 53 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear axles 450511 Page DESCRIPTION 55 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA 56 . . . . . . . . . . . . . TIGHTENING TORQUES 58 . . . . . . . . . . . . . . . . . TOOLS 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE REMOVAL - REFITTING 65 . . . . . . . . -Refitting 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING THE REAR AXLE ASSEMBLY 67 . -Wheel hub overhaul 67 . . . . . . . . . . . . . . . . . . . . -Replacing the wheel hub bearing 68 . . . . . . . . . . DIFFERENTIAL REPAIR OPERATIONS 71 . . . . . . . -Disassembly of differential locking 71 . . . . . . . . . . -Assembling the differential locking device 71 . . . . -Differential locking removal 71 . . . . . . . . . . . . . . . -Differential locking refitting 71 . . . . . . . . . . . . . . . -Adjusting the differential locking device 72 . . . . . -Disassembling the differential unit 72 . . . . . . . . . . -Disassembly of gear housing 73 . . . . . . . . . . . . . . -Assembly of gear housing 75 . . . . . . . . . . . . . . . . -Assembling bevel pinion unit 75 . . . . . . . . . . . . . . -Differential unit refitting 79 . . . . . . . . . . . . . . . . .

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51858 Figure 1 DESCRIPTION The rear axle is the load-bearing type with a single reduction using a hypoid crown wheel and pinion. The axle housing is made of pressed sheet steel with hot pressed arms. The bevel pinion is supported by two pre-lapped tapered roller bearings to hold the bearing pre-load better. The rolling torque of the bearings of the bevel pinion is adjusted by changing the thickness of the adjustment ring between the two tapered roller bearings. In addition, it is possible to adjust the position of the bevel pinion with respect to the ring bevel gear by changing the thickness of the ring between the axle housing and the bevel pinion rear bearing external ring. The gear housing is supported by two tapered roller bearings. The rolling torque of the bearings is adjusted with adjustment rings between the spacer rings and the external rings of the bearings. The clearance between pinion and crown wheel is adjusted by changing the thickness and/or position of the adjustment rings, though the total thickness must be the same as that of the adjustment rings removed. The gear housing is composed of two half-housings. It may be of two different sizes depending on the ratio of the crown wheel and pinion. The gearing of the differential is composed of four planetary gears and two crown wheels. The wheel hubs are keyed, with UNIT BEARINGS lubricated for life, onto the arms of the axle housing. The bearings need no adjustment. The brakes are disc brakes with floating brake calipers. The disc brakes are keyed onto the wheel hubs. The brake calipers are secured with flanges fixed onto the arms of the axle housing. The parking brake is the drum type, built into the brake disc. REAR AXLE 450511 55 D AILY E URO 4 Print 603.93.651 Base - March 2006

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56 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651 SPECIFICATIONS AND DATA Type of rear axle: 450511 Simple reduction type 450511 Electric control mechanical differential locking on request DIFFERENTIAL UNIT 13/41(1/3.15) - 13/43(1/3.31) - 13/47(1/3.62) - 12/47(1/3.92) -11/46(1/4 18) 9/40(1/4 40) 9/44(1/4 89) 9/46(1/5 11) Reduction bevel gear pair ratio (No. of teeth: pinion/crown) 11/46(1/4.18) - 9/40(1/4.40) 9/44(1/4.89) - 9/46(1/5.11) -9/47(1/5.22) - 8/45(1/5.63) - 7/41(1/5.86) 13/47(1/3.62) - 12/47(1/3.92) - 11/46(1/4.18) - 9/40(1/4.40) -8/45(1/5.63) - 9/47(1/5.22) Bevel pinion bearings 2 with taper rollers Bevel pinion bearings rolling torque (lubricated bearings and gaskets) Nm New bearings kgm 1.2 ÷ 2.4 0.12 ÷ 0.24 Adjustment of pre-load of bevel pinion bearings By means of adjustment rings > Bevel pinion bearing preload adjusting ring thickness 1 ÷ 1.975 mm with progression of 0.025 mm. Temperature of assembly of inner bearing ring on bevel pinion 80 ° C ÷ 90 ° C Position of bevel pinion with respect to differential casing By means of adjustment rings > Thickness of adjusting ring placed between bevel pinion bearing and differential carrier. 1 ÷ 1.975 mm with progression of 0.025 mm. Bearings for gear housing 2 with taper rollers Differential casing bearings rolling torque Nm kgm 2 ÷ 2.8 0.20 ÷ 0.28 Adjustment of differential casing bearings rolling torque By means of adjustment rings > Differential carrier bearing rolling torque adjusting ring thickness 1 ÷ 1.95 mm with progression of 0.05 mm. Clearance between pinion and ring bevel gear 0.15 ÷ 0.20 mm Adjustment of clearance between pinion and ring bevel gear By means of adjustment rings Clearance between planetary and crown wheels 0.12 ÷ 0.18 mm

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REAR AXLE 450511 57 D AILY E URO 4 Print 603.93.651 Base - March 2006 Type of rear axle: 450511 Simple reduction type 450511 WHEEL HUBS Wheel hub bearings Unit-Bearing Wheel hub bearings end play -Wheel hub bearings rolling torque Nm kgm --Adjustment of wheel hub bearings end play Non-adjustable Tightening to fixing ring nut torque Rear axle oil Quantity Litres TUTELA W140/M-DA (SAE 85 W 140) 1.9 Dry rear axle weight : -With ABS kg -Without ABS kg 154,6 153 -Max capacity (GRW) kg 3700

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Figure 2 44588 REAR AXLE DIFFERENTIAL SECTION WITH DIFFERENTIAL LOCKING 58 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651 TIGHTENING TORQUES PART TORQUE PART Nm kgm 1 M26x1.5 bevel pinion securing nut. 400 ÷ 500 40 ÷ 50 2 Screw securing half-housing and ring bevel gear M14 x 1.5 200 ÷ 210 20 ÷ 21 3 Screw securing mounting for differential locking to the axle housing or securing cover for differential locking mounting seat cover 21 ÷ 25 2.1 ÷ 2.5 4 Screw securing gearing inspection cover to the axle housing 21 ÷ 26 2.1 ÷ 2.6 5 Screw securing caps to axle housing 96 ÷ 117 9.6 ÷ 11.7

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Figure 3 51862 450511 REAR AXLE DIFFERENTIAL SECTION REAR AXLE 450511 59 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Figure 4 87907 WHEEL HUB SECTION 60 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651 PART TORQUE PART Nm kgm 1 Wheel retaining nut M18 290 ÷ 349 29 ÷ 34.9 2 Screw securing drive shaft to the wheel hub M10x1.25 63 ÷ 76 6.3 ÷ 7.6 3 Ring nut retaining wheel hub bearing M52x1.5 545 ÷ 565 54.5 ÷ 56.5 4 Screw securing brake disc to wheel hub M10x1.25 69 ÷ 76 6.9 ÷ 7.6 5 Screw securing caliper mounting to shoe mounting M14x1.5 180 ÷ 220 18 ÷ 22 6 Screw securing shoe mounting to axle housing M10x1.5 85 ÷ 97 8.5 ÷ 9.7 7 Screw securing guard 8 0.8 ** Screw securing sensor mounting 5 ÷ 7 0.5 ÷ 0.7 * Spread the surface of the drive shaft - wheel hub union with B-type sealant. ** When assembling the screws securing the timing sensor mounting, apply a few drops of LOCTITE 243 thread-lock onto the thread of the corresponding holes of the bracket welded onto the axle arm.

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REAR AXLE 450511 61 D AILY E URO 4 Print 603.93.651 Base - March 2006 TOOLS TOOL NO. DESCRIPTION 99305121 Hot air drier 99321024 Hydraulic trolley for removing and refitting wheels 99322215 Driving and steering axle overhaul stand 99341001 Double effect bridge 99341005 Reaction bridge 99341010 Pair of retainers

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62 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99345056 Counter block for pullers 99348001 Extractor with locking device 99355087 65 mm. diam. box wrench for disassembly - assembly wheel hub locking ring 99370006 Handle, interchangeable drift 99370007 Handle, interchangeable drift 99370309 Tool for measuring thickness of bevel pinion adjustment rings (to be used with 99395728)

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REAR AXLE 450511 63 D AILY E URO 4 Print 603.93.651 Base - March 2006 TOOLS TOOL NO. DESCRIPTION 99370317 Lever and relevant extension bar to retain flanges 99370497 Tool for assembly of wheel hub 99370498 Tool for assembly of wheel hub bearing and phonic wheel 99370617 Axle universal support during removal/installation 99374022 Keying tool for assembly of differential bevel pinion gasket (to be used with 99370006) 99374092 Punch to fit external races of bearings (diameter 69 ÷ 91 mm use with 99370007)

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64 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99389819 Torque wrench (0 to 10 mm) with 1/4” square attachment 99395728 Dial gauge with support to be used with the tools to determine the adjustment thickness of the bevel pinion

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Figure 5 Position the vehicle on level ground and lock the front wheels. Loosen the nuts securing the rear wheels. Lift the vehicle at the back and set it on stands. Put the hydraulic trolley 99321024 under the rear wheels. Take out the nuts securing the wheels. Unscrew the handbrake adjustment nut (4). Free the cables from the vehicle crosspiece, unhooking the retaining clamps (3). Unscrew the screws (6) securing the propeller shaft. Disconnect the electric cables for indicating brake lining wear (2) and (13), for the ABS speed sensors, if present. Disconnect the braking corrector adjustment tie (14) from the axle housing. Unscrew the nuts (5) securing the shock absorbers. Disconnect the oil pipe (1) from the fitting secured to the axle housing. Unscrew the screws (9) securing the stabilizer bar (10) to the axle. Disconnect the pipe (16) from the axle housing oil vapour vent. For axles with differential locking only Release spring (17) and unthread flexible tie rod (18) from bracket (19). Disconnect the electric cable of the differential locking indicator transmitter (15). For all vehicles Position a hydraulic jack equipped with the mounting 99370617 under the axle. Unscrew the nuts (7) of the brackets (8) securing the axle to the leaf spring (11). Lower the hydraulic jack and extract the axle. 52121 Refitting For refitting, carry out the operations described for removal in reverse order, observing the required tightening torques for the screws and/or nuts. At procedure completion: -Check the thread of the brackets joining the leaf springs to the axle. If there are any irregularities, rectify the thread (operation 500412) or replace the brackets. -Bleed the air from the brake hydraulic system as described under the relevant heading (operation 784010). -Adjust the handbrake control ties as described under the relevant heading (operation 502710). -Lock the nuts or screws to the required tightening torque. -Check for self-locking nuts having been replaced; -Check the state of the flexible pads (12) and replace them if they have deteriorated (operation 500417). -Check for rear axle box lubrication oil correct level. Removal REAR AXLE 450511 65 D AILY E URO 4 Print 603.93.651 Base - March 2006 REAR AXLE REMOVAL - REFITTING

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66 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651

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101965 44609 44611 44612 44613 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 525010 OVERHAULING THE REAR AXLE ASSEMBLY Set the entire rear axle assembly on stand 99322215. Disconnect the pipe (2) from the support bracket (1). Remove caps (3), take off screws (4), then remove brake caliper (5) from support (6). Unthread braking pads (1). Take off screws ( → ) and detach support (2). Take out the screws ( ⇒ ) and remove the drive shaft (1). Lift up the notch ( ⇒ ) of the ring nut (1). Using the wrench 99355087 (2) remove the ring nut (1), take out the washer and extract the wheel hubs (3). ! The identification data of the rear axle unit are given on the plate (1) fixed near to the leaf spring attachment support. 525030 Wheel hub overhaul The thread of the screws securing the brake caliper is treated with adhesive. Therefore, they must not be reused, but replaced with new ones every time they are removed. NOTE REAR AXLE 450511 67 D AILY E URO 4 Print 603.93.651 Base - March 2006

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525031 Replacing the wheel hub bearing 44614 44616 44615 44617 44618 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 If the hub is fitted with a phonic wheel (2), take it out with the extractor (1) 99341001 as shown in the figure. Otherwise, take out the bearing guard ring. Take out the screws ( ⇒ ) and remove the brake disc (1) from the wheel hub. Check the brake disc as described under the Brakes heading. The bearing (1) is removed from the wheel hub with the aid of an ordinary punch. Mount the brake disc (1) on the wheel hub (2) and tighten the fixing screws ( ⇒ ) to the required torque. If it is necessary to replace the pins of the wheel hub (1), before mounting the new ones, check that the mating surface of the pin head is free from burrs, dross and blisters. The pins should be driven in by applying a load on their head no greater than 2000 kg. After driving them home, check that the pins are perfectly in touch with the hub: maximum orthogonal tolerance 0.2 mm. Figure 16 45164 The new bearing should be mounted in the wheel hub with a press and tool 99370498. 1 2 Bearing (1) driving load is 2100 ÷ 5000 kg. NOTE 68 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651

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44619 44620 44621 44622 Figure 17 Figure 18 Figure 19 Figure 20 Stand the bearing of the wheel hub (2) on a special mounting that permits rotation. With a magnetic dial gauge (1) check the off-centring of the brake disc on both sides. Off-centring must not exceed 0.1 mm. Check the orthogonality of the phonic wheel (2), proceeding as follows: Position the feeler of the magnetic dial gauge (1) on the phonic wheel. Making the wheel hub (3) turn, check that the maximum error of orthogonality of the phonic wheel (2) is no greater than 0.1 mm. Mount the inserter 99370497 (2) on the sleeve. Lubricate the sleeve with TUTELA W140/M-DA oil and key the wheel hub (1). Mount the washer (1) and a new ring nut (2). Using the wrench 99355087 (3), tighten the ring nut (2) to the required torque. Notch the fixing ring nut (2) on the milling of the axle housing arm. Figure 21 The phonic wheel (2) should be mounted in the hub with the punch 99370498 (1), checking after assembly that the ”phonic” wheel rests perfectly in its seat in the hub. 45165 1 2 Check and, if necessary, adjust the clearance between the parking brake drum and shoes as described in the Brakes section. NOTE REAR AXLE 450511 69 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Apply IVECO 1905685 sealant on the contact surfaces of the drive shaft (2) with the wheel hub (1). Mount the drive shaft (2) in the sleeve. Tighten the screws (3) securing the drive shaft (2) to the hub (1) to the required torque. Fit new protection caps (3). Connect the pipe (2) to the support bracket (1). 44623 101971 44611 101962 44626 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Mount the support (2) and tighten the fixing screws (1) to the required torque. Mount braking pads (1). Fit brake caliper (3) to support (2), then use torque wrench (4) to tighten fastening screws (1) to a torque of 32 to 36 Nm. ! Braking pad with wear signalling unit must be mounted at brake caliper plunger side. Having to move the brake caliper piston back, keep to the instructions given in the BRAKES section. ! Mount only new screws (1, Figure 24). Every time they are removed, they must be replaced. 70 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Mount a new O-ring on the differential locking attachment plane. Position the previously assembled support (3) so as to insert the control lever in the spline on the sliding sleeve. Insert the 4 screws (2) complete with washers and spring washers and tighten the screws to the driving torque of 23 Nm (2.35 kgm). Assemble the spring (1). Adjust the differential locking device by following the procedures below. Remove gasket (4). By means of a normal beater knock out the elastic pin (2), remove the lever (1) complete with ring and washer. Finally, remove the control lever (3) from the support (5). Remove the spring (1). Unscrew and remove the 4 screws (2) including washers and then disconnect the differential locking device (3). If required, remove the unit as described in the following paragraphs. 61869 23227 61869 Figure 27 526210 DIFFERENTIAL REPAIR OPERATIONS 526260 Disassembly of differential locking Assemble the differential locking device by following the removal operations in the reverse order. Re-attach the differential locking device to the rear axle casing as follows: Assembling the differential locking device Differential locking removal Differential locking refitting Figure 28 Figure 29 REAR AXLE 450511 71 D AILY E URO 4 Print 603.93.651 Base - March 2006

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107982 18216 Figure 30 Figure 31 DIFFERENTIAL LOCKING DEVICE COMPONENTS 1. Flexible tie rod bracket (Bowden) - 2. Rear axle casing - 3. Spring - 4. Gasket - 5. Sealing ring - 6. Gasket - 7. Sleeve control lever (9) - 8. Elastic pin to fix lever (7) to lever (12) - 9. Differential locking sliding sleeve - 10. Spring coupling plate (11) - 11. Lever return spring (12) - 12. Transmission lever - 13. Adjusting screw nut - 14. Adjusting screw -15. Differential locking device body. Engage the sliding sleeve (9). Once this has been done, loosen the nut (13), move the adjustment screw (14) so that it is contact with the control lever (7). After this, unscrew the adjustment screw by 9.5 turns (corresponding to 9.5 mm. travel of the screw) and lock it with the fastening nut (13). Adjusting the differential locking device Disassembling the differential unit Unscrew the screws (1) complete with tab washers and spring washers and remove the gear housing inspection cover (2) complete with gasket. Before carrying out repair operations on the differential unit you must drain off the oil and disassemble the drive shafts. For the rear axle, you must disassemble the differential locking as described in the relevant paragraphs. NOTE 72 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651

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44598 Figure 32 Mark the position of the caps (1 and 2) and remove them. 44599a Figure 33 Take out the gear housing (1). Note the assembly position of the adjustment rings (3) and take them out of the housing together with the spacer rings (2). Extract the support bearing inner rings (3 and5) andshoulder ring (2) from the gear housing and, by means ofthe pullertool 99348001 (4), extract the counter block (1). 44600 Figure 34 Disassembly of gear housing 62099 18222 Figure 35 Figure 36 Unscrew the screws (2), remove the ring bevel gear (3) and the gear housing (4) cover (1). Remove the crown wheel (2) on the cover sidewith itsthrust washer (3) from the gear housing (1). Using a generic beater to remove the long pin (4) and the two short pins (5) from the gearing case (1). The thrust ring (2) is only present with rear axles fitted with differential locking. NOTE Mark the cover (1) and the gear housing (4). NOTE In the case of reuse, do not swap over the assembly positions of the external rings (4) of the tapered roller bearings. NOTE REAR AXLE 450511 73 D AILY E URO 4 Print 603.93.651 Base - March 2006

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20378 18226 Figure 37 Remove the spider (1) and the four planetary gears (2) with their shoulder washers (3) from the gear housing. Remove the crown wheel (1) on the gear housing side with the thrust washers. 51863 PARTS COMPRISING THE DIFFERENTIAL UNIT 1. Nut - 2. Transmission connection coupling - 3. Seal - 4. Front bearing - 5. Pinion shim ring - 6. Fixed spacer - 7. Spacer ring - 8. Adjustment ring - 9. Rear bearing - 10. Bevel pinion - 11. Ring bevel gear - 12. Fixed ring -13. Adjustment ring - 14. Bearing - 15. Thrust ring (axle with differential locking) - 16. Gear housing - 17. Crown wheel thrust washer - 18. Spider - 19. Crown wheel - 20. Gear housing cover - 21. Screw - 22. Planetary gear thrust washer - 23. Planetary gear - 24. Short pin - 25. Long pin. Figure 38 Figure 39 74 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Assemble the cover and make the marks made during disassembly coincide. Assemble the ring bevel gear and fasten this to the half-casing by means of the fixing screws. By means of a torque wrench (1) tighten the fixing screws (2) to the required tightening torque. Position the other two planetary gears (1) complete with thrust washers and then insert the two short pins (2). Rotate the planetary gears-crown wheel unit and check that it is free without stiffness. Assemble the other crown wheel complete with thrust washer. Position the two planetary gears (1) complete with thrust washers, spider (2) and then insert the long pin (3). Position the crown wheel (1), gear housing side, complete with thrust washer, into its own housing. 18226 20380 20379 18237 Figure 40 Figure 41 Figure 42 Figure 43 Assembly of gear housing Only for axles with differential lock. Using tool 99305121, heat thrust ring (1) to a temperature of 120ºC ÷ 150ºC for 15’ and fit on the gear casing (2) from the side with the differential lock. Figure 44 1 2 18240 Assembling bevel pinion unit Figure 45 On a surface plate (2) zero the dial gauge (1) placed on the support 99395728 (3) and lightly pre-load it. 18241 REAR AXLE 450511 75 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Figure 46 Figure 47 Figure 48 101977 Fit tapered-roller bearing internal ring (2) onto false pinion 99370309 (1) with the washer supplied (3). 51839 Position the dummy pinion 99370309 (1), assembled as shown in Figure 46, on the external ring (2) of the tapered roller bearing. On the opposite side, fit the taper bearing internal ring (3) on the dummy pinion (1) and the transmission shaft flange (4) . Screw on the nut (5) so that the dummy pinion turns freely with no end float. Fit the mounting 99395728 (2) with the dial gauge (1) on the dummy pinion 99370309 (3). Orientate the, previously zeroed, dial gauge so as to position the rod on the lowest portion of the seat of the bearing supporting the gear housing and note the difference A1 . Repeat the same operation on the seat of the other bearing and note the difference A2 . Thickness S to be added to adjusting ring thickness (4, Figure 50) used for measuring, for pinion positioning is obtained by the following formula: 51840 A1 indicates the value measured on the right-hand seat. A2 indicates the value measured on the left-hand seat. B indicates the value marked on the bevel pinion (see Figure 49). For example: = A1 + A2 2 − (  B) = 1,05 + 1, 10 2 − ( − 0, 05) = 2, 15 2 + 0, 05 = S S The result of the formula must be added algebraically to the value of the adjusting ring used to make the measurements. Example: if the value of the adjusting ring used is 3.00 mm, replace with one measuring 4.125 mm (3.00 + 1.125). 1,125 76 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 18246 Unscrew the retaining nut, the transmission connection flange and remove it and the bearing from the dummy pinion. Remove the dummy pinion with the mounting 99395728, dial gauge and rear bearing from the axle housing. If the value marked on the pinion is preceded by a positive sign (+), it must be subtracted from the value of the sum divided by two for both seats, whereas it has to be added if it is preceded by a negative sign (-). NOTE 51838 If required, replace adjusting ring (4) with a new one having the calculated thickness, after removing bearing outer ring (3) from rear axle casing (5) by beater. Then fit the new adjusting ring (4) into rear axle casing (5). Using the punch 99374092 (2) and grip99370007 (1),mount the external ring (3) of the tapered roller bearing. 18251 Using a suitable punch (1) and a hydraulic press, mount the internal ring (2) of the tapered roller bearing on the bevel pinion (3). Position the fixed spacer (3) and the adjustment ring (2), used previously to obtain the required rolling torque, on the bevel pinion (1). 18252 62097 Position the axle casing as indicated in the figure. Fit the taper bearing internal ring (1) and the transmission shaft flange (2). Position a suitable pipe (3) on the stand so that the flange (2) and the taper bearing internal ring (1) are correctly supported. REAR AXLE 450511 77 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Figure 54 Figure 55 Figure 56 Mount the bevel pinion (1) in the axle housing so as to enter the internal ring (2) of the tapered roller bearing. Tap on the end of the pinion (1) so that the transmission shaft flange retaining nut (3) can be fitted. 51845 Use tool 99370317 (2) to prevent the flange (1) from rotating. Tighten the bevel pinion retainer nut to the required torque with a torque wrench (3). 51846 74728 Using torque meter 99389819 (1), detect bevel pinion rolling torque. If the reading differs from the prescribed value, disassemble the pinion (1, Figure 54), replace the adjuster ring (2, Figure 52) with a ring of the correct thickness. Refit the pinion and repeat the rolling torque check. The rolling torque must be measured at an ambient temperature of 25 ° C, making the pinion turn at a speed of 50 rpm after it has made 10 turns. NOTE 78 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Lubricate the internal ring of the front bearing and position it in the housing. Using the key 99374022 (1) and grip 99370006 (2), mount the pre-lubricated seal. Determine bevel pinion rolling torque adjusting ring as described above. 107983 51865 18252 Figure 57 Using a suitable punch, with a grip, drive the external ring (4) for the front bearing into the axle housing (1). Position stop ring (5) with 2 mm thickness and drive outer ring (3) of rear bearing using a proper beater. Determine bevel pinion position adjusting shim as described above. Remove the external ring (3) of the tapered roller bearing. Position adjusting ring (2) having the calculated thickness, on stop ring (5). Refit the external ring (3) of the tapered roller bearing. Heat the internal ring (4) of the tapered roller bearing to 80 ° C ÷ 90 ° C for approximately 15 min. and drive it, with a suitable punch, onto the bevel pinion (1). Position the spacer ring (3) and adjustment ring (2), calculated beforehand to obtain the required rolling torque, on the bevel pinion (1). 51866 Position the axle housing as shown in the figure. On the stand, set a pipe (3) of such diameter and length as to provide a solid supporting surface for the flange (2) and the internal ring (1) of the front bearing above, already mounted in the axle housing. Figure 58 Figure 59 Figure 60 4 The rolling torque of the bevel pinion must be measured with lubricated bearings and seals. NOTE REAR AXLE 450511 79 D AILY E URO 4 Print 603.93.651 Base - March 2006 Differential unit refitting

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Mount the spacers and adjustment rings in the same number, thickness and position found during disassembly, in the following order: spacer (1), adjustment ring (2), adjustment ring (3) and spacer (4). Position the sliding sleeve in the rear axle housing for differential locking (if present). Mount the external rings (1) for the gear housing support bearings and then position the previously mounted gear housing in the rear axle housing. Make a cut in the collar of the nut (1) by the milling of the bevel pinion (2) as shown in the figure. 51867 51868 20384 44594 Figure 61 Insert the bevel pinion (1), assembled as shown in the figure, in the internal ring of the front bearing (2) and in the flange (3). Block rotation of the transmission flange with the retainer tool 99370317. Using a suitable Allen wrench and the torque wrench, tighten the bevel pinion retainer nut (1, Figure 62) to the required torque. To be on the safe side, check the rolling torque of the bevel pinion with the dynamometer 99389819. * * DIRECTION OF ROTATION OF THE NUT Figure 62 Figure 63 Figure 64 4 Strike the top of the bevel pinion until it is possible to fit the nut (1, Figure 62) securing the flange (3). Take out the support pipe (4). Complete assembling the pinion by fully tightening the nut. NOTE 80 REAR AXLE 450511 D AILY E URO 4 Base - March 2006 Print 603.93.651

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18262 Figure 65 Complete mounting operation by checking total rolling torque and the clearance of ring gear and pinion coupling as described for NDA rear axles. α Position a new seal ring over the gear housing inspection attachment surface. Mount the cover (3), insert the fixing screws (2) complete with tab washers and spring washers. Tighten the screws (2) with the torque wrench (1) to the required tightening torque. Mount the differential locking device (if present) and adjust it as described under the relevant heading. Mount the drive shafts as described under heading: “525030 Overhauling the Hubs”. Screw on the oil drainage plug and tighten it to the required torque. Add lubricating oil in the required quantity and grade through the hole. Screw on the oil filler plug and tighten it to the required torque. Take the assembly off the stand. The assembly should be put back on its mounting to prevent the dust guards and/or brake discs from getting damaged. Do not tighten the screws to a torque greater than the value indicated since this would impair the sealing effect of the gasket placed between the coupling plane and the gear housing inspection cover. NOTE NOTE REAR AXLE 450511 81 D AILY E URO 4 Print 603.93.651 Base - March 2006

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REAR AXLE 450517/2 83 D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear axle 450517/2 Page DESCRIPTION 85 . . . . . . . . . . . . . . . . . . . . . . . . . . CHARACTERISTICS AND DATA 86 . . . . . . . . . . . TIGHTENING TORQUES 88 . . . . . . . . . . . . . . . . . TOOLS 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE REMOVAL - REFITTING 95 . . . . . . . . -Removal 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING THE REAR AXLE ASSEMBLY 97 . -Air breather disassembly - assembly 97 . . . . . . . . . -Overhaul of wheel hubs 97 . . . . . . . . . . . . . . . . . -Disassembly 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Stud replacement 99 . . . . . . . . . . . . . . . . . . . . . . -Assembly 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL REPAIR OPERATIONS 102 . . . . . . . -Differential locking 102 . . . . . . . . . . . . . . . . . . . . . . -Differential unit removal 103 . . . . . . . . . . . . . . . . . -Gearing case removal 103 . . . . . . . . . . . . . . . . . . . -Differential components check 105 . . . . . . . . . . . . -Rear axle casing check 105 . . . . . . . . . . . . . . . . . . . -Gearing case refitting 105 . . . . . . . . . . . . . . . . . . . . -Differential unit refitting 109 . . . . . . . . . . . . . . . . . .

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62983 Figure 1 DESCRIPTION The rear axle is the load-bearing type with a single reduction using a hypoid crown wheel and pinion. The axle housing is made of pressed sheet steel with hot pressed arms. The central portion, seat of the differential unit, is equipped with cooling fins. The bevel pinion is supported by two pre-lapped tapered roller bearings to hold the bearing pre-load better. The rolling torque of the bearings of the bevel pinion is ad-justed by changing the thickness of the adjustment ring be-tween the two tapered roller bearings. In addition, it is possible to adjust the position of the bevel pin-ion with respect to the ring bevel gear by changing the thick-ness of the ring between the axle housing and the bevel pinion rear bearing external ring. The gear housing is supported by two tapered roller bearings. The rolling torque of the bearings is adjusted with adjustment rings between the spacer rings and the external rings of the bearings. The clearance between pinion and crown wheel is adjusted by changing the thickness and/or position of the adjustment rings, though the total thickness must be the same as that of the adjustment rings removed. The gear housing is composed of two half-housings. It may be of two different sizes depending on the ratio of the crown wheel and pinion. The gearing of the differential is composed of four planetary gears and two crown wheels. Wheel hubs are supported by two ”SET RIGHT” type bear-ings set on the sleeve. The bearings need no adjustment. The brakes are disc brakes with floating brake calipers. The disc brakes are keyed onto the wheel hubs. Perrot type brake callipers are supported by flanges welded to rear axle casing arms. The parking brake is the drum type, built into the brake disc. REAR AXLE 450517/2 85 D AILY E URO 4 Base - March 2006 Print 603.93.651

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CHARACTERISTICS AND DATA 86 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651 Type of rear axle: Bearing with single reduction and mechanical control differential locking 450517/2 DIFFERENTIAL UNIT Reduction bevel gear pair ratio (tooth no.: pinion/crown wheel), on request 1/3,91 (11/43) - 1/4,30 (10/43) -1/4,56 (9/41) - 1/5,13 (8/41) Bevel pinion bearings 2 with taper rollers Bevel pinion bearing rolling torque (lubricated gaskets and bearings) Nm New bearings kgm 2 ÷ 3 0.20 ÷ 0.30 Bevel pinion bearing preload adjustment through adjustment rings > Bevel pinion bearing preload adjustment ring thickness 1 - 2 mm with 0.025 mm progression Temperature for fitting inner bearing ring on bevel pinion 80 ° C ÷ 90 ° C Bevel pinion position with reference to differential casing By means of shims > Thickness of adjustment rings between bevel pinion and differential casing 3.45 ÷ 4.35 mm with 0.025 mm progression Bearings for gearing case 2 taper rollers Differential case bearing rolling torque Nm kgm 2.6 ÷ 3.9 0.26 ÷ 0.39 Adjustment of differential case bearing rolling torque Through adjustment rings > Thickness of adjustment rings for differential case bearing rolling torque 2.65 ÷ 3.20 mm with 0.05 mm progression Backlash between pinion and crown wheel 0 . 15 ÷ 0.20 mm Adjustment of backlash between pinion and crown wheel Through adjustment rings

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REAR AXLE 450517/2 87 D AILY E URO 4 Base - March 2006 Print 603.93.651 Type of rear axle: 450517/2 WHEEL HUBS Wheel hub bearings Two ”SET-RIGHT” type taper rollers Hub bearing end play 0.16 max. Wheel hub bearing rolling torque Nm kgm 0 ÷ 4 0 ÷ 0.4 Adjustment of wheel hub bearings end play Fastening nut tightening to torque Rear axle oil Amount Litres kg Max. capacity GAW kg Tutela W140/M-DA (SAE 85 W140) 3 2.7 5000

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Figure 2 62879 450517/2 (R0537) REAR AXLE DIFFERENTIAL SECTION 88 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651 TIGHTENING TORQUES PART TORQUE PART Nm kgm 1 Bevel pinion retaining nut 533 ÷ 589 53.3 ÷ 58.9 2 Screw fastening gearing inspection cover to rear axle casing* 26 ÷ 21 2.6 ÷ 2.1 3 Screw fastening crown gear to 12RDAC5 half casing* 309,5 ÷ 342,5 30.9 ÷ 34.2 3 Screw fastening crown gear to 10RDAC5 half casing 266 ÷ 294 26.6 ÷ 29.4 4 Screw fastening half casings 61 ÷ 74 6.1 ÷ 7.4 5 Screw fastening differential locking device or cover 23 2,3 6 Screw fastening caps to rear axle casing 102 ÷ 113 10.2 ÷ 11.3 * Before tightening the screws, smear their threaded holes with IVECO sealant 1905683.

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62878 Figure 3 ABS VERSION 74729 Figure 4 REAR AXLE 450517/2 89 D AILY E URO 4 Base - March 2006 Print 603.93.651 PART TORQUE PART Nm kgm 1 Wheel fastening nut 238.8 ÷ 342.6 23.8 ÷ 34.2 2** Screw fastening axle shaft to wheel hub 56 ÷ 69 5.6 ÷ 6.9 3 Wheel hub bearing retaining ring nut 441 ÷ 540 44.1 ÷ 54 4 Safety screw 9.5 ÷ 11.5 0.9 ÷ 1.1 5 Screw fastening brake disc to wheel hub 54 ÷ 59 5.4 ÷ 5.9 6 Screw fastening brake calliper to rear axle 176 ÷ 194 17.9 ÷ 19.7 7 Screw fastening brake shoe support to rear axle casing 68 ÷ 75 6.9 ÷ 7.6 8*** Rpm sensor support fastening screw 5 ÷ 7 0.5 ÷ 0.7 * Apply IVECO 1905685 sealant on half shaft - wheel hub joint surface ** Apply IVECO 1905683 sealant on the threading of plugging screws *** Apply LOCTITE 243 on the threading of holes

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90 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99305121 Hot air operated equipment 99306004 300 kg hydraulic crane 99306010 Equipment for bleeding air from brake and clutch system 99321024 Hydraulic truck for removing - refitting wheels 99322215 Stand to overhaul axles 99345056 Counter block for pullers

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REAR AXLE 450517/2 91 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99348001 Puller with locking device 99357080 Wrench (91.5 mm) for wheel hub bearing adjustment nut 99370006 Handle for interchangeable beaters 99370007 Handle for interchangeable beaters 99370296 Tool to find bevel pinion shims (to be used with 99395728) 99370317 Counter lever and relevant extension to retain flanges

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92 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99370617 Universal support to hold axles during removal/refitting 99374093 Beater to fit in place bearing outer races (91-134) (to be used with 99370007) 99374132 Element to fit in place wheel hub internal gasket (to be used with 99370006) 99374201 Element to fit in place differential bevel pinion gasket 99389819 Dynamometric wrench (0-10 Nm) connection 1/4” 99395026 Tool to check hub rolling torque (to be used with dynamometric wrench)

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REAR AXLE 450517/2 93 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99395684 Dial gauge with magnetic base 99395728 Dial gauge with support to be used with the tools for finding proper bevel pinion shims

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Figure 5 Removal Position the vehicle on level ground and lock the front wheels. Loosen rear wheel fastening nuts. Lift the rear part of the vehicle and position it on proper stands. Fit hydraulic truck 99321024 under the rear wheels, remove wheel fastening nuts and then remove wheels. Loosen handbrake lever adjustment nut (4). Release cables (2) from vehicle cross member by releasing the retaining clips (5), and from the side member brackets by loosening clamp fastening screws (3). Loosen propeller shaft fastening screws (6). Release cables from clamps and disconnect the brake lining (1) and (7) wear indication electrical cables of ABS sensors, if any. Loosen shock absorber (14) fastening nuts (16). Loosen the screws (17) fastening the stabilizer bar (10) tothe rear axle. Disconnect brake oil pipes from connection (13) and secure them to the chassis to prevent oil draining from system. Disconnect pipe (15) from rear axle casing oil vapour bleed. Position the hydraulic jack fitted with support 99370617 under the rear axle. Loosen the nuts (8) of the brackets (9) fastening the rear axle to the leaf spring (10). Lower the hydraulic jack and remove the rear axle. 61988 Refitting For refitting, carry out the operations described for removal in reverse order, observing the required tightening torques for the screws and/or nuts. Afterwards, check that: -Check the thread of the brackets joining the leaf springs to the axle. If there are any irregularities, rectify the thread (operation 500412) or replace the brackets. -Bleed the air from the brake hydraulic system as described under the relevant heading (operation 784010). -Adjust the handbrake control ties as described under the relevant heading (operation 502710). -Lock the nuts or screws to the required tightening torque. -The self-locking nuts must not be reused. -Check the state of the flexible pads (12) and replace them if they have deteriorated (operation 500417). -The lubricating oil in the axle housing should be at the right level. REAR AXLE 450517/2 95 D AILY E URO 4 Base - March 2006 Print 603.93.651 REAR AXLE REMOVAL - REFITTING

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62881 62880 62882 62883 Figure 6 Figure 7 Figure 8 Figure 9 525010 OVERHAUL OF REAR AXLE ! The drive shafts, brake disc and calipers, air breather and differential can all be removed and refitted even with the unit mounted on the vehicle. Before positioning the rear axle assembly on the stand for overhauling, drain oil by loosening rear axle casing plug. Dis-connect brake fluid pipes (2) from brake callipers (1) and from rear axle casing and pipes (3) from rear axle casing. Set the entire rear axle assembly on stand 99322215. Take out the screws (1) and remove the brake caliper with its brake linings from the mounting. 525013 Air breather disassembly - assembly Take out the screws (1) and remove the brake caliper (2) with its brake linings from the mounting. 525030 Overhaul of wheel hubs Disassembly ! The caliper must not be violently knocked or dropped. Prevent the rubber caps coming into contact with sharp metal tools. Do not dirty or wet the rubber caps with mineral grease or oil. Do not dirty the pads with liquids or grease. Check proper brake calliper and brake lining conditions as described in ”Brake” section. The identification data of the rear axle unit are given on the plate (1) fixed near to the leaf spring attach-ment support. NOTE REAR AXLE 450517/2 97 D AILY E URO 4 Base - March 2006 Print 603.93.651

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62891 62889 62892 62893 62894 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Remove the axle shaft (2) from the wheel hub (1). Remove ring nut (1) safety screw (2). Loosen bearing retaining ring nut (2, Figure 12) using wrench 99357080 (1). Remove the safety washer (1). Rotate the wheel hub (1) to set downward one of the two screws (2) located between hub reliefs; remove the screws and drain oil completely from wheel side. Remove the other screws fastening the axle shaft (3) to the wheel hub (1). 62890 Figure 15 Sling brake disk (1) with rope and hoist, take off wheel hub (2) complete with brake disk (1), front (3) and rear bearings, seal ring and spacer. 98 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651

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62884 32445 62885 62887 62888 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Remove front bearing (1) inner ring and spacer (2). Remove screws (4) and disconnect the brake disc (5) from the wheel hub (3). Remove phonic wheel (1), if any, using suitable equipment. Remove sealing ring (2) and the rear bearing inner ring (4) set below from the wheel hub (3). Where the studs of wheel hub (1) must be replaced, before mounting the new studs, make sure that studs head rest plane is free from slag, burr and blisters. The pins should be driven in by applying a load on their head no greater than 2000 kg. After driving them home, check that the pins are perfectly in touch with the hub: maximum orthogonal tolerance 0.2 mm. Use handle 99370007 (1) and beater 99374093 (2) to fit taper roller bearing outer rings into the wheel hub. Use a suitable punch to remove the rear taper roller bearing outer ring (1). Repeat this operation to remove the front taper roller bearing outer ring. Check the brake disc as described in the ”Brake” section. NOTE This operation shall be performed using a press until positioning the rings at 5 mm from their abutting end, their fitting shall be then completed by hand. NOTE REAR AXLE 450517/2 99 D AILY E URO 4 Base - March 2006 Print 603.93.651 Stud replacement

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62932 62896 62938 62897 Figure 21 Figure 22 Figure 23 Figure 24 Lubricate the sleeve and the sealing ring supporting ring (1) with TUTELA W140/M-DA (SAE 85W140) oil. Use suitable rope and hoist to fit wheel hub (1) on sleeve (4). Lubricate spacer (2) and outer bearing inner ring (3) with Tutela W140/M-DA and fit them on sleeve (4). Lubricate rear taper roller bearing inner ring (4) with SAE W 140 M-DA oil and fit it to wheel hub (5). Use tool 99374132 (2) provided with proper handle 99370006 (1) to fit sealing ring (3). Fit the brake disc (3) on the wheel hub (1) and tighten the fastening screws (2) to the specified torque. Fit the phonic wheel, if any, on the wheel hub. Use tool 99374132 (2) side to position the sealing ring (3) at 1.5 mm from wheel hub side surface. NOTE Phonic wheel fitting shall be performed after heating it at 150ºC. When fitting is over, check whether the phonic wheel is resting perfectly on the hub seat. Check whether phonic wheel squareness and oscillation is lower than 0.2 mm. NOTE Check and, if necessary, adjust the clearance between the parking brake drum and shoes as described in the Brakes section. NOTE 100 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651

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62898 62900 62899 62891 62902 62903 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Fit the safety washer (3) so that the clip is guided properly into rear axle casing sleeve groove. Tighten ring nut (4) with wrench 99357080 (1) and dynamometric wrench (2), tighten the new ring nut (4) to the specified torque. Position the dial gauge 99395684 (1) with a magnetic base on the wheel hub (3) and rest the rod on the sleeve (2). Check whether wheel hub end play is falling between 0 and 0.16 mm. Use tool 99395026 (2) and the dynamometric wrench 99389819 (1) to check whether the wheel hub rolling torque is falling between 0 and 4 Nm (0 - 0.4 kgm). After checking the end play and the rolling torque, check whether one of the adjustment nut (1) holes is coinciding with one of the safety washer holes otherwise loosen the adjustment nut (1) until it is possible to fit the fastening screw (2). Tighten the fastening screw (2) and the adjustment nut to the specified torque. Smear the contact surface between axle shaft (3) and wheel hub (1) with IVECO sealing compound 1905685. Fit axle shaft (3), tighten the fastening screws (2), excluding those set between the two wheel hub marks (see Figure 30) with tool 99370317 (4) lock wheel hub (1) rotation. Set horizontally to ground the two holes (1) located between the wheel hub marks and pour through 0.2 l of W140 M-DA oil on each wheel side. Smear the threaded section of the screws acting as plug with IVECO sealant 1905683 and tighten to the specified torque. REAR AXLE 450517/2 101 D AILY E URO 4 Base - March 2006 Print 603.93.651

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62904 Figure 31 Position brake calliper (1) including the brake lining on the supporting flange (2). Tighten the fastening screws to the specified torque. 62880 Figure 32 Remove the rear axle assembly from the overhaul stand. Refit brake fluid pipes (2 and 3) to rear axle casing and brake callipers (1). Fill rear axle casing with oil in the specified amount and quality. Figure 33 Figure 34 Remove the 4 screws (1) including washersand disconnectthe differential locking device (2). When refitting, replace the gasket located between differential locking device and rear axle casing. Tighten screws (1) to the specified torque. 62906 DIFFERENTIAL LOCKING DEVICE SECTION Differential locking device engagement/disengagement lever stroke shall be equal to 5 mm. 62907 526260 Differential locking The brake lining with the wear sensor shall be fitted on brake calliper piston side. Comply with BRAKE section requirements to move back the brake calliper piston. NOTE 102 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651 526210 DIFFERENTIAL REPAIR OPER-ATIONS

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Differential unit removal Remove gearing (1) inspection cover including the gasket. 33077 Figure 35 Figure 36 Figure 37 Figure 38 Remove caps (1) after marking them. Remove the spacer (1) and remove the gearing case (3) in-cluding the crown wheel (4) and the outer rings (2) for sup-porting bearings. Remove the other spacer and the adjust-ment rings. Do not reverse the outer races of the gearing case supporting bearings. Remove gearing case supporting bearings (1 and 2) using puller 99348001 (3) and counter block 99345056 (4). Figure 39 Clamp the gearing case (2) in a vice and remove the ring bevel gear (1) from the gearing case (2). 33082 33083 Mark gearing half-boxes (1 and 2), loosen the fastening screws, position the gearing case on a bench and remove the two half-boxes. Figure 40 Gearing case removal 33078 33079 33081 Before performing differential repair, drain oil and remove axle shafts as described previously. NOTE REAR AXLE 450517/2 103 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 41 33084 Remove sun gears (5) and planetary gears (2) including the spi-der (6) from the gearing half-box (4). Recover the shoulder washers (1 and 3). Figure 42 Remove bevel pinion retaining nut safety crimp and loosen the nut using the counter lever 99370317 (1). 33086 Figure 43 Remove transmission connection flange (1). 33087 Figure 44 Use a bronze beater in arrow direction to remove the bevel pinion (1) including the rear bearing, the fixed spacer and the adjustment rings from the rear axle casing (2). 33088 Figure 45 33089 Remove the sealing ring (1) and the front taper roller bearing from the rear axle casing (2). Use a bronze beater to remove the front taper roller bearing outer ring. Figure 46 33090 Use a bronze beater to remove the rear taper roller bearing outer ring (1) from the rear axle casing (2). 104 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 47 Use puller 99348001 (3) to remove the rear taper roller bearing (2) from the bevel pinion (1). 33091 Differential components check Carefully clean each differential component. Lubricate the bearings and rotate the roller cage freely. The rotation must be even and without sign of stiffness. Check the ring bevel gear contact surfaces and the half-box striker plate to ensure that the crown wheel adheres perfectly. Deforma-tions on these surfaces cause the crown wheel fastening screws to vibrate, thus jeopardizing the correct operation of the unit. Check that the splined section for flange-pinion connection is not badly worn, otherwise replace the pinion. Check the planetary gears and the relevant shoulder washers, the spider and the crown wheels with the relevant shoulder washers. Replace all sealing elements, the bevel pinion retaining nut and gearing case bearing adjustment nut with new parts. Rear axle casing check Check whether rear axle casing is not deformed. Gearing case refitting Figure 48 Fit in place the sun gear (2) with the shoulder washer set below in gearing half-box (1). 33092 Figure 49 33084 Fit in place the planetary gears (2) with shoulder washers (3), the spider (6) and the sun gear (5) with shoulder washer (1) in the gearing half-box (4). Figure 50 33094 Fit between them the half-boxes (1 and 2) and tighten the fastening screws to the specified torque. Carefully clean all threads in order to obtain exact adjustments and accurate tightening torque. When replacing the crown wheel or pinion it is necessary to replace both parts since they are supplied in pairs. NOTE NOTE REAR AXLE 450517/2 105 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Heat in air-circulation furnace at 100ºC for approx. 15’ the taper roller supporting bearing (1) on toothing side and fit it down onto the gearing case (2) completely. Figure 51 33095 Figure 52 Heat in air-circulation furnace at 100ºC for approx. 15’ the taper roller supporting bearing (1) on toothing opposite side and fit it down onto the gearing case (2) completely. 33096 Figure 53 Pour few drops of LOCTITE 270 into crown wheel (1) holes, fit the crown wheel (1) on the gearing case (2) and tighten the fastening screws to the specified torque. 33097 Figure 54 33098 Figure 55 33099 Figure 56 33100 Mount the outer ring of front taper roller bearing into rear axle box using beater 99374093 (1). Use beater 99374093 (1) to fit in place rear taper roller bearing outer ring on rear axle casing (2) without adjustment ring. On surface plate (2), set to zero dial gauge 99395728 (1) on support (3) and slightly preload it. 106 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 57 33101 Fit the rear bearing (2) on the false pinion 99370296 (1). 33102 Position the false pinion 99370296 (1) including the rear bear-ing (2) into its seat on rear axle casing (3). Fit the front bearing, the transmission connecting flange and the bevel pinion retaining nut and tighten so as to remove end play and to enable false pinion rotation. 8,00 2 S = - 0,05 3,90 + 4,10 2 S = - ( ± 0,05) Set dial gauge 99395728 (1) including support (3) on false pinion 99370296 (2). Direct suitably the dial gauge previously set to zero (see Figure 56) to position the rod to the bottom of the gearing case supporting bearing housing. 33103 Repeat this operation for the other bearing and take note of both found values. Pinion adjustment ring thickness is obtained through the following formula: S = - ( ± B ) A 1 + A 2 2 ”S” = thickness of the adjustment rings to be positioned between bevel pinion rear bearing outer ring and rear axle casing. ”A1” = value found on right housing ”A2” = value found on left housing ”B” = reference value marked on bevel pinion (see Figure 60) Example: S = 4,00 - 0,05 S = 3,95 Adjustment ring thickness shall therefore be: 3.95 mm. Figure 58 Figure 59 REAR AXLE 450517/2 107 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 60 33104 Figure 61 33099 Choose an adjustment ring having the same thickness ob-tained by using the formula shown in SENZA CODICE and fit it into the rear axle casing after removing rear taper roller bearing outer ring previously mounted. Use beater 99374093 (1) to fit definitely the rear taper roller bearing outer ring into rear axle casing (2). Figure 62 Heat the rear bearing (1) to 100 ° C for approx. 15’ into an air-circulation furnace and then fit it down onto the bevel pinion (2). 32481 Figure 63 Position the fixed spacer (2) and the adjustment ring (3), previously used to obtain the specified rolling torque, on the bevel pinion (1). 32482 Figure 64 Position the complete bevel pinion into the rear axle casing. Heat the front bearing (1) to 100 ° C for approx. 15’ into an air-circulation furnace and then fit it down onto the bevel pinion (2). 33111 If the value marked on the pinion is preceded by positive sign (+), it shall be subtracted from the value obtained by the sum divided by two of the housings, whereas it shall be added if preceded by negative sign (-). NOTE 108 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 65 74730 Fit the seal ring (2) in the axle casing with tool 99374201 (1). Figure 66 Fit the transmission connecting flange (1) and the bevel pinion retaining nut (2). 33113 Figure 67 74731 Assemble the flange (3) and prevent rotation with tool 99370317 (1). Using the torque wrench (2), tighten the bevel pinion flange (3) retaining nut to the correct torque value. Figure 68 32480 Using the torque wrench 99389819 (1), measure the rolling torque of the bevel pinion. If the value is incorrect disassemble the pinion (2, Figure 64), and replace the adjuster ring (3, Figure 63) with a suitable ring. Refit the pinion and repeat the rolling torque check. Figure 69 33116 Fit gearing case supporting bearing outer rings (2) and then position the gearing case (1), previously fitted, in the rear axle casing. Differential unit refitting The rolling torque must be measured at an ambient temperature of 25 ° C, making the pinion turn at a speed of 50 rpm after it has made 10 turns. NOTE REAR AXLE 450517/2 109 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 70 Insert the spacer (2), adjuster ring (1), adjuster ring (4) and then spacer (3). 33117 Figure 71 Refit caps (1) taking into account the marks made at removal. Use dynamometric wrench 99389827 (2) to tighten the fastening screws to the specified torque. Set gearing case supporting bearings and check total rolling torque. 33119 Figure 72 33107 Use dynamometric wrench 99389819 (1) to check total rolling torque: Figure 73 Position magnetic dial gauge 99395684 (1) and check the clearance between the pinion and crown on four equidistant teeth on the crown. The average of the measurements must equal the required value. If a different clearance is found, remove the caps (3) again and swap over the assembly position of the adjustment rings (1 and 4, Figure 70). If this is not sufficient, replace the adjustment rings with ones of a different thickness, but the total thickness must still be the same as that of the adjustment rings removed. This is so as not to change the total rolling torque. Apply a thin layer of Prussian blue on ring gear teeth by brush. Turn the pinion and measure the impression of the contact of the pinion toothing on the crown wheel toothing. Here we illustrate the possible contacts with the corrections to obtain precise coupling of the crown wheel and pinion. 33121 If the value is incorrect, replace the adjuster rings (1 and 4, Figure 70) with rings of the correct thickness. Ct = 2.5 + ( x 0.99) Cp = bevel pinion bearing rolling torque Cd = 2 ÷ 2.8 Nm (0.2 ÷ 0.29 kgm) Ct = Cp + ( x 0.99) Cd R Ct = total rolling torque R = Rear axle reduction ratio Example: Ct = 2.5 + 0.71 Ct = 3.21 Nm (0.33 kgm) 2,8 3,91 The rolling torque must be measured at an ambient temperature of 25 ° C, making the pinion turn at a speed of 50 rpm after it has made 10 turns. NOTE 110 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651

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44603 44605 44604 44606 44607 44608 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Excessive contact in the upper part or crest of the tooth . Move the pinion towards the ring bevel gear and then move the ring bevel gear away from the pinion to ad-just clearance. Excessive contact on heel of tooth . Move the ring bevel gear to-wards the pinion and then move the pinion away from the ring bevel gear to adjust clearance. A = Coupling depth B = Crest C = Side D = Play Correct contact. Excessive contact on side of tooth . Move the pinion away from the ring bevel gear and then move the ring bevel gear to-wards the pinion to adjust clearance. E = Greater base F = Heel G = Top land H = Contact surface I = Lateral surface Excessive contact on the top land of the tooth . Move the ring bevel gear away from the pinion them move the pinion towards the ring bevel gear to adjust clearance. REAR AXLE 450517/2 111 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 80 Fit a new sealing gasket on gearing inspection cover connec-tion surface. Apply Loctite 270 on the thread of the holes for screws to secure cover (1). Fit cover (1) and use dynamomet-ric wrench to tighten the fastening screws to the specified torque. 33122 Figure 81 33123 Fit oil drain plug (2). Pour 3 litres of W140/M-DA oil through the proper hole and fit inspection and filling plug (1). 51853 Figure 82 Crimp nut (1) collar on bevel pinion (2) milling as shown in the figure. Do not tighten screws at higher torque value since this shall jeopardize the effect of the sealing gasket located between the connection surface and the gearing inspection cover. NOTE * * NUT ROTATION DIRECTION 112 REAR AXLE 450517/2 D AILY E URO 4 Base - March 2006 Print 603.93.651

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AXLES 1 D AILY E URO 4 Print 603.93.651 Base - March 2006 SECTION 7 5206 Axles Page This section contains: DIAGNOSTICS 3 . . . . . . . . . . . . . . . . . . . . . . . . . AXLE 5817 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE 5818 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE 5819 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE 5823 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL GEOMETRY 49 . . . . . . . . . . . . . . . . . . . . .

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Front axle main working faults: 1 - Stiff steering; 2 - Wobble; 3 - Noise. YES 1 NO YES NO STIFF STEERING YES NO YES Front wheels not aligned. Align front wheels. Irregular wheel toe-in. Adjust front wheel toe-in. Irregular tyre pressure. Inflate tyres to prescribed pressure. Elements involved in the stub axle rotation on the pin inefficient. Check and replace the elements deteriorated. AXLES 3 D AILY E URO 4 Print 603.93.651 Base - March 2006 AXLES DIAGNOSTICS

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Eccentric wheels: eccentric, deformed rim tyre assembled on wrong rim. YES 2 NO YES NO YES YES NO YES NO YES NO YES NO WOBBLE Irregular wheel camber. Check the tie rod assembly, adjust or repair the deformed parts. Front wheels not aligned. Align front wheels. Irregular wheel toe-in. Correctly adjust toe-in. Steering gear tie rod king-pins inefficient. Replace defective parts. Irregular play of wheel hub bearings. Replace the wheel hubs. Replace the wrong rim. Deflate and centre the tyre on the rim. Unbalanced wheels. Balance the wheels. 4 AXLES D AILY E URO 4 Base - March 2006 Print 603.93.651

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3 YES NO YES NOISE Wheel hub bearings worn. Replace worn bearings and adjust end play. Stabiliser bar elastic inserts worn or relevant fixing brackets loosen. Replace elastic inserts, tighten fixing nuts. NO YES Play between torsion bar-suspension arm splines. Replace worn parts and adjust torsion bar pre-loading. NO YES Suspension arm bushes and/or articulation pins worn. Replace worn parts. AXLES 5 D AILY E URO 4 Print 603.93.651 Base - March 2006

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6 AXLES D AILY E URO 4 Base - March 2006 Print 603.93.651

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AXLE 5817 7 D AILY E URO 4 Print 603.93.651 Base - March 2006 Axle 5817 Page DESCRIPTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA 10 . . . . . . . . . . . . . TIGHTENING TORQUES 11 . . . . . . . . . . . . . . . . . TOOLS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING AND REFITTING AXLE 5817 13 . . . . -Removal 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIRS 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING AXLE 5817 15 . . . . . . . . . . . . . . . -Wheel hub removal and refitting 15 . . . . . . . . . . -Removal 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Replacing phonic wheel 16 . . . . . . . . . . . . . . . . . . -Refitting 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUB AXLE REMOVAL-REFITTING 17 . . . . . . . . . -Removal 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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8 AXLE 5817 D AILY E URO 4 Base - March 2006 Print 603.93.651

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The front axle 5817 is composed of a load-bearing cross member on which are mounted the suspensions and power steering. The stub axles turn, by means of swivel heads, on the ends of the suspensions. The steering levers are cast on the king-pin of the stub axles to which are secured the brake calipers. Figure 1 The wheel hubs are supported on the pins of the stub axles by UNIT - BEARINGS that need neither lubrication nor adjustment. The wheel rims are secured onto the wheel hubs by five screws. 108374 AXLE 5817 9 D AILY E URO 4 Print 603.93.651 Base - March 2006 DESCRIPTION Print 603.43.351

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10 AXLE 5817 D AILY E URO 4 Base - March 2006 Print 603.93.651 SPECIFICATIONS AND DATA Axle type 5817 WHEEL HUBS Wheel hubs bearings UNIT BEARING Hub bearings end play -Wheel hub bearings play adjustment Not Adjustable Fixing nut torque tightening WHEEL GEOMETRY Wheel camber angle (vehicle at static load) 0º ± 20’ Wheel caster angle (vehicle at static load) 3º ± 20’ Wheel toe-in (vehicle at static load) 2 ± 1 mm

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Figure 2 AXLE 5817 108351 AXLE 5817 11 D AILY E URO 4 Print 603.93.651 Base - March 2006 TIGHTENING TORQUES PART TORQUE PART Nm kgm Screw securing caliper mounting to stub axle 176 ÷ 217 18 ÷ 22 1 Nut securing the upper swinging arm jointed head to the stub axle 125 ÷ 140 12.5 ÷ 14 2 Nut securing the steering rod jointed head to the lever 68 ÷ 83 6.8 ÷ 8.3 3 Nut securing the lower swinging arm jointed head to the stub axle 160 ÷ 180 16 ÷ 18 4 Screw securing stub axle guard 6 ÷ 7.5 0.6 ÷ 0.7 5 Screw securing brake disc to wheel hub 19.5 ÷ 24.9 2 ÷ 2,5 6 Screw securing wheel 180 ÷ 200 18 ÷ 20 7 Nut securing wheel hub 320 ÷ 420 32 ÷ 42

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12 AXLE 5817 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99305354 Portable optical reading tool for checking wheel trim 99306010 Apparatus to purge air from brakes and clutch 99321024 Hydraulic trolley for removing/refitting wheels 99322215 Guide to wheel hub assembly 99347074 Puller for steering tie rod king-pins

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Figure 3 REMOVING AND REFITTING AXLE 5817 Removal Set the vehicle on solid, level ground. Lock the rear wheels with scotches, remove the wheel rim guards and loosen the screws or nuts fixing the wheel. Lift the front of the vehicle and rest the chassis frame on supports. Take out the screws or nuts fixing the wheel and remove them with tool 99321024. From underneath the vehicle: -remove the central guard (15) under the engine by taking out the screws securing it to the side guards and to the front cross member of the chassis frame; -remove the engine side guards (6) and (19) by taking out the screws securing them to the chassis frame; -remove the gearbox side guards (5) and (20) by taking out the screws securing them to the chassis frame and the nuts securing them to the cross member under the gearbox (23); -disconnect the brake fluid pipe (21) from the retaining blocks on the axle (22); -drain off the power-steering fluid and disconnect the pipes (11) and (12) in correspondence with the fittings on the hydraulic power steering (13); -disconnect the power steering column in correspondence with the coupling (14). If it is decided to leave the brake callipers on the axle, proceed to: -disconnect the electrical connection (1) signalling brake lining wear and the ABS sensor (4) if there is one; -disconnect the brake fluid pipes in correspondence with the fittings (7) and (18) after draining the system. If it is decided to leave the brake callipers on the vehicle, proceed to: -disconnect the brake fluid pipes from the axle (22) in correspondence with the brackets (8, 10, 16, 17); -then disconnect the brake callipers (3) from their respective stub axles by taking out the screws (2) and supporting the callipers to prevent any strain on the pipes. To complete removing the axle: -unscrew five of the six fixing screws (9) on both sides of the chassis frame; -put a hydraulic lift under the axle and take out the last two screws; -lower the hydraulic jack and extract the axle. Refitting Reverse the steps described for removal tightening the screws or nuts to the prescribed torque. Adjust the load of the torsion bar as illustrated under the specific heading. Top up the power-steering fluid. If the brake callipers have been left on the axle, restore the brake fluid level and bleed off any air. Check and adjust the front wheel geometry. 75583 AXLE 5817 13 D AILY E URO 4 Print 603.93.651 Base - March 2006 Print 603.43.351

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14 AXLE 5817 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Lift the deformation ( ⇒ ) of the nut (1) and unscrew this with a suitable wrench. Figure 4 Figure 5 Figure 6 Figure 7 Free the screws (1) securing the wheel rim. Lift the vehicle and put the stands (2) under the structural members in a forward position. Undo screws (1), remove screw guard (1) and remove the entire wheel. Remove the braking gaskets as described in the ”Brake” section, or remove screws (1) and take the support together with brake caliper (2) off the stub axle. Support the brake caliper suitably to prevent strain on the oil pipe. Remove centring pin (2), then take brake disc (1) off wheel hub (4). Remove the cup (3) from the wheel hub (4). 520620 Wheel hub removal and refitting Removal Check the conditions of the brake disc and the braking gaskets, as described in the ”BRAKING SYSTEM” section. NOTE 108364 108365 108367 108366 AXLE 5817 15 D AILY E URO 4 Print 603.93.651 Base - March 2006 Print 603.43.351/D REPAIRS 520610 OVERHAULING AXLE 5817

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61668 61668 Figure 8 Figure 9 Figure 10 Figure 11 Extract the wheel hub (1) from the pin of the stub axle (2). Phonic wheel (2) can be taken off wheel hub (1) by using generic tools. Pull-in load: 500 ÷ 900 kg. On completing assembly, make sure the phonic wheel sits in its seat in the hub properly. Check that the orthogonality and oscillation of the phonic wheel is no greater than 0.1 mm. Lubricate the surface of the stub axle pin (2) with TUTELA MR3 grease and key the wheel hub (1). After hub (1) is force-fitted, screw down nut (3). Tighten the nut (3) to the required torque with the Allen wrench (2). 526712 Replacing phonic wheel Refitting If any trouble is found with the wheel hub or bearing, the assembly needs to be replaced since the parts are not supplied as single spares. When repairing the wheel hub (1), take care not to damage the phonic wheel (3). NOTE The wheel hub must be keyed without forcing.. If there are difficulties, do not assemble since the bearing may be damaged. Extract the wheel hub, check the cause of the difficulties and eliminate them. NOTE 109048 109050 Nut (3) is equipped with a fixed washer (4). NOTE 16 AXLE 5817 D AILY E URO 4 Base - March 2006 Print 603.93.651 Print 603.43.351

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Fit the wheel onto the brake disc, then place the screw guard into position. Tighten the wheel fastening screws to the specified torque, in accordance with the diagram illustrated in the figure. Figure 12 Figure 13 Figure 14 Figure 15 Deform the collar of the nut (1) by the milling ( ⇒ ) of the pin (2). Mount the cup (3) in the wheel hub (4). Mount the brake disc (1) and secure it to the wheel hub (4) with the two centring pins (2). Rest the brake caliper (2) with the brake linings on the stub axle (1). Tighten brake calliper (2) fixing screws to the prescribed torque. Remove the wheel hubs as described under the relevant heading (operation 520620). 522820 STUB AXLE REMOVAL-REFIT-TING Removal The brake lining with its wear indicator must be mounted from the piston side of the brake caliper. If it is necessary to move the brake caliper piston back, use tool 99372236, taking the precautions given in the BRAKES section. NOTE 108368 108366 108369 108370 AXLE 5817 17 D AILY E URO 4 Print 603.93.651 Base - March 2006

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52260 52259 61670 61669 Figure 16 Figure 17 Figure 18 Figure 19 Remove screws (5) and remove protection (4) from stub axle (6). Remove nut (2) fixing kingpin (1) to lever (3). Using the extractor 99347074 (1), remove the pin (2) of the swivel head from the steering lever of the stub axle (3). With the hydraulic jack under the bottom suspension arm (3) oppose the action of the transverse leaf spring. Remove the nuts (2 - 6) securing the swivel head pin (1 - 5) to the stub axle (4). Using the extractor 99347074 (2), remove the link pins (1 -3) of the stub axle (4) and put this aside. Fit the proper setscrew wrench into kingpin (1) to stop its rotation, if required. NOTE To block rotation of the swivel head pins (1 - 5), insert a suitable Allen wrench into the hexagon sunk into them. NOTE 18 AXLE 5817 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Insert the pins of the swivel heads (1 - 2) of the top and bottom suspension arms into the seats of the stub axle (3). Then screw on the self-locking nuts (5) and lock them at the required torque. 61671 Figure 20 Refitting Figure 21 52259 Connect the pin of the swivel head (1) of the power steering tie to the lever (3) of the stub axle (6) and tighten the fixing nut (2) to the required torque. Mount the guard (4) on the stub axle and secure it, tightening the screws (5) to the required torque. Refit the wheel hub as described in the relevant chapter (operation 520620). Once removed, self-locking nuts (5) must not be reused. To block rotation of the swivel head pins (1 - 2), insert a suitable Allen wrench (4) into the hexagon sunk into them. NOTE Once removed, self-locking nuts (2) must not be reused. To block rotation of the swivel head pin (1), insert a suitable Allen wrench into the hexagon sunk into them. NOTE AXLE 5817 19 D AILY E URO 4 Print 603.93.651 Base - March 2006

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20 AXLE 5817 D AILY E URO 4 Base - March 2006 Print 603.93.651

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AXLE 5818 21 D AILY E URO 4 Print 603.93.651 Base - March 2006 Axle 5818 Page DESCRIPTION 23 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATION AND DATA 23 . . . . . . . . . . . . . . TIGHTENING TORQUES 24 . . . . . . . . . . . . . . . . . TOOLS 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING AXLE 5818 26 . . . . . . . . . . . . . . . -Replacing phonic wheel 27 . . . . . . . . . . . . . . . . . . -Refitting 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUB AXLE REMOVAL AND REFITTING 28 . . . .

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22 AXLE 5818 D AILY E URO 4 Base - March 2006 Print 603.93.651

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SPECIFICATION AND DATA Axle 5818 differs from axle 5817 for wheel hub, brake disc and wheel rim fixing to brake disc that is implemented by nut studs without stabiliser bar. Figure 1 108375 AXLE 5818 23 D AILY E URO 4 Print 603.93.651 Base - March 2006 DESCRIPTION Axle type 5818 WHEEL HUBS Wheel hubs bearings UNIT BEARING Hub bearings end play -Wheel hub bearings play adjustment Not Adjustable Fixing nut torque tightening WHEEL GEOMETRY Wheel camber angle (vehicle at static load) 0º ± 20’ Wheel caster angle (vehicle at static load) 3º ± 20’ Wheel toe-in (vehicle at static load) 2 ± 1 mm

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AXLE 5818 Figure 2 108352 24 AXLE 5818 D AILY E URO 4 Base - March 2006 Print 603.93.651 TIGHTENING TORQUES PART TORQUE PART Nm kgm Screw securing caliper mounting to stub axle 176 ÷ 217 18 ÷ 22 1 Nut securing the upper swinging arm jointed head to the stub axle 125 ÷ 140 12.5 ÷ 14 2 Nut securing the steering rod jointed head to the lever 68 ÷ 83 6.8 ÷ 8.3 3 Nut securing the lower swinging arm jointed head to the stub axle 160 ÷ 180 16 ÷ 18 4 Screw securing guard to stub axle 6 ÷ 7.5 0.6 ÷ 0.7 5 Nut securing wheel 180 ÷ 200 18 ÷ 20 7 Screw securing the brake disc and flange to the wheel hub. 98.1 ÷ 107.9 9.8 ÷ 10.7 8 Nut securing wheel hub 320 ÷ 420 32 ÷ 43

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AXLE 5818 25 D AILY E URO 4 Print 603.93.651 Base - March 2006 TOOLS TOOL NO. DESCRIPTION 99305354 Portable optical reading tool for checking wheel trim 99306010 Apparatus to purge air from brakes and clutch 99321024 Hydraulic trolley for removing/refitting wheels 99322215 Guide to wheel hub assembly 99347074 Puller for steering tie rod king-pins

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The overhauling operation different from the ones concerning the axle 5817 are described below. Free the screws (1) securing the wheel rim. Lift the vehicle and put the stands (3) under the structural members in a forward position. Unscrew the nuts (1), take off the protection (2) and remove the entire wheel. Remove the braking gaskets as described in the ”Brake” section, or remove the mounting with the brake caliper as described for axle 5817. 19603 Figure 3 Figure 4 Figure 5 Stop flange (2) rotation by means of a proper lever (3), then remove screws (4) and take flange (3) and brake disc (1) off the wheel hub. To remove and refit axle 5818, proceed in a similar manner as for axle 5817. Adjustment values, tightening torque values and equipment are those specified in this chapter. Check the conditions of the brake disc and the braking gaskets, as described in the ”BRAKING SYSTEM” section. NOTE If any trouble is found with the wheel hub or bearing, the assembly needs to be replaced since the parts are not supplied as single spares. When putting aside the wheel hub, take care not to damage the phonic wheel. NOTE 520620 Wheel hub removal and refitting Removal 109051 108367 Figure 6 109052 Lift the deformation ( ⇒ ) of the nut (1) and unscrew this with a suitable wrench. Extract the wheel hub (1) from the pin of the stub axle (2). 26 AXLE 5818 D AILY E URO 4 Base - March 2006 Print 603.93.651 520610 OVERHAULING AXLE 5818

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Phonic wheel (2) can be taken off wheel hub (1) by using generic tools. Pull-in load: 500 ÷ 900 kg. The phonic wheel should be mounted on thewheel hubafter heating it to a temperature of 150 ° C. On completing assembly, make sure the ”phonic” wheel sits in its seat in the hub properly and is positioned at the distance shown in the figure. Check the oscillation of the phonic wheel (2). Tolerance must be no greater than 0.1 mm. Figure 7 526712 Replacing phonic wheel 109053 Figure 8 Refitting 109052 Lubricate the surface of the stub axle pin (2) with TUTELA MR3 grease and key the wheel hub (1). The wheel hub must be keyed without forcing.. If there are difficulties, do not assemble since the bearing may be damaged. Extract the wheel hub, check the cause of the difficulties and eliminate them. NOTE After hub (1) is force-fitted, screw down nut (3). Tighten the nut (3) to the required torque with the Allen wrench (2). Nut (3) is equipped with a fixed washer (4). NOTE 109050 Figure 9 Figure 10 108368 Deform the collar of the nut (1) by the milling ( ⇒ ) of the pin (2). AXLE 5818 27 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Assemble: -the wheel on the brake drum; -the nut protection and screw the fixing nuts. Tighten the nuts fixing the wheel to the prescribed torque according to the diagram shown in figure. Fit brake disc (1) and flange (2) onto the wheel hub. Stop flange (2) rotation by means of a proper lever (3), then tighten fastening screws (4) to the specified torque. Using a magnetic dial gauge, check the eccentricity of the brake disc: it must not exceed 0.125 mm. Fit the support, together with the brake caliper and braking gaskets, into place back to the stub axle, by tightening the fastening screws to the specified torque. Figure 11 Figure 12 522820 STUB AXLE REMOVAL AND RE-FITTING Perform stub axle removal and refitting as described for axle 5817, without considering the points concerning the stabiliser bar since the latter is lacking on axle 5818. 109055 28 AXLE 5818 D AILY E URO 4 Base - March 2006 Print 603.93.651

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AXLE 5819 29 D AILY E URO 4 Print 603.93.651 Base - March 2006 Axle 5819 Page DESCRIPTION 31 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATION AND DATA 32 . . . . . . . . . . . . . . TIGHTENING TORQUES 33 . . . . . . . . . . . . . . . . . TOOLS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIR OPERATIONS 35 . . . . . . . . . . . . . . . . . . . . AXLE 5819 OVERHAUL 35 . . . . . . . . . . . . . . . . . . -Stub axle removal and refitting 35 . . . . . . . . . . . . -Removal 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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30 AXLE 5819 D AILY E URO 4 Base - March 2006 Print 603.93.651

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30772 The front axle 5819 has independent wheels. It is basically composed of: -stub axles; -wheel hubs; -suspension arms. The stub axles are also the end elements of the suspension. They are connected to the top and bottom suspension arms by swivel heads that allow turning the stub axle. The brake calipers and steering levers are secured on the king-pin of the stub axles. The hubs are supported on the stub axle pins by Unit-Bearings, which need no adjustment or lubrication. Figure 1 AXLE 5819 31 D AILY E URO 4 Print 603.93.651 Base - March 2006 DESCRIPTION

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32 AXLE 5819 D AILY E URO 4 Base - March 2006 Print 603.93.651 SPECIFICATION AND DATA Axle type 5819 WHEEL HUBS Wheel hubs bearings UNIT BEARING Hub bearings end play -Wheel hub bearings play adjustment Not Adjustable Fixing nut torque tightening WHEEL GEOMETRY Wheel camber angle (vehicle at static load) 0 o 30’ ± 20’ Wheel caster angle (vehicle at static load) 1 o 35’ ± 20’ Wheel toe-in (vehicle at static load) 2.5 ± 1

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AXLE 5819 Figure 2 108353 AXLE 5819 33 D AILY E URO 4 Print 603.93.651 Base - March 2006 TIGHTENING TORQUES PART TORQUE PART Nm kgm Screw securing caliper mounting to stub axle 176 ÷ 217 18 ÷ 22 1 Nut securing the upper swinging arm jointed head to the stub axle 157 ÷ 177 15.7 ÷ 17.7 2 Nut securing the steering rod jointed head to the lever 68 ÷ 83 6.8 ÷ 8.3 3 Nut securing the lower swinging arm jointed head to the stub axle 157 ÷ 177 15.7 ÷ 17.7 4 Nut securing wheel hub 320 ÷ 420 32 ÷ 42 5 Screw securing plate and brake disc to wheel hub 98 ÷ 108 9.8 ÷ 10.8 7 Nut securing wheel 180 ÷ 200 18 ÷ 20 Screw securing guards to stub axle 7 ÷ 10 0.7 ÷ 1

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34 AXLE 5819 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99305354 Portable optical reading tool for checking wheel trim 99306010 Apparatus to purge air from brakes and clutch 99321024 Hydraulic trolley for removing/refitting wheels 99322215 Driving and steering axle overhaul stand 99347074 Tool for extracting steering tie rod king-pins 99357144 Wrench for spindle pin ring nut

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Set upper and lower lever kingpins (6 and 8) into stub axle seat (4) then tighten self-locking nuts (1 and 5) to the prescribed torque. Refit steering lever (3) on stub axle by tightening the relevant fixing screw and nut (7) to the prescribed torque. Refit dust cover (2) to stub axle by means of the proper screws indicated with arrows. 19026 19027 19028 Figure 3 Removal REPAIR OPERATIONS The following paragraphs describe the overhaul operations that differ from axle 5818 operations. To remove and refit axle 5819, proceed in a similar manner as for axle 5823. Adjustment values, tightening torque values and equipment are those specified in this chapter. 520610 AXLE 5819 OVERHAUL 520611 Stub axle removal and refitting Remove wheel hub as described in the relevant chapter (operation 520620) concerning axle 5817. Remove from stub axle (5): -dust cover (2) by loosening screw (7); -steering lever (3) by loosening screw (8); Loosen kingpin (1 and 6) fixing nuts from stub axle (5). Refitting Use tool 99347074 (3) to remove kingpin (1) from stub axle (2) then remove the latter. Figure 4 Figure 5 Self-locking nuts (1 and 5) cannot be reused after removing. Refit wheel hub as described in the relevant chapter (operation 520620) concerning axle 5818. NOTE AXLE 5819 35 D AILY E URO 4 Print 603.93.651 Base - March 2006

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36 AXLE 5819 D AILY E URO 4 Base - March 2006 Print 603.93.651

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AXLE 5823 37 D AILY E URO 4 Print 603.93.651 Base - March 2006 5206 Axle 5823 Page DESCRIPTION 39 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATION AND DATA 40 . . . . . . . . . . . . . . TIGHTENING TORQUES 41 . . . . . . . . . . . . . . . . . TOOLS 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING AND REFITTING AXLE 5823 43 . . . . -Removal 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE 5823 OVERHAUL 45 . . . . . . . . . . . . . . . . . . -Wheel hub removal and refitting 45 . . . . . . . . . . -Removal 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Replacing phonic wheel 46 . . . . . . . . . . . . . . . . . . -Re-fitting 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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38 AXLE 5823 D AILY E URO 4 Base - March 2006 Print 603.93.651

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62909 The front axle 5823 has independent wheels. It is basically composed of: -stub axles; -wheel hubs; -suspension arms. The stub axles are also the end elements of the suspension. They are connected to the top and bottom suspension arms by swivel heads that allow turning the stub axle. The brake calipers and steering levers are secured on the king-pin of the stub axles. The hubs are supported on the stub axle pins by Unit-Bearings, which need no adjustment or lubrication. Figure 1 AXLE 5823 39 D AILY E URO 4 Print 603.93.651 Base - March 2006 DESCRIPTION

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40 AXLE 5823 D AILY E URO 4 Base - March 2006 Print 603.93.651 SPECIFICATION AND DATA Axle type 5823 WHEEL HUBS Wheel hubs bearings UNIT BEARING Hub bearings end play 0.11 ÷ 0.14 Wheel hub bearings play adjustment Not Adjustable Fixing nut torque tightening WHEEL GEOMETRY Wheel camber angle (vehicle at static load) 1 o ± 20’ Wheel caster angle (vehicle at static load) 2 o 30’ ± 20’ Wheel toe-in (vehicle at static load) 2.5 ± 1 mm

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AXLE 5823 Figure 2 108354 AXLE 5823 41 D AILY E URO 4 Print 603.93.651 Base - March 2006 TIGHTENING TORQUES COMPONENT TORQUE COMPONENT Nm kgm 1 Nut securing the upper swinging arm jointed head to the stub axle 125 ÷ 140 12.5 ÷ 14 2 Nut securing the steering rod jointed head to the lever 68 ÷ 83 6.8 ÷ 8.3 3 Nut securing the lower swinging arm jointed head to the stub axle 160 ÷ 180 16 ÷ 18 5 Nut securing wheel hub - torque 50 ÷ 60 5 ÷ 6 - angle 30.1 ˚ ÷ 34.1 ˚ 6 Screw securing the brake disc and flange to the wheel hub. - torque 43 ÷ 53 4.3 ÷ 5.3 - angle 28.4 ˚ ÷ 30.4 ˚ 4 Nut securing wheel 284.5 ÷ 343.3 28.4 ÷ 34.3 Screw securing caliper to stub axle 7 ÷ 10 0.7 ÷ 1 Screw securing caliper mounting to stub axle 110 ÷ 140 11.2 ÷ 14.3

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42 AXLE 5823 D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL No. DESCRIPTION 99305354 Portable optical reading tool for checking wheel trim 99321024 Hydraulic truck for removing - refitting operations 99322215 Stand to overhaul axles 99347074 Tool to remove drag link joints and wishbones

Page 667

Figure 3 REMOVING AND REFITTING AXLE 5823 Removal Set the vehicle on solid, level ground. Lock the rear wheels with scotches, remove the wheel rim guards and loosen the screws or nuts fixing the wheel. Lift the front of the vehicle and rest the chassis frame on supports. Take out the screws or nuts fixing the wheel and remove them with tool 99321024. Remove the front right and left mudguard (1). Remove the right and left mudguards under the bumpers (17). To help remove the front suspension mounting (2), free thetop screw stay (14) in correspondence with the screw (15) fixing to the suspension arm (13). Remove the front suspension mounting (2) by taking out the chassis frame fasteners (16). Fit the top screw stay (14) back onto the suspension arm (13). The same steps must be performed on both left and right. Adjust the load on the right and left torsion bars (9). Undo the nut (11) and unscrew the threaded pin (12) until the torsion bar (9) is entirely ”discharged”. Remove the fasteners (10) fixing the mounting (8) to the chassis frame. Extract the mounting (8) from the torsion bar (9). If it is decided to leave the brake callipers on the axle, proceed to: -disconnect the electrical connection (3) signalling brake lining wear and the ABS sensor (5) if there is one; -disconnect the brake fluid pipes in correspondence with the fittings (7) after draining the system; -if it is decided to leave the brake callipers on the vehicle, proceed to: -disconnect the brake callipers (4) from their respective stub axles by taking out the screws (6) and supporting the callipers to prevent any strain on the pipes. 75581 AXLE 5823 43 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Figure 4 From underneath the vehicle: -remove the central guard (7) under the engine by taking out the screws securing it to the side guards (8) and to the front cross member of the chassis frame; -remove the right and left side guards (8) of the engine by taking out the screws securing them to the chassis frame; -remove the right and left side guards (9) of the gearbox by taking out the screws securing them to the axle (11) and to the cross member (12) under the gearbox; -disconnect the brake fluid pipe (10) from the retaining blocks on the axle; -drain off the power-steering fluid and disconnect the pipes (4) and (5); -disconnect the power steering column (3) in correspondence with the coupling (6); -place the removal bracket on the hydraulic jack and put it all under the axle; -undo the chassis frame bottom fixing screws (2) and the top fixing nuts (1); -lower the hydraulic jack and extract the axle (11). Refitting Reverse the steps described for removal tightening the screws or nuts to the prescribed torque. Adjust the load of the torsion bar as illustrated under the specific heading. Top up the power-steering fluid. If the brake callipers have been left on the axle, restore the brake fluid level and bleed off any air. Check and adjust the front wheel geometry. 75582 44 AXLE 5823 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Loosen wheel rim fastening nuts (1). Lift the vehicle and set the supporting stands under the side members in forward position. Loosen nuts (1), remove protection (2) and remove the entire wheel. 62911 Figure 5 Figure 6 Figure 7 Figure 8 Remove screws (3), then take the support, together with brake caliper (1), off stub axle (2). Suitably support the brake calliper (1) to prevent oil pipe tensioning. Overhaul operations described in this sections are those differing from axle 5819. 520620 Wheel hub removal and refitting Removal Check brake disc and lining conditions as described in the BRAKE SYSTEM section. NOTE 109056 Remove safety springs (2) from pins (3). Take pins (3) out of brake caliper (6), then recover braking gasket (1) retaining clips (4). Disconnect gasket wear indicator electric connection (5). Take braking gaskets (1) out of brake caliper (6). 109057 109051 Stop flange (2) rotation by means of a proper lever (3), then remove screws (4) and take flange (3) and brake disc (1) off the wheel hub. NOTE AXLE 5823 45 D AILY E URO 4 Print 603.93.651 Base - March 2006 520610 AXLE 5823 OVERHAUL

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The possible extraction of the phonic wheel (2) can be taken off wheel hub (1) by using generic tools. Pull-in load: 500 ÷ 900 kg. When the assembly is ended, make sure that the “phonic” wheel perfectly rests on the hub housing and that is positioned at the dimension shown in figure. Check that the orthogonality and oscillation of the phonic (2) wheel is no greater than 0.1 mm. Figure 9 Figure 10 Use a box wrench (2) to remove nut (5) securing wheel hub (3) to stub axle (1) pin. Take wheel hub (3) and washer (4) out of stub axle (1) pin. 526712 Replacing phonic wheel Figure 11 Figure 12 Refitting Lubricate the surface of the stub axle pin (2) with TUTELA MR3 grease and key the wheel hub (1). If any trouble is found with the wheel hub or bearing, the assembly needs to be replaced since the parts are not supplied as single spares. When repairing the wheel hub, take care not to damage the phonic wheel. NOTE The wheel hub must be keyed without forcing.. If there are difficulties, do not assemble since the bearing may be damaged. Extract the wheel hub, check the cause of the difficulties and eliminate them. NOTE 109059 109052 109058 108367 Lift nut (1) countersink ( ⇒ ). Nut (6) is equipped with a fixed washer (5). NOTE Nut (6) is equipped with a fixed washer (5). NOTE See Figure 10. Fit washer (4) into place, then screw down nut (6). 46 AXLE 5823 D AILY E URO 4 Base - March 2006 Print 603.93.651

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Place brake caliper (1) onto stub axle (2). Screw down screws (3) and tighten them to the specified torque. Figure 13 Figure 14 Figure 15 Figure 16 Fit brake disc (1) and flange (2) onto the wheel hub. Screw down screws (4). Stop flange (2) rotation. Tighten screws (4) in two separate phases: phase 1: torque tightening to 43 ÷ 53 Nm (4.3 ÷ 5.3 kgm) phase 1: angle tightening (28.4 ˚ ÷ 30.4 ˚ ). Fit braking gaskets (1) into place. Position springs (4), then fit pins (3) into brake caliper (6). Fit safety springs (2) into pins (3). Connect braking gaskets wear indicator electric connection (5). Fit the wheel onto the flange, then position the nut protection. Tighten the wheel fastening nuts to the specified torque, in accordance with the diagram illustrated in the figure. Figure 17 109060 α 109055 α 109057 109056 89007 Use a torque wrench and a box wrench (3) to tighten nut (1) in two separate phases: phase 1: torque tightening to 50 ÷ 60 Nm (5 ÷ 6 kgm) phase 2: angle tightening (30.1 ˚ ÷ 34.1 ˚ ). Countersink nut (1) collar at pin (2) milled portion ( ⇒ ). AXLE 5823 47 D AILY E URO 4 Print 603.93.651 Base - March 2006

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48 AXLE 5823 D AILY E URO 4 Base - March 2006 Print 603.93.651

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WHEEL GEOMETRY 49 D AILY E URO 4 Print 603.93.651 Base - March 2006 Wheel geometry Page DESCRIPTION 51 . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL GEOMETRY 53 . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA 53 . . . . . . . . . . . . . TIGHTENING TORQUES 53 . . . . . . . . . . . . . . . . . TOOLS 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING CHARACTERISTIC ANGLES 55 . . . . . -Positioning jaws and projectors 55 . . . . . . . . . . . . -Electronic balancing of rim eccentricity 56 . . . . . . -Wheel alignment 56 . . . . . . . . . . . . . . . . . . . . . . . -Checking toe-in 57 . . . . . . . . . . . . . . . . . . . . . . . . -Front wheel deviation test (vehicle wheelbase check) 57 . . . . . . . . . . . . . . . . -Checking camber 58 . . . . . . . . . . . . . . . . . . . . . . . -Checking king-pin angle and caster angle 58 . . . . . -Checking steering angles 59 . . . . . . . . . . . . . . . . . -Checking rear axle alignment 59 . . . . . . . . . . . . . . -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) 60 . . . . . .

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50 WHEEL GEOMETRY D AILY E URO 4 Base - March 2006 Print 603.93.651

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The king-pin camber angle ( β ) is the angle formed by the axis passing through the king-pin and the vertical to the ground, looking at the vehicle from the front. When the projection of the king-pin axis is near to the contact point of the wheel with the ground (opposite tendency to the wheel camber) the angle is positive, it is difficult to say that it is impossible to have the king-pin camber angle negative. The wheel camber angle ( α ) and the king-pin camber angle ( β ) enable wheel axis and the king-pin axis to come nearer as much as possible to the contact centre of the tyre on the ground. In this way, reduced tyre wear and lower steering torque are obtained. In order to have a good vehicle ground holding, a low consumption of tyre and to enable the driving wheels to return to straight running after steering, the front wheels are adjusted at defined assembly angles: -wheel camber angle; -king-pin camber angle; -caster angle; -wheel toe-in. Theseangles,accurately calculated,enablethe correctbalancing of the forces created when the vehicle is moving, in the different load conditions, tending to change the position of the wheels on the ground. Figure 1 Caster angle Wheel camber angle The camber angle ( α ) is the angle formed by the axis passing through the wheel centre line and the vertical to the ground, looking at the vehicle from the front. The camber angle is positive (A) when the upper part of the wheel tends toward the outside; it is negative (B) when the wheel upper part tend toward the inside. 32956 32957 32958 Figure 2 Figure 3 A B a a ß The caster angle ( γ ) is the angle formed by the king-pin axis with the vertical to the ground, looking at the vehicle from one side. If the projection formed by the king-pin axis falls in front of the wheel contact point with the ground, in the direction of travel of the vehicle, the caster angle is by convention positive (A); it is negative (B) if it falls behind the wheel contact point with the ground; it is equal to zero if it is perfectly vertical to the contact point. A B + _ γ γ Camber angle WHEEL GEOMETRY 51 D AILY E URO 4 Print 603.93.651 Base - March 2006 Print 603.93.281 DESCRIPTION

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This angle makes it possible to keep the front wheels straight when the vehicle is running straight and allows the wheels to return spontaneously to running straight from the position taken in the bend, as soon as the steering wheel is released by the driver. 32359 32960 32961 Figure 4 Figure 5 Figure 6 The toe-in is negative if B is lower than A. The toe-in is equal to zero if B is equal to A. A B A B A B The wheel toe-in results from the difference between the distances A and B (value expressed in mm) measured on the horizontal axis of the rims, looking at the vehicle from the top. In this way a light drive and a low tyre consumption is obtained. The toe-in is positive if B is higher than A. Wheel toe-in 52 WHEEL GEOMETRY D AILY E URO 4 Base - March 2006 Print 603.93.651

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WHEEL GEOMETRY 53 D AILY E URO 4 Print 603.93.651 Base - March 2006 WHEEL GEOMETRY SPECIFICATIONS AND DATA MODELS 29L - 35S 35 (1) 35 (2) .40 - 45. - 50. 60C - 65C WHEEL GEOMETRY ----Wheel camber angle (vehicle at static load) ( ± 20’) 0 o ± 20’ 0º 30’ ± 20’ 1º ± 20’ Wheel caster angle (vehicle at static load) 3 o ± 20’ 1º 35’ ± 20’ 2º 30’ ± 20’ Wheel toe-in (vehicle at static load) mm 2 ± 1 2.5 ± 1 b Steering angle: a b Internal a 47 o 30’ ± 30’ 43º 37º 7’ External b 39 o ± 30’ 36º 30’ 45º 6’ a Stub axle king-pin camber α 13.38 ° 7 ° (1) Front suspension with transverse leaf spring (2) Front suspension with torsion bar TIGHTENING TORQUES PART TORQUE PART Nm kgm Nut fixing king-pin to the side tie rod of the steering box 15 ÷ 20 1.5 ÷ 2

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54 WHEEL GEOMETRY D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99305354 Tool for checking wheel geometry 99347074 Puller for king-pins

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Revi - February 2005 -Ensure the presence of spacers (1) between side members (2) and tie rod (4) attachment mountings (3) (with the exception of vehicles equipped with 5 mm thick side members). If not, proceed as described on page 60. Perform the geometry check using the tool 99305354. Before proceeding with the checks, it is necessary to perform a preliminary inspection at some of the vehicle members, which can affect the geometry: if malfunctions are found, it is necessary to eliminate them in order to avoid wrong detection. The check to be performed are the following: -tyre pressure; -wheel hub bearing play -play between steering tie rod pins and stub axle levers; -shock absorber efficiency; -unallowed deformation of the wheel rims. 33137 23311 Figure 7 Figure 8 Place the vehicle with the wheel in straight running position on a level surface. Lift the rear of the vehicle and position the board (3). Lower the vehicle, brake the rear wheels and apply the hook (1) with the slide rule (2). Lift the vehicle front part and position the floating wheels (1) locking them with the locks (2). 25114 32818 Figure 9 Figure 10 Position the clutch jaw (1) fitted with fixing pins (2). Operating the handgrip (3), lock the jaw on the wheel, making sure that it is perfectly secured. Figure 11 33137 Positioning jaws and projectors Assemble the detecting unit (1) on the jaws (3) and constrain it with the screw (2). Repeat the operation on the other wheel. 1 2 3 1 2 3 The checks and possible operations on the wheel geometry must be carried out with the vehicle at static load. Make sure, periodically, that the optical unit are perfectly calibrated. NOTE ! For modification of the characteristic angles of the wheels, in vehicles with ESP, follow the calibrating procedure of the steering angle sensor assembled in the flywheel as described on page 63 of the Brake Section. WHEEL GEOMETRY 55 D AILY E URO 4 Print 603.93.651 Base - March 2006 Print 603.93.281/A CHECKING CHARACTERISTIC ANGLES

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Using the level (4) arrange horizontally the detectors (3) and fix them to their position with the screw (2). Move the slide rules (1) until they arecentred by the lightsignal transmitted by the detector (3) and note down the values. Press the push-button ”out of centre” (1) for at least two seconds, the display (3) shows nine lines. Manually rotate the wheel slowly in the running direction and project the light signal on the slide rule scale (5). Stop the wheel when the signal read on the slide rule (5) has reached the maximum value and note down the value (e.g. 12). Rotate the wheel again until the minimum value is reached and note it down (e.g. 8). Calculate the mean value of the amplitude: 12 + 8 = 20 : 2 = 10 and position the wheel on the mean value calculated marking its position. Press the push-button ”out of centre ” again (1) until the LED (4) of the wheel camber is lighted and on the display (3) a fictitious value is shown. Repeat the operations on the other wheel. Lower the vehicle sothat thewheels, in the position previously marked, completely rest at the centre of the floating discs (9). Loosen the floating discs (9) from their bases extracting the pins (10). Figure 12 Figure 13 Figure 14 Press the brake pedal locking it with the suitable tool (1) positioned against the seat. Wheel alignment Electronic balancing of rim eccentricity Connect the detectors plugs (7) to the transformer (6) and switch on the switch (8); loosen the locking screw (2) of the detector and lift the detector lens guard (7). 32819 25120 52269 Make sure that the laser beam does not hit the eyes of people, it will severely damage their sight. The wheels must be braked during the whole measuring cycle. NOTE 56 WHEEL GEOMETRY D AILY E URO 4 Base - March 2006 Print 603.93.651 Print 603.93.281

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The positive or negative toe-in adjustment is carried out as follows: Loosen the nuts (3) on the joint heads (2, right and left). Turn tie rods (1) up to obtain the toe-in of each wheel equal to half of the prescribed value. Then tighten the nuts (3) to the prescribed torque. Front wheel deviation test (vehicle wheelbase check) The front wheel deviation test and toe-in reading are carried out at the same time. The partial toe-in values, to be detected on the proper straightedges divided into millimetres, must have the same value and their sum must correspond to the whole toe-in value. If between the readings there is a difference (e.g.: -2 and + 3), it means that there is a deviation between the two wheels: a wheel onward as to the other wheel, equal to 5 lines of the toe-in scale. The number of lines is calculated by the algebraic sum [+3-2(-1)=5] or counting the lines included between the two values. If the values are different, steer the wheels until the light signal indexes are set to two values equal (A) and exactly the mean value of the two previous readings. In this way a perfect wheel alignment is obtained. 13952 25122 52270 32295 Figure 15 Figure 16 Figure 17 Figure 18 Keeping the detectors in horizontal position and the wheels perfectly aligned, move the lens guard (2) using the lever (1) Operate the lever (3) and direct the light signal index on the slide rule scale (4) corresponding to the rim diameter. Repeat the same operations on the opposite detector and read the toe-in value on the scales (in millimetres): the result of the algebraic sum of the two values must be the prescribed value. Checking toe-in WHEEL GEOMETRY 57 D AILY E URO 4 Print 603.93.651 Base - March 2006

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For vehicles with transverse leaf spring suspension: The deviation error may be due to deformation of the frame or of the assemblies connected to the wheels. Each line corresponds to a deviation of 2 mm, so the deviation between the two wheels is equal to 10 mm (5 x2). For vehicles with torsion bar suspension: After determining which is the defective wheel, check its conditions and the exact assembly dimension of the upper and lower tie rods of the wheel suspension. If the tie rods have been subject to deformations, replace them; if the assembly dimension is wrong, screw or unscrew the tie rod on the king-pin so that the vehicle wheel base is adjusted and the wheel are on the same axis. Steer the wheels 20 ° toward the outside, press the king-pin camber push-button (2) and the display (1) shows the king-pin camber angle. Steer the wheel 20 ° toward the inside; press twice the king-pin camber push-button (2), the LED lights up and the display (1) shows 9 horizontal lines. When the front wheels are aligned to the rear ones, loosen the knurled knobs (3) and zero the graduated sector (2) on the index (1) of the floating disc. When the front wheels are aligned to the rear ones and the detectors are on an horizontal plane, press the key wheel camber (2) the LED lights up and the display (1) shows the camber angle value. 32821 32823 32824 32825 Figure 19 Figure 20 Figure 21 Figure 22 Checking camber Checking king-pin angle and caster angle In order not to change wheel caster angle, a lengthening or shortening of the lower tie rod must correspond to a lengthening or shortening of the upper tie rod. NOTE 58 WHEEL GEOMETRY D AILY E URO 4 Base - March 2006 Print 603.93.651

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-under the above conditions, check on the other wheel that the steering angle value is as expected; -reverse steering and check again. If different values are found, possible causes can be: -wrong centering of the steering box; -deformations caused by impacts; -deviation error between axles (front and rear axles) higher than 20 mm. -Steer the wheels until the floating disc index of the wheel inside the bend in correspondence with the prescribed steering angle. For regulating the caster angle proceed as follows: -set wheels in a straight running condition; -press the kingping angle button until its relevant LED starts blinking; -screw and unscrew, as required, lower tie rod joint head, considering that the joint head can’t carry out more than one turn. Without moving the wheel, press the caster angle push-button (2), the LED lights up and the display (1) shows the caster angle value. Repeat these operations on the other wheel. This check is carried out during the king-pin camber check of during the caster angle check, making the following operations: -if the prescribed steering angles exceed 30 ° , the mark 20 ° (1) on the floating disc (2) and the mark 30 ° (3) on the graduated selector (4) mast be considered as initial reference values. 32826 33134 Figure 23 Figure 24 Checking steering angles Apply the slide rule (1) to the front wheels checking that the cursor (2) is exactly in the middle of the two ring splines of the shaft (3) Apply the detectors to the rear wheels and proceed as already described for the front axle wheels. 44933 Figure 25 Checking rear axle alignment The king-pin camber angle and the wheel caster angle are stored, after detection, by the instrument and can be recalled when necessary pressing the push-button relevant to the concerned angle. NOTE For steering angles higher than 30 ° , it is necessary to consider as reference index the mark 20 ° (1). NOTE WHEEL GEOMETRY 59 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Proceed as follows. Measure external chassis width A 1 at the axle. If chassis width is not 864 mm (reference value A ), subtract your reading (for example, A 1 = 859 mm) from the reference value: 864 - 859 = 5 mm. Divide this figure by 2 (5 : 2 = 2.5 mm). 2.5 mm is therefore the thickness of thecompensating spacers that should be fitted to each side member. Spacers are supplied as spare parts in the following thicknesses: 1 - 1.5 - 2 mm. 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) Project the light signal on the slide rule (1) and mark the value shown. Repeat the measure on the other wheel and check that the value is equal to the noted down value, otherwise carefully check the vehicle rear axle assembly If no malfunctions are detected, check that the frame is not deformed, sticking to the procedures described in the section ”Body and frame”. 44934 46951 Figure 26 Figure 27 Introduction The external width of the chassis with reference to tie rod mountings attachment point can vary from vehicle to vehicle depending on chassis assembling tolerances and side member thickness. Therefore, width A (864 mm) is considered as an acceptable reference value on which to base correct wheel geometry. The above value results from the sum of chassis internal width B (854 ± 2 mm) plus thickness D 1 - D 2 of a 4 mm thick chassis. Proceed as follows to install compensating spacers (1). Dismantle: -Rh and lh front engine guard (5 and 6). -Engine oil sump guard (3). -Rh and lh wheel guard (4 and 7). -Rh and lh side engine guard (2 and 8). Position spacers (1) of the thickness calculated before, fit mounting (10), screw in screws (11) and lock them to a torque of 14.25 kgm (142.5 Nm). Reassemble all previously dismantled guards. When assembly is completed, check and adjust wheel geometry as required following directions provided in the relevant chapters. 46952 Figure 28 60 WHEEL GEOMETRY D AILY E URO 4 Base - March 2006 Print 603.93.651

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SUSPENSIONS 1 D AILY E URO 4 Print 603.93.651 Base - March 2006 SUSPENSIONS SECTION 8 Suspensions Page FRONT AND REAR MECHANICAL SUSPENSIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . REAR AIR SUSPENSIONS 81 . . . . . . . . . . . . . . . . .

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2 SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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FRONT AND REAR MECHANICAL SUSPENSIONS 3 D AILY E URO 4 Print 603.93.651 Base - March 2006 FRONT AND REAR MECHANICAL SUSPENSIONS Front and rear mechanical suspensions Page DIAGNOSTICS 5 . . . . . . . . . . . . . . . . . . . . . . . . . FRONT MECHANICAL SUSPENSIONS 9 . . . . . . REAR MECHANICAL SUSPENSIONS 51 . . . . . . . .

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4 FRONT AND REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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1 Main possible suspension defects 1 -noisy suspension; 2 -the vehicle tends to drift to one side; 3 -excessive suspension flexibility; 4 -excessive suspension stiffness. Insufficient lubrication. Lubricate carefully. Wishbone spring bushes worn. Detach wishbones and replace bushes. Tie-rod articulated heads worn (vehicles with torsion bar suspension). Replace tie-rod articulated heads. Shock absorbers noisy or inefficient. Check and if necessary replace shock absorbers. Wheel bearings worn and with excessive backlash. Replace bearings or adjust backlash. Wishbone articulated heads worn. Replace wishbone articulated heads. NO YES NO YES NO YES NO YES NO YES YES (Continues) NOISY SUSPENSION FRONT AND REAR MECHANICAL SUSPENSIONS 5 D AILY E URO 4 Print 603.93.651 Base - March 2006 DIAGNOSTICS FRONT AND REAR MECHANICAL SUSPENSIONS

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6 FRONT AND REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Steering knuckle nuts or fastening ring nuts loose (vehicles with torsion bar suspension). Check and tighten nuts and fastening ring nuts to driving torque. NO YES Stabilizer bar spring bushes worn. Replace spring bushes. NO YES Stabilizer bar fastening screw nuts loose. Check and tighten to torque. NO YES Suspension fastening nuts and screws loose. Check and tighten suspension fastening nuts andscrews to torque. NO YES Torsion bar toothing worn. Detach torsion bars and replace them and adjust pre-loading. NO YES Toothing of torsion bar rear supports or of wishbones worn. Replace rear support or upper wishbones and adjust torsion bar pre-loadings. NO YES Leaf spring supports loose. Check the supports and replace chassis fastening screws or rivets if they are loose. Leaf spring pack loose for central fastening pin failure. Overhaul leaf springs and replace central pin and its self-locking nut. NO YES YES (Continues)

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FRONT AND REAR MECHANICAL SUSPENSIONS 7 D AILY E URO 4 Print 603.93.651 Base - March 2006 Leaf spring pack loose for spring fixing brackets fastening rivets failure. Check leaf spring fixing brackets and replace fastening rivets. YES 2 THE VEHICLE TENDS TO DRIFT TO ONE SIDE Tyre pressure low or incorrect. Check and accurately inflate tyres to the prescribed pressure. Replace the wheel hubs. Incorrect front wheel geometry. Too much front wheel bearing play. Check and correct wheel geometry. NO YES NO YES NO YES Inefficient hydraulic shock absorbers. Torsion bar broken. Remove shock absorbers and replace them. Replace torsion bar and adjust pre-loading. NO YES NO YES Incorrect torsion bar pre-loading adjustment. Check and adjust torsion pre-loading. YES Leaf spring broken. Overhaul the leaf spring and replace if necessary. NO YES (Continues)

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8 FRONT AND REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Incorrect vehicle loading. Check the load and arrange it evenly over the loading area. YES 3 Leaf spring central pin broken. Replace the component. YES Torsion bars yielded. Replace torsion bars and adjust pre-loading. NO YES Incorrect torsion bar pre-loading adjustment. Check and adjust torsion bar pre-loading. NO YES Shock absorbers inefficient. Check and replace the shock absorbers if necessary. NO YES Overhaul the spring and replace the unusable components or, if necessary, the entire spring. NO YES 4 EXCESSIVE SUSPENSION STIFFNESS Incorrect torsion bar pre-loading adjustment. Check and adjust torsion bar pre-loading. YES EXCESSIVE SUSPENSION FLEXIBILITY Leaf spring leaves yielded or broken.

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FRONT MECHANICAL SUSPENSIONS 9 D AILY E URO 4 Print 603.93.651 Base - March 2006 PRINT 603.43.351/D Front mechanical suspensions Page DESCRIPTION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . ARTICULATED QUADRILATERAL SUSPENSION WITH TRANSVERSE LEAF SPRING 11 . . . . . . . SPECIFICATIONS AND DATA 12 . . . . . . . . . . . . . -Front leaf spring 12 . . . . . . . . . . . . . . . . . . . . . . . . -Front shock absorbers 14 . . . . . . . . . . . . . . . . . . . -Front stabilizer bar 14 . . . . . . . . . . . . . . . . . . . . . . TOOLS 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 15 . . . . . . . . . . . . . . . . . -Vehicles 29 L - 35 S 15 . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 16 . . . . . . . . . . . . . . . . . -Vehicles 35 C 16 . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 17 . . . . . . . . . . . . . . . . . -Vehicles 29 L - 35 S - 35C 17 . . . . . . . . . . . . . . . . REPAIRS 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Check the clearance of upper swinging arm articulated head 18 . . . . . . . . . . . . . . . . . . . . . . . . -Check the clearance of lower swinging arm articulated head 19 . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING THE SUSPENSION 19 . . . . . . . . . -Suspension arms 19 . . . . . . . . . . . . . . . . . . . . . . . -Removal 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Replacing suspension arm bushings 19 . . . . . . . . . -Disassembly 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Assembly 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SHOCK ABSORBERS 21 . . . . . . . . . . . . . . -Removal 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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10 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Print 603.43.351 Page LEAF SPRING 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORSION BAR SUSPENSION Axle 5819 - vehicles 35C - 40C - 45C - 50C 25 . -Description 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA 26 . . . . . . . . . . . . . -Front shock absorbers 26 . . . . . . . . . . . . . . . . . . . -Stabilizer bar diameter 26 . . . . . . . . . . . . . . . . . . . TOOLS 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 29 . . . . . . . . . . . . . . . . . -Vehicles 35 C - 40 C - 45 C - 50 C 29 . . . . . . . . REPAIRS 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Check the clearance of upper swinging arm articulated head 31 . . . . . . . . . . . . . . . . . . . . . . . . -Check the clearance of lower swinging arm articulated head 32 . . . . . . . . . . . . . . . . . . . . . . . . OVERHAULING THE SUSPENSION 33 . . . . . . . . . TIE RODS 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Replacing swivel heads 33 . . . . . . . . . . . . . . . . . . . -Refitting 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORSION BARS 34 . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Replacing silentbloc and limit stops 35 . . . . . . . . . -Replacing link pins 35 . . . . . . . . . . . . . . . . . . . . . . -Refitting 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Adjusting torsion bar pre-load 38 . . . . . . . . . . . . . STABILIZER BAR 39 . . . . . . . . . . . . . . . . . . . . . . . . . Page -Removal 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SHOCK ABSORBERS 39 . . . . . . . . . . . . . . -Removal 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORSION BAR SUSPENSION Axle 5823 - vehicles 60C - 65C 41 . . . . . . . . . . . -Description 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA 42 . . . . . . . . . . . . . -Front shock absorbers 42 . . . . . . . . . . . . . . . . . . . -Stabilizer bar 42 . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 43 . . . . . . . . . . . . . . . . . EQUIPMENT 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIR OPERATIONS 46 . . . . . . . . . . . . . . . . . . . . SUSPENSION OVERHAUL 46 . . . . . . . . . . . . . . . . -Lower tie rod articulated heads replacement 46 . TORSION BARS 46 . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Rubber bush replacement 47 . . . . . . . . . . . . . . . . -Removal 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Torsion bar preload adjustment 50 . . . . . . . . . . . .

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The front suspension has independent wheels of the type: -with an articulated quadrilateral with a transverse leaf spring for axles 5817 and 5818; -with longitudinal torsion bars for axle 5819 and 5823. 62102 Figure 1 ARTICULATED QUADRILATERAL SUSPENSION WITH TRANSVERSE LEAF SPRING (vehicles 29l - 35s - 35c) The suspension comprises: -two top triangular suspension arms, composed of a sheet-metal shell, connected by elastic bushings to the crosspiece by pins articulated to the stub axle; -two bottom triangular suspension arms, composed of two sheet-metal half-shells welded together, connected by elastic bushings with metal reinforcement to the crosspiece and pins articulated to the stub axle. The bottom suspension arms have reaction points for the leaf spring and the bottom mountings of the shock absorbers; -a single-blade leaf spring, made of composite material for axles 5817 mounted on vehicles 29 L and 35 S, steel for axles 5818 mounted on vehicles 35 C; the spring is kept inside the crosspiece by two top reaction plugs fitted on the ends of the spring housed in the seats in the bottom suspension arms. The steel leaf spring, due to the resistance it provides for the rolling movements of the vehicle, makes mounting the front stabilizer bar superfluous; -two double-acting hydraulic shock absorbers with integrated limit stops. DESCRIPTION FRONT MECHANICAL SUSPENSIONS 11 D AILY E URO 4 Print 603.93.651 Base - March 2006 MECHANICAL FRONT SUSPENSIONS

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52322 Figure 2 COMPOSITE LEAF SPRING SECT. A-A 12 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 SPECIFICATIONS AND DATA Front leaf spring Models: 29 L - 35 S Transverse Nº 1 Transverse Nº 1 Spring length (mm) 1313.2 Sheet thickness measured at (mm) A 39.92 ± 0.50 Sheet width measured at (mm) B 56.0 ± 0.5 C 81.0 ± 0.5 NEW LEAF SPRING CHECK DATA 29 L 35 S STATIC LOAD (N) 19865 21040 SAG WITH STATIC LOAD (mm) 71.7 68.4 DYNAMIC LOAD (N) 34270 37005 SAG WITH DYNAMIC LOAD (mm) 123.7 120.4 FLEXIBILITY ± 5%1 (mm/kN) 277 307.0 DISTANCE BETWEEN SUPPORT PLUGS (mm) 540 600

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50824 Figure 3 STEEL LEAF SPRING FRONT MECHANICAL SUSPENSIONS 13 D AILY E URO 4 Print 603.93.651 Base - March 2006 Front leaf spring Models: 35 C Transverse Nº 1 Spring length (mm) 1365 ± 3 Sheet thickness (mm) 20 ± 0.2 Sheet width (mm) 80 ± 0.5 NEW LEAF SPRING CHECK DATA POSITION LOAD CAMBER FLEXIBILITY POSITION daN kg CAMBER (mm) mm/100 daN mm/100 kg STATIC LOAD 845.1 861.5 70.25 8 31 8 15 DYNAMIC LOAD 1453.3 1481.4 120.8 8.31 8.15

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14 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Front shock absorbers Models: 29 L - 35 S - 35 C Mannesmann - Sachs Arvin Meritor Distance between centre of eyes: Open (mm) 405  3 Closed (mm) 320  3 Stroke (mm) 85 Front stabilizer bar Models: 35C - 40C - 45C - 60C* - 65C* 60C - 65C dual cab Stabilizer bar diameter 24 22 * except for dual cab TOOLS TOOL NO. DESCRIPTION Hydraulic trolley for wheel removal and refitting 99321024 99347074 Extractor to take out link pins 99374179 Tool for disassembling and reassembling suspension arm flexible bushings The torsion bar is not provided for the COMBI version. NOTE

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85873 Figure 4 FRONT MECHANICAL SUSPENSIONS 15 D AILY E URO 4 Print 603.93.651 Base - March 2006 TIGHTENING TORQUES Vehicles 29 L - 35 S COMPONENT TORQUE COMPONENT Nm kgm 1 Screw for nut securing steering gear housing 50 ÷ 61 5 ÷ 6.1 2 M12 screw for nut securing leaf spring mounting to the cross member 100 ÷ 124 10 ÷ 12.4 3 M10 screw for nut securing leaf spring mounting to the cross member 39 ÷ 48 3.9 ÷ 4.8 4 Nut for screw securing shock absorber top and bottom 124 ÷ 152 12.4 ÷ 15.2 5 Screw for nut securing shock absorber mounting to bottom suspension arm 39 ÷ 48 3.9 ÷ 4.8 6 Nut securing bottom suspension arm ball joint to the stub axle 160 ÷ 180 16 ÷ 18 7 Nut securing steering gear housing tie rod ball joint to the stub axle 68 ÷ 83 6.8 ÷ 8.3 8 Screw securing wheel 180 ÷ 200 18 ÷ 20 9 Nut securing hub to stub axle 256 ÷ 314 25.6 ÷ 31.4 10 Screw securing brake disc to wheel hub 19.5 ÷ 24 1.9 ÷ 2.4 11 Nut securing top suspension arm ball joint to the stub axle 125 ÷ 140 12.5 ÷ 14 12 Nut securing ball joint to the steering gear housing tie rod 70 ÷ 100 7 ÷ 10

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SECTION D-D SECTION M-M SECTION E-E SECTION B-B 49351 Figure 5 16 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 TIGHTENING TORQUES Vehicles 35 C COMPONENT TORQUE COMPONENT Nm kgm 1 Screw for nut securing steering gear housing 50 ÷ 61 5 ÷ 6.1 2 M12 screw for nut securing leaf spring mounting to the cross member 100 ÷ 124 10 ÷ 12.4 3 M10 screw for nut securing leaf spring mounting to the cross member 39 ÷ 48 3.9 ÷ 4.8 4 Nut for screw securing shock absorber top and bottom 124 ÷ 152 12.4 ÷ 15.2 5 Screw for nut securing shock absorber mounting to bottom suspension arm 39 ÷ 48 3.9 ÷ 4.8 6 Nut securing bottom suspension arm ball joint to the stub axle 160 ÷ 180 16 ÷ 18 7 Nut securing steering gear housing tie rod ball joint to the stub axle 68 ÷ 83 6.8 ÷ 8.3 8 Nut securing wheel 180 ÷ 200 18 ÷ 20 9 Screw securing cover and brake disc to wheel hub 98.1 ÷ 107.9 9.8 ÷ 10.7 10 Screw retaining ring nut securing hub to stub axle 20 ÷ 24 2 ÷ 2.4 11 Ghiera fissaggio mozzo al fuso snodo 257 ÷ 314 25.7 ÷ 31.4 12 Stud to brake disc (apply LOCTITE 242 or 270 sealant to the thread) 85 ÷ 104 8.5 ÷ 10.4 13 Nut securing ball joint to the steering gear housing tie rod 70 ÷ 100 7 ÷ 10 14 Nut securing top suspension arm ball joint to the stub axle 125 ÷ 140 12.5 ÷ 14

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SECTION N-N SECTION G-G SECTION F-F SECTION L-L SECTION H-H 49352 Figure 6 1 2 3 4 5 6 7 FRONT MECHANICAL SUSPENSIONS 17 D AILY E URO 4 Print 603.93.651 Base - March 2006 TIGHTENING TORQUES Vehicles 29 L - 35 S - 35C COMPONENT TORQUE COMPONENT Nm kgm 1 - 2 Screw for nut securing suspension arm to the top cross member and bottom to the cross member 170 ÷ 280 17 ÷ 28 3 Screw securing disc guard to the axle stub 6 ÷ 7.5 0.6 ÷ 0.7 4 Nut for screw securing cross member to chassis frame 83 ÷ 101 8.3 ÷ 10.1 5 Nut for screw securing cross member to chassis frame 83 ÷ 101 8.4 ÷ 10.1 6 Screw securing caliper mounting to the axle stub 170 ÷ 196 17.0 ÷ 19.6 7 M14 screw securing covers to the cross member 151 ÷ 184 15.1 ÷ 18.4

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88671 88672 88673 88674 Figure 7 Figure 8 Figure 9 Figure 10 Adjust vehicle on flat ground and lock rear wheels. Unloosen rear wheels securing nuts. By a hydraulic jack, lift the vehicle on front side and rest it on two supporting stands. Unscrew wheels securing nuts and detach wheels again by hydraulic truck 99321024. Check that protection cowlings (1 and 2) of articulated heads are not damaged. By suitable lever (3) resting on articulated spindle (4), lift swinging arm (2) as much as possible and reset comparator (1). Apply the magnetic base of comparator 99395684 (1) to brake disk (4) and position comparator tracer point on the top of the articulated head (2) of upper swinging arm (3). Pre-load comparator by approximately 4 mm. By suitable pliers (2) applied on articulated head (1) and on articulated spindle (4), apply strong pressure on head and spindle and check comparator (3) hand displacement corresponding to articulated head clearance. If detected value is between 1.5 and 2.0 mm, the swingingarm needs to be replaced, as described in relating chapter. In operation, take care not to damage the protection cowling of articulated head . NOTE 18 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 REPAIRS Check the clearance of upper swinging arm articulated head

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61665 61664 52325 Figure 11 Figure 12 Figure 13 Suspension arms Removal Remove the stub axle as described under the relevant heading (operation 520611 including removal of the wheel hubs operation 520620). Take out the nuts (2), extract the screws (3) and remove the top suspension arm (4) from the mountings of the cross member (1). Replacing suspension arm bushings Disassembly Using general tools, extract the flexible bushings (4) from the suspension arms (1). If there is damage to the caps (3) protecting the link pins (2) or if these have too much play, replace the suspension arm (1). Take out the nut (6) and remove the shockabsorber (5)from the mounting (8) of the bottom suspension arm, extracting the screw (7). Take out the nuts (2), extract the screws (3) and remove the bottom suspension arm (4) from the mountings of the cross member (1). 500760 OVERHAULING THE SUSPEN-SION Check the clearance of lower swinging arm articulated head 88692 Figure 14 The check of the clearance of the articulated head (2) of lower swinging arm (1) is similar to the one of upper swinging arm. If detected value is between 1.5 and 2.0 mm, the swingingarm needs to be replaced, as described in relating chapter. NOTE FRONT MECHANICAL SUSPENSIONS 19 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Refitting 52327 52328 74994 Figure 15 Figure 16 Figure 17 Insert the bushing (7) into the suspension arm (1). Apply the parts (2 - 3 - 5 - 6) of the tool 99374179, as shown in the figure. Screw on the nut (6) to make the bushing (7) flush with the suspension arm (1). Remove the parts of tool 99374179. Insert the spacer (2) into the bushing (1). Apply the parts (3 - 4 - 5) of the tool 99374179, as shown in the figure. Screw on the nut (5) to fully insert the spacer (2) into the flexible bushings (1). To refit the bottom (5) and top (1) suspension arms to the crosspiece (2), reverse the steps described for removal tightening the nuts (6 - 3) for the fixing screws (4 - 7) to the prescribed torque. Self-locking nuts, once removed, must be replaced with new ones. 52326 Figure 18 Insert the bushing (2) into the suspension arm (1). Apply the parts (3 - 4 - 5 - 6) of the tool 99374179, as shown in the figure. Screw on the nut (6) to make the bushing (2) flush with the suspension arm (1). Remove the parts of tool 99374179. Assembly The flexible bushings of the bottom suspension arms are equipped with metal reinforcement. NOTE NOTE 20 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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74996 Figure 19 500910 FRONT SHOCK ABSORBERS Removal Check that the bushings and/or elastic elements are not worn or deteriorated; if they are, replace the rel-evant part. FRONT SHOCK ABSORBER VEHICLES 29 L - 35S Set the vehicle on level ground. Lock the rear wheels with a scotch, remove the wheel rim guards and loosen the screws or nuts fixing the wheel. Lift the front of the vehicle and rest the chassis frame on sup-ports. Take out the screws or nuts fixing the wheel and remove them with tool 99321024. Unscrew the top and bottom bolts (2) and remove the shock absorbers (1) from the vehicle. Check the efficiency of the shock absorbers with a suitable instrument. Refitting For refitting, carry out the removal operations in re-verse order and keep to the required tightening tor-ques. FRONT MECHANICAL SUSPENSIONS 21 D AILY E URO 4 Print 603.93.651 Base - March 2006

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22 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Set the vehicle on level ground. Lock the rear wheels with chocks. Take off the wheel rim guards and loosen the screws or nuts securing the wheel. Lift the front of the vehicle and rest the chassis frame on stands. Take out the screws or nuts securing the wheel with tool 99321024. On the right-hand side: -using a hydraulic jack, slightly lift the stub axle so as to limit the load of the leaf spring; -disconnect the electrical connection (1) for indicating brake lining wear; -disconnect the ABS speed sensor (4) (if there is one); -take out the screws (2) securing the brake caliper to the axle stub and remove it. Remove the brake linings from the brake caliper (3) and support this adequately to prevent strain on the brake pipes; LEAF SPRING Figure 20 Removal Check the state of the brake linings and brake disc as described in the BRAKES section. -take out the nut locking the link pin of the tie rod (20) and, with tool 99347074 (19), remove the link pin (20) of the steering tie rod from the stub axle; -take out the nut (21) and, with tool 99347074 (19), remove the link pin (22) of the top suspension arm from the stub axle; -take out the nuts (16) and screws (18) securing the shock absorber mounting (15) to the bottom suspension arm; -lower the hydraulic jack; Repeat the similar operations on the left-hand side; -take out the nuts (6 and 5) and screws (10 and 11) and remove the covers (8, 9 and 12) from the cross member (7). Note the assembly position of the bottom flexible plugs (13) on the cover (8). Remove the leaf spring (17). Note the assembly position of the top flexible plugs (14) in the cross member (7). NOTE NOTE NOTE 112173 FRONT MECHANICAL SUSPENSIONS 23 D AILY E URO 4 Print 603.93.651 Base - March 2006 PRINT 603.43.351

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Figure 21 61663 Carry out the operations described for removal in reverse order, but you must take the following precautions: -fit the top flexible plugs (2) in the cross member (1) at the position found during disassembly; -fit the flexible plugs (4) onto the ends of the new leaf spring (3); -fit the leaf spring (3) into the cross member and support it with a hydraulic lift; -with two lifts arranged under the stub axles, lift them together, checking that the flexible plugs (4) of the leaf spring (3) get correctly positioned in the honeycomb of the bottom suspension arms (5 and 8) and the centre line ( ⇒ ) of the leaf spring is aligned with the central holes ( ⇒ ) della traversa (1), of the cross member (1), max. error ± 2 mm; -then complete refitting by tightening the screws or nuts to the required torque; -position the bottom flexible plugs (6) on the cover (7) at the position found during disassembly; -mount the cover (7) and tighten the screws and nuts to the required torque. The nylon self-locking nuts must be replaced with new ones every time they are taken down. Refitting To block rotation of the pins of the swivel heads (9 - 10), insert a suitable Allen wrench into the hexagon sunk in it. NOTE NOTE 24 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 22 ASSEMBLY DRAWING OF FRONT TORSION BAR SUSPENSION The hydraulic shock absorbers are the double-acting telescopic type. The side tie rods are mounted at the front to the chassis frame mounting by means of adjustable link pins, and at the rear to the transverse levers. The purpose of the stabilizer bar, mounted on the bottom reaction screw stays, is to maintain the parallelism between the axis of the wheels and the chassis frame, cancelling any load unbalance on the wheels mounted on the same axle. The purpose of the rubber pads fixed on the top mounting of the shock absorbers is to limit the upward movement of the suspension. (Axle 5819 - vehicles 35C - 40C - 45C - 50C) Description The torsion bar suspension is composed of: -two bottom suspension arms. -two top suspension arms; -two longitudinal torsion bars; -two hydraulic shock absorbers; -two bottom reaction tie rods; -two top reaction tie rods; -a stabilizer bar; -two rubber pads. The longitudinal torsion bars are anchored at the front to the top suspension arms and at the rear to a mounting secured to the chassis frame. 112216 FRONT MECHANICAL SUSPENSIONS 25 D AILY E URO 4 Print 603.93.651 Base - March 2006 Print 603.43.351 TORSION BAR SUSPENSION

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26 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 SPECIFICATIONS AND DATA Torsion bar suspension with independent wheels, stabilizer bar Models Torsion bar suspension with independent wheels, stabilizer bar and hydraulic shock absorbers 35 C 40 C 45 C 50 C Torsion bar diameter mm 29 Top tie rod adjustment distance 378 ± 0.15 mm Top tie rod adjustment distance 220.4 ± 0.15 mm Bottom tie rod adjustment distance 364.5 ± 0.15 mm Bottom tie rod adjustment distance 300.4 ± 0.15 mm Front shock absorbers Models: 35 C - 40 C - 45 C - 50 C Mannesmann - Sachs Arvin Meritor Distance between centre of eyes: Open mm 430  3 444  3 mm Closed mm 280  3 286  3 mm Stroke mm 150 158 mm Stabilizer bar diameter Models: 35 C - 40 C - 45 C - 50 C Stabilizer bar diameter mm 20 The torsion bar is not provided for the COMBI version. NOTE

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FRONT MECHANICAL SUSPENSIONS 27 D AILY E URO 4 Print 603.93.651 Base - March 2006 TOOLS TOOL NO. DESCRIPTION Hydraulic trolley for wheel removal - refitting 99321024 Extractor to take out tie rod link pins 99347060 Extractor to take out steering tie rod link pins and suspension arms 99347074 Wrench for ring nut securing link pins 99357144 Tool for disassembling and reassembling front suspension flexible bushings 99374241

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28 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 23 62103 FRONT MECHANICAL SUSPENSIONS 29 D AILY E URO 4 Print 603.93.651 Base - March 2006 PRINT 603.43.351 TIGHTENING TORQUES Vehicles 35 C - 40 C - 45 C - 50 C DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 Nut, reaction rod mounting upper fastening to chassis fixing screw 126 ÷ 154 12.8 ÷ 15.7 2 Nut, reaction rod ball joint to mounting 98 ÷ 137 10 ÷ 14 3 Nut, reaction rod and knckle joint stiffener to chassis fixing screw 33 ÷ 49 3.4 ÷ 5.0 4 Nut for screw fixing cross member to reaction rod support 126 ÷ 154 12.8 ÷ 15.7 5 Nut, ball joint to upper tie rod 98 ÷ 137 10 ÷ 14 6 Nut, upper tie rod to upper arm fastening screw 150 ÷ 183 15.3 ÷ 18.7 7 Nut, shock absorber upper and lower fastening screw 116 ÷ 142 11.8 ÷ 14.5 8 Nut, lower bracket fastening screw suspension adjustment unit 151 ÷ 184 15.4 ÷ 18.8 9 Nut, torsion bar adjusting lever pin 254 ÷ 311 25.9 ÷ 31.7 10 Nut, cross member to chassis side member lower wing fixing screw 72 ÷ 88 7.3 ÷ 9 11 Nut for steering box fixing screw 50 ÷ 61 5 ÷ 6.1 12 Nut, lower arms to cross member anchoring screw 206 ÷ 252 21.0 ÷ 25.7 DESCRIPTION TORQUE DESCRIPTION Nm kgm 13 Ring nut, ball joint to upper/lower arms 83 ÷ 152 8.5 ÷ 15.5 14 Nut, ball joint to steering knuckle 157 ÷ 177 16 ÷ 18 15 Nut, fixing will 180 ÷ 200 18 ÷ 20 16 Nut fixing steering box rod ball joint to stub axle lever 68 ÷ 83 6.8 ÷ 8.3 17 Hexagonal-head slotted nut, torsion bar to supension arm 84 ÷ 103 8.5 ÷ 10.5 18 Nut, cross member upper fastening to bracket on chassis side member upper wing fixing screw 47 ÷ 58 4.8 ÷ 5.9 19 Nut, cross member upper anchoring bracket to chassis side member upper wing fixing screw 18 ÷ 22 1.8 ÷ 2.2 20 Nut, upper and intermediate bracket fastening screw (suspension adjustment unit) 94 ÷ 115 9.6 ÷ 11.7 -Screw for nut fixing front tubular cross member to side members 42 ÷ 51 4.2 ÷ 5.2 -Nut, stabilizer bar clamps fixing screw 18 ÷ 22 1.8 ÷ 2.2 -Rubber plug nut 68 ÷ 83 6.9 ÷ 8.5

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30 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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88675 88677 88676 88678 88679 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Adjust vehicle on flat ground and lock rear wheels. Unloosen rear wheels securing nuts. By a hydraulic jack, lift the vehicle on front side and rest it on two supporting stands. Unscrew wheels securing nuts and detach wheels again by hydraulic truck 99321024. Check that protection cowlings (1) of articulated heads are not damaged. Remove nut (5) and dismount shock absorber(1) fromlower swinging arm (2). Unloosen nut (4) for the screw to secure lower swinging arm (2) to cross member (3). Remove screw (3) and detach tie rod (2) from lower swinging arm (1). By suitable jack (2), positioned under wheel hub (1), load suspension. Check the clearance of upper swinging arm articulated head Apply the magnetic base of comparator 99395684 (1) to brake disk (2) and position comparator tracer point on the top of the articulated head (4) of upper swinging arm (3). FRONT MECHANICAL SUSPENSIONS 31 D AILY E URO 4 Print 603.93.651 Base - March 2006 REPAIRS

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88680 88681 88682 Figure 29 Figure 30 Figure 31 Pre-load comparator (1) by approximately 4 mm and reset it by suitable lever (4), lift upper swinging arm (3) as much as possible and detect the displacement of comparator (1) hand corresponding to the clearance of articulated head (2). If detected value is between 1.5 and 2.0 mm, the articulated head (2) needs to be replaced, as described in relating chapter. Position comparator (1) tracer point with magnetic base 99395684 on the top of the articulated head of lower swinging arm (2). By suitable lever, lower swinging arm (2) and reset comparator (1). By suitable pliers (2) applied on articulated head (3) and on lower swinging arm (1), apply strong pressure on head and arm and write down comparator (4) hand displacement corresponding to articulated head clearance. If detected value is between 1.5 and 2.0 mm, the swingingarm needs to be replaced, as described in relating chapter. Remount dismounted parts in order to make checks. Check the clearance of lower swinging arm articulated head See Figure 26: the nut for screw (3) to secure tie rod (2) to lower swinging arm (1) and see Figure 25: the nut (4) for the screw to secure lower swinging arm (2) to cross member (3): they must be tightened at prescribed torque with the vehicle lowered and vehicle empty weight weighing down on suspension. NOTE 32 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Loosen the nut (2) and unscrew the swivel head (1) from the bottom tie rod (3). Screw the new swivel head (1) onto the tie rod (3) positioning it at the values shown in the figure. Tighten the nut (2) to the prescribed torque. Figure 32 75360 44664 Figure 33 Figure 34 Figure 35 TIE RODS Remove the stabilizer bar as described under the relevant heading (operation 528030). Take out the nut for the screw (2) securing the tie rod (3) to the bottom suspension arm (1) and remove the screw (2) from this. Take out the nut securing the link pin (5) to the mounting (4). Using the extractor 99347060, remove the swivel head (5) from the mounting (4). Take out the nut (3) for the screw (4) securing the tie rod (1) to the top suspension arm (2) and remove the screw (4) from this. Take out the nut securing the link pin (5) to the mounting (7). Using the extractor 99347074 (6), remove the swivel head (5) from the mounting (7). Remove the screw stay (1) from the vehicle. Loosen the nut (2) and unscrew the swivel head (1) from the top tie rod (3). Screw the new swivel head (1) onto the tie rod (3) positioning it at the values shown in the figure. Removal If removing the mounting (7), so as not to change the wheel geometry, not the number and thickness of the spacers (if there are any) under the mounting to mount them in the same way when refitting the mounting (7). 500764 Replacing swivel heads 75359 Using the extractor 99347060 (1), detach the stub axle (2) from the mounting (4) Figure 22. Remove the screw stay (3) from the vehicle. 300.4 ± 0,.6 364.5 ± 0.7 3 2 1 19056 220 ± 0.5 378 ± 0.8 44666 1 2 3 Figure 36 NOTE FRONT MECHANICAL SUSPENSIONS 33 D AILY E URO 4 Print 603.93.651 Base - March 2006 PRINT 603.43.351 500760 OVERHAULING THE SUSPENSION

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Refit the top tie rod (5) to the top suspension arm (3) and to the mounting (6). Tighten the nut securing the link pin (1) to the required torque. Refitting The nut (4) for the screw securing the tie rod (5) to the lever (3) must be tightened when the load of the empty vehicle weighs on the suspension. 44668 Figure 37 Refit the bottom tie rod (3) to the bottom suspension arm (1) and to the mounting (4). Tighten the nut securing the link pin (5) to the required torque. Figure 38 44664 At the end of the re-fitting check the wheels geometry as described in the relevant paragraph. Then tighten the nuts, which fasten the articulated head to the relevant tie-rods, to the prescribed torque. The nut (2) for the screw securing the tie rod (3) to the bottom lever must be tightened when the load of the empty vehicle weighs on the suspension. Re-fit the stabilizer bar. Figure 39 Remove the nut which fastens the articulated head (2) of the gearbox tie-rod to the steering knuckle; with the puller No. 99347074 (1) remove the articulated head (2). 44935 Removal Remove the lower and upper tie-rods as described in the relevant paragraph (operation 500761) and go on as follows: Figure 40 Loosen the nut (2) and unscrew the threaded pin (1) until the torsion bar (3) is fully ”unloaded”. Take out the nuts (4) for the screws securing the mounting (5) to the chassis frame. Remove the mounting (5) from the torsion bar (3). Remove the nuts securing the link pins (1) from the top (4) and bottom (6) suspension arms to the stub axle (5). Support in an appropriate way the steering knuckle (5) together with brake caliper and wheel hub and with the tool No. 99347074 (2) remove the steering knuckle (5) from the levers (4 and 6). Place the steering knuckle (5) on a support without straining the brake fluid hose and the electrical wires. 44671 Figure 41 74997 NOTE NOTE NOTE 34 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 500666 TORSION BARS

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Remove the split pin (6), the nut (5) and the washer (4). Disconnect the top suspension arm (2) from the cross member (3) extracting the torsion bar (1). 19603 Fit the new knuckle pin (3) on upper and lower swinging arm (1). Loosen ring (2). 19602 Silentbloc is replaced using tool 99374241 (1); the limit stops (2) are replaced with general tools. 19045 Replacing silentbloc and limit stops 44673 1 2 3 4 5 6 44672 Take out the nut (5), remove the screw (4) and recover the two washers. Disconnect the bottom suspension arm (3) from the cross member (1) extracting the bushing (2). Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Using tool 99357151 (1) loosen the ring nut and extract the link pin (2) from the suspension arm. Replacing link pins 1 2 FRONT MECHANICAL SUSPENSIONS 35 D AILY E URO 4 Print 603.93.651 Base - March 2006

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The letters AD - AS, printed in the back of torsion bars, indicate respectively the right bar and the left one. Moreover the splined part has a double tooth (1) which, at the reassembly, must correspond to the double spline (2) of the upper lever. With the tool No. 99357151 (1) fasten the ring nut (3, Figure 46) to the prescribed torque. 19604 19046 52370 Figure 47 Figure 48 Figure 49 Figure 50 Position the top suspension arm (2) in the cross member. Then insert the torsion bar (1), with the washer (3), in the cross member and in the suspension arm. Refitting 44674 Figure 51 Place the washer (1) and screw the nut (2) without tightening it. 19052 Position the bottom suspension arm in the cross member and insert the bushing (1). Insert the screw with its washers and screw the nut without tightening it. 1 1 2 1 2 1 NOTE 36 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Refit the wheels, mount the nut guard and screw on the fixing nuts; lower the vehicle, removing the stands.. Following the order shown in the figure, tighten the fixing nuts to the required torque. Then tighten the torsion bar fixing nuts to the required torque and mount the safety split pins on them. Tighten the nuts for the screws securing the top and bottom tie rods to their respective levers to the required torque. Fit the stabilizer bar (1) back onto the bottom screw stays (2) with the clamps (3), taking care that the screws (4) go into the slots in the stabilizer bar. Complete fitting the suspension back on by mounting the shock absorber. Lubricate the grooved portion of the torsion bar (3). Assemble the torsion bar (3) and the support (1) so that the splines (2) of the toothed bush and of the torsion bar coincide. Fix the support (1) to the chassis tightening the fastening screw nuts to the prescribed torque. 74998 44675 44697 Figure 52 Figure 53 Figure 54 Figure 55 Connect the stub axle (3) to the link pins of the top (1) and bottom (4) suspension arms. Tighten the fixing nuts (2) to the required torque. 1 2 3 4 7768 Figure 56 44676 Refit the tie rods (4 and 7) to the suspension arms (1 and 6) without tightening the nuts for the screws (3 and 5) to their torque; connect the link pin (2) of the steering gear housing tie rod to the lever of the stub axle and tighten the nut to the required torque. FRONT MECHANICAL SUSPENSIONS 37 D AILY E URO 4 Print 603.93.651 Base - March 2006

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If the value is different, act on the adjusting screw (1) as much as you need it, but remember that, before acting on the screw, it is necessary, to lift the vehicle with the hydraulic jack, so that the wheels are lifted from the ground. This is necessary if you do not want to damage the screw. Once the vehicle has reached the right position, lock the screw with the lock nut (2). TORSION BAR PRE-LOADING CONTROL DIAGRAM H = mm, distance from ground of the side frame upper thread, measured as near as possible the suspension connecting area RSC = mm, loaded wheel radius Ensure that the wheel pressure complies with the prescribed one and check, with the suitable gauge, that the thread depth of tyres is more or less the same on both wheels. Measure on both sides of the vehicle, the distance from ground (H) of the side frame upper thread, measured as near as possible the suspension connecting area. The height H must correspond to the value given in the table below. 20986 74999 Figure 57 Figure 58 38 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Adjusting torsion bar pre-load HEIGHT OFF GROUND (H in millimetres) OF THE TOP EDGE OF THE CHASSIS FRAME IN RELATION TO THE WEIGHT FOR MODELS 35C/40C/45C/50C WITH TORSION BAR DIAMETER 29 mm. Weight on the front wheels Tyres Weight on the front wheels (Kg) 195/75 R 16 6. 50 R 16 1200 610 629 1220 608 627 1240 606 625 1260 604 623 1280 603 622 1300 601 620 1320 599 618 1340 597 616 1360 596 615 1380 594 613 1400 592 611 1450 588 607 1500 584 602 1550 579 598 1600 575 593 1650 571 589 1700 566 585 1750 562 580 1800 558 576 1850 553 571 1900 549 567

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75000 75001 Figure 59 Figure 60 528030 STABILIZER BAR Removal FRONT STABILISER BAR Vehicles 35C - 40C - 45C - 50C Unscrew the screws (2) fixing the half-brackets (3) and remove the stabilizer bar (1) from the vehicle, recovering the rubber plugs (4). Check that the bushings and/or elastic elements are not worn or deteriorated; if they are, replace the relevant part. 500910 FRONT SHOCK ABSORBERS Removal Check that the bushings and/or elastic elements are not worn or deteriorated; if they are, replace the relevant part. FRONT SHOCK ABSORBER Vehicles 35C - 40C - 45C - 50C Set the vehicle on level ground. Lock the rear wheels with scotches, remove the wheel rim guards and loosen the screws or nuts fixing the wheel. Lift the front of the vehicle and rest the chassis frame on supports. Take out the screws or nuts fixing the wheel and remove them with tool 99321024. Unscrew the top and bottom bolts (2), then remove the shock absorbers (1) from the vehicle. Refitting To fit it back on, perform the steps carried out for removal in reverse order, keeping to the prescribed tightening torques. Using a suitable instrument, check the efficiency of the shock absorbers. Refitting To fit it back on, perform the steps carried out for removal in reverse order, keeping to the prescribed tightening torques. FRONT MECHANICAL SUSPENSIONS 39 D AILY E URO 4 Print 603.93.651 Base - March 2006

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40 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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Figure 61 ASSEMBLY DRAWING OF FRONT TORSION BAR SUSPENSION The hydraulic shock absorbers are the double-acting telescopic type. The side tie rods are mounted at the front to the chassis frame mounting by means of adjustable link pins, and at the rear to the transverse levers. The purpose of the stabilizer bar, mounted on the bottom reaction screw stays, is to maintain the parallelism between the axis of the wheels and the chassis frame, cancelling any load unbalance on the wheels mounted on the same axle. The purpose of the rubber pads fixed on the top mounting of the shock absorbers is to limit the upward movement of the suspension. (Axle 5823 - vehicles 60C - 65C) Description The torsion bar suspension is composed of: -two bottom suspension arms; -two top suspension arms; -two longitudinal torsion bars; -two hydraulic shock absorbers; -two bottom reaction tie rods; -two top reaction tie rods; -a stabilizer bar; -two rubber pads. The longitudinal torsion bars are anchored at the front to the top suspension arms and at the rear to a mounting secured to the chassis frame. FRONT MECHANICAL SUSPENSIONS 41 D AILY E URO 4 Print 603.93.651 Base - March 2006 PRINT 603.43.351 TORSION BAR SUSPENSION

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42 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 PRINT 603.43.351/D SPECIFICATIONS AND DATA Torsion bar suspension with independent wheels, stabilizer bar Models Torsion bar suspension with independent wheels, stabilizer bar and hydraulic shock absorbers 60 C - 65 C Torsion bar diameter mm 33 Top tie rod adjustment distance 378 ± 0.8 mm Top tie rod adjustment distance 220 ± 0.5 mm Bottom tie rod adjustment distance 369 ± 0.5 mm Bottom tie rod adjustment distance 300.4 ± 0.5 mm Lower linkage adjustment (for recently manufactured vehicles) 363.5 ± 0.5 mm Lower linkage adjustment (for recently manufactured vehicles) 299 ± mm +0.3 0 377 ± 0.15 mm 219 ± 0.15 mm Front shock absorbers Models: 60 C - 65 C Mannesmann - Sachs ARVIN Distance between centre of eyes: Open mm 430  3 400  3 Closed mm 280  3 280  3 Stroke mm 150 120 Stabilizer bar 60 C - 65 C Models: Twin cab Truck Chassis Cabs Cut Away Vans Chassis Cowls Semi-Glazed Stabilizer bar diameter mm 20 22 The torsion bar is not provided for the Combi version. NOTE

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Figure 62 62103 FRONT MECHANICAL SUSPENSIONS 43 D AILY E URO 4 Print 603.93.651 Base - March 2006 PRINT 603.43.351 TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 Nut, reaction rod mounting upper fastening to chassis fixing screw 140 14 2 Nut, reaction rod ball joint to mounting 98 ÷ 137 10 ÷ 14 3 Nut, reaction rod and knckle joint stiffener to chassis fixing screw 41 4.1 4 Nut for screw fixing cross member to reaction rod support 140 14 5 Nut, ball joint to upper tie rod 98 ÷ 137 10 ÷ 14 6 Nut, upper tie rod to upper arm fastening screw 150 ÷ 183 15.3 ÷ 18.7 7 Nut, shock absorber upper and lower fastening screw 116 ÷ 142 11.8 ÷ 14.5 8 Nut, lower bracket fastening screw suspension adjustment unit 151 ÷ 184 15.4 ÷ 18.8 9 Nut, torsion bar adjusting lever pin 197 ÷ 241 20 ÷ 24 10 Nut, cross member to chassis side member lower wing fixing screw 80 8 11 Nut for steering box fixing screw 50 ÷ 61 5.1 ÷ 6.2 12 Nut, lower arms to cross member anchoring screw 206 ÷ 252 21.0 ÷ 25.7 DESCRIPTION TORQUE DESCRIPTION Nm kgm 13 Ring nut, ball joint to upper/lower arms 83 ÷ 152 8.5 ÷ 15.5 14 Nut, ball joint to steering knuckle 157 ÷ 177 16 ÷ 18 15 Nut, fixing will 284.5 ÷ 343.3 28.4 ÷ 34.3 16 Nut fixing steering box rod ball joint to stub axle lever 83 ÷ 68 8.4 ÷ 6.9 17 Hexagonal-head slotted nut, torsion bar to supension arm 84 ÷ 103 8.6 ÷ 10.5 18 Nut, cross member upper fastening to bracket on chassis side member upper wing fixing screw 52.5 5.2 19 Nut, cross member upper anchoring bracket to chassis side member upper wing fixing screw 20 2 20 Nut, upper and intermediate bracket fastening screw (suspension adjustment unit) 104 10.4 -Screw for nut fixing front tubular cross member to side members 42 ÷ 51 4.2 ÷ 5.2 -Nut, stabilizer bar clamps fixing screw 24.5 2.4 -Rubber plug nut 68 ÷ 83 6.9 ÷ 8.5

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44 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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FRONT MECHANICAL SUSPENSIONS 45 D AILY E URO 4 Print 603.93.651 Base - March 2006 PRINT 603.43.351 TOOLS TOOL No. DESCRIPTION Hydraulic trolley for wheel removal and refitting 99321024 Tool for removing front suspension rubber bushes 99347027 Extractor to take out link pins 99347060 Extractor to take out link pins and suspension arms 99347074 Tool for link pins fixing screw 99357144 Tool for refitting front suspension rubber bushes 99374166

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Remove the nut (2), withdraw the screw (3) and disconnect the shock absorber (4) from the upper support (1). Remove the nut (7) fastening the articulated head (6) from the upper lever (5) to stub axle (8). Suitably support the stub axle (8) including the brake calliper and the wheel hub and using tool 99347074 remove the lever (5) from the stub axle (8). Rest the stub axle (8) on a proper stand to prevent brake fluid pipes and electric cables tensioning. 62925 Figure 63 62924 62926 61984 Figure 64 Figure 65 Figure 66 Loosen the nut (2) and unscrew the articulated head (1) from the upper tie rod (3). Screw the new articulated head (1) on the tie rod (3). Position it according to the values show in the above figure. Remove the nut fastening the steering box tie rod kingpin (4) from stub axle lever; use puller 99347074 (2) to remove the kingpin (4). Remove suspension lever (1) upper tie rod (3). Loosen the nut (3) and loosen the threaded pin (2) until the torsion bar (1) is completely ”released”. 500764 Lower tie rod articulated heads replacement 500666 TORSION BARS Removal It differs from suspension overhaul with torsion bars for vehicles: 35C, 40C, 45C, 50C for the following points. NOTE Take note of the number of pin (2) threads above nut (3); these data shall provide the starting point to adjust the torsion bar after assembling.. NOTE For left torsion bar disconnect the fuel tank. NOTE 46 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 REPAIR OPERATIONS 500760 SUSPENSION OVERHAUL

Page 731

62929 Refitting Remove the lock nut (6), the nut (7) and withdraw the washer (5). Remove the torsion bar (2) with the washer (1) from the upper lever (3) and remove it from the bracket (4). 62930 Remove the torsion bar (2) including the circlip (3) and the washer (4) from the adjustment lever (5) and remove it from the bracket (1). 62928 62927 62931 Remove the circlip (1) from the sleeve (2) and remove it. Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Position rubber bushes (2-5) in cross member (1). Apply tool 99374166 (4) to bushes (2-5) as shown in the figure. Hold the screw (6) and tighten the nut (3) until fitting in place the rubber bushes (2-5). Apply tool 99347027 (5) as shown in the figure. Hold the screw (6), tighten the nut (4) and remove the rubber bushes (3 and 7) from the cross member (1). Rubber bush replacement Removal The rubber stop plug (2) is pressure-fitted to cross member (1) and no tool is required for its replacement. NOTE FRONT MECHANICAL SUSPENSIONS 47 D AILY E URO 4 Print 603.93.651 Base - March 2006

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The splined part is provided with a double tooth (1), that shall coincide at refitting with the double space (2) of the upper lever. 62931 Set the upper lever (2) in the cross member, then insert the torsion bar (1), including the washer (3), into cross member and lever, making the double tooth coinciding with the double space of the lever. 52370 19046 62928 Set the adjustment lever (5) in the bracket (1) and insert the torsion bar (2) including the washer (4) and the circlip (3). Figure 72 Figure 73 Figure 74 Figure 75 Fit the sleeve (3) on the torsion bar (1) and in the adjustment lever (2) so that the marks on these components coincide as shown in the following figure. Set the washer (1) and screw the nut (2) without locking it. The rear part of the torsion bars is marked with AD-AS to identify respectively the right bar and the left bar. 44674 Figure 76 Figure 77 44675 Connect the stub axle (3) to the upper lever (1) ball joint; tighten the fastening nut (2) to the specified torque. 1 2 3 2 NOTE 48 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

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62934 Figure 78 1. Bracket - 2. Adjustment lever - 3. Sleeve - 4. Torsion bar - 5. Washer - 6. Circlip - A. Front reference mark on sleeve (3) - B. Front reference mark on adjustment lever (2) - C. Rear reference mark on sleeve (3) - D. Reference mark on torsion bar (4) - E. Reference mark on left torsion bar - F. Reference mark on right torsion bar. After refitting torsion bar (4)/ sleeve (3)/ adjustment lever (2), secure the sleeve (3) to the bracket with the circlip (6). Refit the fuel tank (if removed). AD. Right torsion bar AS. Left torsion bar FRONT MECHANICAL SUSPENSIONS 49 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Torsion bar preload adjustment TORSION BAR PRELOAD CHECK DIAGRAM H = mm, height from ground of side member upper edge measured as close as possible to suspension connection area RSC (Loaded radius): -with 225/75R16 tyres, 345 mm with 2500 kg load -with 7.00R16 tyres, 364 mm with 2000 kg load 62935 Refit the tie rod (6) to the lever (3) without tightening to torque the nut for screw (7); connect the articulated head (4) of the steering box tie rod to the stub axle lever and tighten the nut to the specified torque. Connect the shock absorber with the screw (5) and the nut (1) and tighten the latter to the specified torque. Refit wheels, fit nut protection and tighten the fastening nuts; remove stands and lower the vehicle. Then tighten to the specified torque the following components: -wheel fastening nuts; -nut and lock nut fastening the torsion bars to the relevant levers; -nuts for screws fastening the upper tie rods to the relevant levers. Adjust torsion bar preload as described in the following paragraph. Figure 79 Figure 80 Figure 81 If a different value is found, operate on the adjustment screw (1) as required, taking into account that before performing this operation the vehicle shall always be lifted from ground with hydraulic jack to prevent screw damaging. Once proper vehicle setup is obtained, lock the screw with the lock nut (2). 62936 20986 Check whether tyre pressure is the specified one and then using the proper gauge, check whether tyre tread depth is almost the same on both wheels. Measure on both vehicle sides the height (H) from ground of side member upper edge - measured as close as possible to suspension connection area Height (H) shall correspond to the value specified in the following table. 50 FRONT MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Load on front wheels Tyres wheels (Kg) 225/75 R 16 7.00 R 16 1400 672 ,0 691 ,0 1500 665.6 684.6 1700 652.6 671.6 1800 646 ,0 665 ,0 1900 639.4 658.4 2100 626.1 645.1 2300 612.8 631.8 2400 606.1 625.1 2500 599.5 618.5

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REAR MECHANICAL SUSPENSIONS 51 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear mechanical suspensions Page DESCRIPTION 53 . . . . . . . . . . . . . . . . . . . . . . . . . . CHARACTERISTICS AND DATA 54 . . . . . . . . . . . -Rear leaf spring 54 . . . . . . . . . . . . . . . . . . . . . . . . -Rear shock absorbers 71 . . . . . . . . . . . . . . . . . . . . TOOLS 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 73 . . . . . . . . . . . . . . . . . -Vehicles 29 L - 35 S 73 . . . . . . . . . . . . . . . . . . . . . -Vehicles 35 C - 40 C - 45 C- 50 C 74 . . . . . . . . . -Vehicles 60 C - 65 C 75 . . . . . . . . . . . . . . . . . . . . REAR LEAF SPRING 76 . . . . . . . . . . . . . . . . . . . . . . -Vehicles: 29 L - 35 S 76 . . . . . . . . . . . . . . . . . . . . -Removal 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Vehicles: 35 C - 40 C - 45 C - 50 C -60 C - 65 C 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIRS 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Disassembling the leaf spring 78 . . . . . . . . . . . . . . -Checks 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Assembling the leaf spring 78 . . . . . . . . . . . . . . . . -Replacing the bushings 78 . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBERS 79 . . . . . . . . . . . . . . . . -Removal 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STABILIZER BAR 80 . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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52 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651

Page 737

52371 The rear suspension is composed of: -two leaf springs which, according to the vehicle, can be of a semi-elliptic type with double flexibility or of a parabolic type with simple flexibility.; -two stop bumpers; -two hydraulic double acting shock absorbers; -stabilizer bar. The semi-elliptic leaf spring is very stiff because all leaves forming the leaf spring have the same thickness from one end to the other. Moreover, leaves are placed one against the other and this causes a great internal friction which limits the movements of the leaf spring. The parabolic leaf spring is formed by leaves which have a greater thickness in the middle than at the two ends. Leaves are spaced by means of shims and this reduces much of the internal friction. The low internal friction and the particular form of the leaves make the parabolic leaf spring more ”soft”, this makes driving easier. Hydraulic double-acting telescopic shock absorbers, hinder the wheel movement both upwards and downwards, allowing a great driving stability. The stabilizer bar must keep the geometry between the wheel axle and the chassis and arrange the load evenly over the wheels on the same axle. REAR SUSPENSION Figure 82 REAR MECHANICAL SUSPENSIONS 53 D AILY E URO 4 Print 603.93.651 Base - March 2006 DESCRIPTION

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54 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 CHARACTERISTICS AND DATA Rear leaf spring Vehicles: 29 L - 35 S mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1500 ± 3 S Leaf thickness (measured at centre) 24 (22)* S Gap between leaves -L Leaf width 80 ± 0.5 CONTROL DATA WITH NEW SPRING: Spring flexibility with static load 8.6 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0 (*) Alternatively

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REAR MECHANICAL SUSPENSIONS 55 D AILY E URO 4 Print 603.93.651 Base - March 2006 0 Rear leaf spring Vehicles: 35 C - Camper version mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1415 ± 3 S Leaf thickness (measured at centre) Leaf thickness (measured at centre) -S Gap between leaves 15 L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Spring flexibility with static load 6.4 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 D d d = bush inner diameter 16.5 + 0.2 − 0

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56 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear leaf spring Vehicles: 35 C mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1415 ± 3 S Leaf thickness (measured at centre) 19 S Gap between leaves 3 (1 x 3 + 1 x 25)* L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Spring flexibility with static load 10.5 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0 (*) For versions with maximum front load = 1900 kg

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REAR MECHANICAL SUSPENSIONS 57 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear leaf spring Vehicles: 40 C chassis cowls mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1415 ± 3 S Leaf thickness (measured at centre) 22 S Gap between leaves 3 L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load 7.6 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

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58 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear leaf spring Vehicles: 40 C mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1415 ± 3 S Leaf thickness (measured at the centre) thickness of the auxiliary leaf (measured at the centre) 18 18 S Gap between leaves 3 L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load 7.6 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

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REAR MECHANICAL SUSPENSIONS 59 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear leaf spring Vehicles: 45 C mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1415 ± 3 S Leaf thickness (measured at centre) 22 (23)* S Gap between leaves 3 L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Spring flexibility with static load 6.9 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0 (*) Alternatively

Page 744

60 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear leaf spring Vehicles: 50 C mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1415 ± 3 S Leaf thickness (measured at centre) 19 S Gap between leaves 3 L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring deflection with static load Auxiliary spring deflection with static load Main spring flexibility with static load 5.6 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

Page 745

REAR MECHANICAL SUSPENSIONS 61 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear leaf spring Vehicles: 60 C - 65 C mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1415 ± 3 S Thickness of the main leaves (measured at the centre) thickness of the auxiliary leaf (measured at the centre) 18 (19)* 28 S Gap between leaves 3 L Leaf width 70 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring deflection with static load Flexibility with static load after aux. spring action 9.3 mm/kN 3.4 mm/kN D Main leaf eye inner diameter (Bush seat) 40 + 0.5 − 0.2 D d D = bush outer diameter 40 + 0.02 − 0.07 d = bush inner diameter 16.5 + 0.2 − 0 (*) Alternatively

Page 746

62 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear leaf spring Vehicles: 35 C mm Semi-elliptical springs N o 2 L Spring length (measured at centre of eyes) 1415 ± 4 S Leaf thickness (measured at the centre), main leaf (1st - 4th) auxiliary leaf (1st - 2nd) 9 15 S Gap between leaves --L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load Flexibility with static load after aux. spring action 20.2 mm/kN 10.4 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

Page 747

REAR MECHANICAL SUSPENSIONS 63 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear leaf spring Vehicles: 35 C - 40 C mm Semi-elliptical springs N o 2 L Spring length (measured at centre of eyes) 1415 ± 4 S Leaf thickness (measured at the centre), main leaf (1st - 4th) auxiliary leaf (1st - 3rd) 9 15 S Gap between leaves --L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load Flexibility with static load after aux. spring action 19.7 mm/kN 6.4 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

Page 748

64 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear leaf spring Vehicles: 45 C - 50 C (semi-elliptical with leaf spring) mm Semi-elliptical springs N o 2 L Spring length (measured at centre of eyes) 1415 ± 4 S Leaf thickness (measured at the centre), master leaf (1st - 7th) additional leaf (1st - 6th) 9 8 S Gap between leaves 7 L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load Flexibility with static load after aux. spring action 15 mm/kN 3.6 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

Page 749

REAR MECHANICAL SUSPENSIONS 65 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear leaf spring Vehicles: 45 C mm Semi-elliptical springs N o 2 L Spring length (measured at centre of eyes) 1415 ± 4 S Leaf thickness (measured at the centre), master leaf (1st - 4th) additional leaf (5th - 7th) 9 15 S Gap between leaves -L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load Flexibility with static load after aux. spring action 19.7 mm/kN 5.8 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

Page 750

66 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear leaf spring Vehicles: 45 C - 50 C (semi-elliptical with leaf spring) mm Semi-elliptical springs N o 2 L Spring length (measured at centre of eyes) 1415 ± 4 S Leaf thickness (measured at the centre), master leaf (1st - 7th) additional leaf (1st - 6th) 9 8 S Gap between leaves 10 L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load Flexibility with static load after aux. spring action 14.5 mm/kN 3.4 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

Page 751

REAR MECHANICAL SUSPENSIONS 67 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear leaf spring Vehicles: 50 C mm Semi-elliptical springs N o 2 L Spring length (measured at centre of eyes) 1415 ± 4 S Leaf thickness (measured at the centre), master leaf (1st - 4th) additional leaf (1st - 3th) 9 16 S Gap between leaves 10 L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load Flexibility with static load after aux. spring action 19.7 mm/kN 4.9 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0

Page 752

68 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear leaf spring Vehicles: 50 C mm Parabolic springs N o 2 L Spring length (measured at eye centres) 1415 ± 3 S Leaf thickness (measured at the centre) master leaf 22 (24)* S Gap between leaves 3 (10)* L Leaf width 60 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load 5.6 mm/kN D Main leaf eye inner diameter (Bush seat) 40 ± 0.5 D d D = bush outer diameter 40 + 0 − 0.1 d = bush inner diameter 16.5 + 0.2 − 0 (*) Alternatively

Page 753

REAR MECHANICAL SUSPENSIONS 69 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear leaf spring Vehicles: 60 C - 65 C mm Semi-elliptical springs N o 2 L Spring length (measured at centre of eyes) 1415 ± 4 S Leaf thickness (measured at the centre), master leaf (1st - 4th) additional leaf (1st - 2nd) 11 22 S Gap between leaves --L Leaf width 70 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load Flexibility with static load after aux. spring action 9.3 mm/kN 3.1 mm/kN D Main leaf eye inner diameter (Bush seat) 40 + 0.5 − 0.2 D d D = bush outer diameter 40 + 0.02 − 0.07 d = bush inner diameter 16.5 + 0.2 − 0

Page 754

70 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 Rear leaf spring Vehicles: 60 C - 65 C (semi-elliptical with leaf spring) mm Semi-elliptical springs N o 2 L Spring length (measured at centre of eyes) 1415 S Leaf thickness (measured at the centre), master leaf (1st - 10th) auxiliary leaf thickness (1st - 10th) 9 7 S Gap between leaves 9 L Leaf width 70 ± 0.5 CONTROL DATA WITH NEW SPRING: Main spring flexibility with static load Flexibility with static load after aux. spring action 8.5 mm/kN 2.4 mm/kN D Main leaf eye inner diameter (Bush seat) 40 + 0.5 − 0.2 D d D = bush outer diameter 40 + 0.02 − 0.07 d = bush inner diameter 16.5 + 0.2 − 0 (*) Alternatively

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REAR MECHANICAL SUSPENSIONS 71 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear shock absorbers Models: 29 L - 35 S Arvin Meritor Sachs Distance between centre of eyes: Open 505 ± 3 mm 507 ± 3 mm Closed 318 ± 3 mm 317 ± 3 mm Stroke 187 mm 180 mm Models: 35 C - 40 C - 45 C - 50 C Arvin Meritor Sachs Distance between centre of eyes: Open 571 ± 3 mm 565 ± 3 mm Closed 350 ± 3 mm 345 ± 3 mm Stroke 221 mm 220 mm Models: 60 C - 65 C Arvin Meritor Sachs Distance between centre of eyes: Open 564 ± 3 mm 565 ± 3 mm Closed 347 ± 3 mm 345 ± 3 mm Stroke 217 mm 220 mm Rear stabilizer bar Models: 29 L - 35 S 35 C - 40 C * 45 C - 50 C * Vans 45 C - 50 C * Truck Chassis Cabs 60 C - 65 C * Stabilizer bar diameter (mm) 20 20 22 28 * The torsion bar is not provided for the COMBI version.

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72 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 TOOLS TOOL NO. DESCRIPTION 99306064 Hydraulic trolley to support leaf spring during removal and refitting 99321024 Hydraulic trolley for wheel removal and refitting 99370617 Bracket for removal - refitting and/or support of rear axle

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Figure 83 A A B B C C B--B A--A 112213 REAR MECHANICAL SUSPENSIONS 73 D AILY E URO 4 Print 603.93.651 Base - March 2006 TIGHTENING TORQUES Vehicles 29 L - 35 S COMPONENT TORQUE COMPONENT Nm kgm 1 M10 nuts for screws securing leaf spring rear support to chassis 47 ÷ 58 4,7 ÷ 5,8 2 Securing leaf spring and shackle: - M16 screw 160 ÷ 196 16,0 ÷ 19,6 - M16 nut 146 ÷ 178 14,6 ÷ 17,8 3 M16 nut securing shock absorber to chassis 124 ÷ 152 12,4 ÷ 15,2 4 M16 nut securing shock absorber to rear axle 124 ÷ 152 12,4 ÷ 15,2 5 M14 nuts for U bolts securing leaf spring to rear axle 118 ÷ 144 11,8 ÷ 14,4 6 M10 nut securing spring buffer support bracket 47 ÷ 58 4,7 ÷ 5,8 7 Securing articulated connecting rod to upper bracket: - M16x2 screw 137 ÷ 167 13,7 ÷ 16,7 - M16x2 nut 124 ÷ 152 12,4 ÷ 15,2 8 M10x1.5 nut securing bracket for stabiliser bar to rear axle 32 ÷ 39 3,2 ÷ 3,9 9 M10 nut securing bracket for stabiliser bar support shackle 32 ÷ 39 3,2 ÷ 3,9 10 M8 nut securing spring buffer to bracket 16 ÷ 24 1,6 ÷ 2,4

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Figure 84 50814 SECTION A-A SEEN FROM B 74 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 TIGHTENING TORQUES Vehicles 35 C - 40 C - 45 C- 50 C COMPONENT TORQUE COMPONENT Nm kgm 1 M16 nut for screw securing front leaf spring 139 ÷ 170 13.9 ÷ 17 2 Nuts for stands securing leaf spring to the rear axle M 14 M16 74.5 ÷ 91.2 113 ÷ 170 7.4 ÷ 9.1 11.3 ÷ 17 3 M16 nut for screw securing top and bottom shock absorber 124 ÷ 152 12.4 ÷ 15.2 4 M10 nut for screw securing stabilizer bar support cap 26.4 ÷ 35.3 2.6 ÷ 3.5 5 M10 nut for screw joining stabilizer bar anchoring connecting rods 26.4 ÷ 35.3 2.6 ÷ 3.5 6 M16 screw for nut securing connecting rod to mounting 179.4 ÷ 220.6 17.9 ÷ 22 7 M16 screw for nut securing rear leaf spring 139 ÷ 170 13.9 ÷ 17 8 M16 screw for nut securing shackle to rear mounting 139 ÷ 170 13.9 ÷ 17 9 M10 screw for nut securing connecting rod mounting to the chassis frame 43 ÷ 53 4.3 ÷ 5.3 10 M8 screw for nut securing buffer to the chassis frame 26.4 ÷ 35.3 2.6 ÷ 3.5

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Figure 85 62937 REAR MECHANICAL SUSPENSIONS 75 D AILY E URO 4 Print 603.93.651 Base - March 2006 TIGHTENING TORQUES Vehicles 60C - 65C COMPONENT TORQUE COMPONENT Nm kgm 1 Screw for front leaf spring fastening nut 186 ÷ 152 18.6 ÷ 15.2 2 M16 nut for upper and lower shock absorber fastening screw 92 ÷ 74 9.2 ÷ 7.4 3 Nut for stands fastening leaf spring to rear axle 150 ÷ 190 15.3 ÷ 19.3 4 Nut for screw fastening brackets and spacers to stabilizer bar supporting rod 5 Screw for rear leaf spring fastening nut 186 ÷ 152 18.6 ÷ 15.2 6 Screw for nut fastening connecting rods to support 186 ÷ 152 18.6 ÷ 15.2 7 Nut for screw fastening stabilizer bar spacer and rod to support 109.9 ÷ 137.7 11.2 ÷ 14 8 M10 screw for nut fastening support to chassis 26.4 ÷ 32.3 2.7 ÷ 3.3 9 Screw for nut fastening cross member to chassis 71.7 ÷ 87.7 7.3 ÷ 8.9 10 Nut fastening bumper to chassis 49 ÷ 40 4.9 ÷ 4

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Refitting Removal Set the vehicle on level ground. Lock the front wheels with chocks. Loosen the screws securing the rear wheels. Put the bracket 99370617 on a hydraulic lift, position it under the rear axle and lift the vehicle. Rest the chassis frame on stands, keeping the bracket in contact with the rear axle. Take out the nuts securing the wheels with tool 99321024. Take out the nuts (4) and remove the brackets (5) joining the leaf springs (2) to the rear axle. Position the trolley 99306064 under the leaf spring (2) and fasten this to the trolley support with the brackets. Take out the nuts and remove the screw (3) securing the leaf spring (2) to the front mounting (1). Take out the nut and remove the screw (7) securing the leaf spring (2) to the shackle (8) of the rear mounting (9). Lower the trolley 99306064 and extract the leaf spring. Figure 86 REAR SUSPENSION WITH SINGLE-BLADE PARABOLIC LEAF SPRING Check the threads of brackets which fasten the leaf springs to the axle; if they are damaged, re-machine the threads (operation 500412) or replace the brackets. Tighten the nuts to the prescribed driving torque. Following the order shown in the figure. After replacing the leaf springs and the hydraulic shock absorbers, it is necessary to check the efficiency of the braking control and, if necessary, carry out its adjustment (operation 796910. See Braking System Section). To re-fit, carry out the removal operations in reverse, taking the following precautions. Check the conditions of bumpers (6), if they are damaged, replace them (operation 500417). 112177 76 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 REAR LEAF SPRING Vehicles: 29 L - 35 S

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Removal Set the vehicle on level ground. Lock the front wheels with chocks. Loosen the screws securing the rear wheels. Put the bracket 99370617 on a hydraulic lift, position it under the rear axle and lift the vehicle rest the chassis frame on stands, keeping the bracket in contact with the rear axle. Take out the nuts securing the wheels with tool 99321024. Take out the nuts (5) and remove the brackets (4) joining the leaf springs (3) to the rear axle. Position the trolley 99306064 under the leaf spring and fasten this to the trolley support with the brackets. Take out the nut and remove the screw (2) securing the leaf spring (3) to the front mounting (1). Take out the nut and remove the screw (8) securing the leaf spring (3) to the shackle (7) of the rear mounting (6). Operating the hydraulic lift, lower the rear axle to be able to remove the centring setscrew of the leaf spring from it and extract the leaf spring. ! When lowering the rear axle, make sure the brake system pipes are not put under strain. Figure 87 REAR SUSPENSION WITH SEMI-ELLIPTICAL LEAF SPRING Check the threads of brackets which fasten the leaf springs to the axle; if they are damaged, re-machine the threads (operation 500412) or replace the brackets. Check the conditions of bumpers (9), if they are damaged, replace them. Tighten the nuts to the prescribed driving torque. Following the order shown in the figure. After replacing the leaf springs and the hydraulic shock absorbers, it is necessary to check the efficiency of the braking control and, if necessary, carry out its adjustment (operation 796910. See Braking System Section). Refitting To re-fit, carry out the removal operations in reverse, taking the following precautions. 50973 REAR MECHANICAL SUSPENSIONS 77 D AILY E URO 4 Print 603.93.651 Base - March 2006 Vehicles: 35 C - 40 C - 45 C - 50 C - 60 C - 65 C

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Assembling the leaf spring Ensure that the leaf contact surfaces are perfectly smooth and clean. Before re-assembling the leaves, grease contact surfaces with a little of CA IG Grease. Re-assemble the pack as follows (see Figure 88): -place the main leaf (1) with the end eyes in the end pin of the 1st leaf (4); -place the other leaves, included the one with the clip (5), near the former ones, rest them on one side and align them in the bench vice; -insert through the central hole of the leaves, the central pin (7), then lock the pack in the vice; -insert the nut (2) on the central pin (7) and lock; -close the two side retaining clamps (5) by folding the ends back as shown in the figure. Side clips (5) fastened with a rivet (6) to the leaf, can be re-used, provided that they do not show signs of breakage when they are re-bent to hold the pack. In this case, it is necessary to replace them with new ones to be fixed to the leaf with new rivets. Place the leaf spring in the vice of the suitable bench, clamping it near the central pin; remove the relevant nut and extract the central coupling pin. Unscrew the fastening nut (2) of the central pin (7) and extract the pin. Open the pack side clips (5), lifting the two ends that are bent on the main leaf. Open the vice and disassemble the leaf spring. Disassembling the leaf spring 19075 Figure 88 Leaf springs must be disassembled only Figure 88 if it is necessary to replace the main leaf (1) or the first leaf (4), in this case go on as follows. In case other leaves are broken or yielded, replace the whole leaf spring. 19074 ! Checks Carefully clean, with diesel oil or solvent, all components; ensure that the bushes are firmly driven in the spring eyes and shackles. Check that the internal surface is not ovalized and that the pins are not worn or strained, in case they are, replace them. Figure 89 500454 Replacing the bushings 1 2 3 4 5 6 7 The leaf spring bushings (3) are replaced with the hydraulic press and a suitable punch. NOTE 78 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 REPAIRS

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Refitting To re-fit shock absorbers carry out the removal operations in reverse and comply with the prescribed torques. Removal REAR AXLE SHOCK ABSORBERS VEHICLES 29 L - 35 S Figure 90 REAR AXLE SHOCK ABSORBERS VEHICLES 35 C - 65 C Figure 91 50977 Remove the shock absorber (1) extracting the upper and lower fastening nuts or bolts ( ⇐ ) of the shock absorber. 112214 REAR MECHANICAL SUSPENSIONS 79 D AILY E URO 4 Print 603.93.651 Base - March 2006 500940 REAR SHOCK ABSORBERS

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Check that the bushings and/or flexible parts are not worn or deteriorated, if they are, replace them. Refitting For refitting, carry out the removal operations in reverse and comply with the prescribed torques. Removal REAR STABILIZER BAR VEHICLES 29 L - 35 S Figure 92 REAR STABILIZER BAR VEHICLES 35 C - 65 C Figure 93 50978 Remove stabilizer bar (3) from its attachment points by removing nuts (4) and screws (1) together with the fastening nuts, then release the bar from articulated rod (2). 112215 NOTE 80 REAR MECHANICAL SUSPENSIONS D AILY E URO 4 Base - March 2006 Print 603.93.651 528960 STABILIZER BAR

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REAR AIR SUSPENSIONS 81 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear air suspensions Page DIAGNOSTIC 83 . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PNEUMATIC SUSPENSIONS - WABCO TYPE (for R 29L - 35S vehicles) 84 . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA 85 . . . . . . . . . . . . . -Air system components 85 . . . . . . . . . . . . . . . . . -Rear leaf spring 86 . . . . . . . . . . . . . . . . . . . . . . . . -Rear shock absorbers 86 . . . . . . . . . . . . . . . . . . . -Stabilizer bar 86 . . . . . . . . . . . . . . . . . . . . . . . . . . -Levelling and height values 86 . . . . . . . . . . . . . . . ELECTRIC SYSTEM WABCO (ECAS) 87 . . . . . . . . PNEUMATIC SYSTEM WABCO (ECAS) 88 . . . . . . PNEUMATIC SYSTEM ON VEHICLE 89 . . . . . . . . -Vehicles without ABS 89 . . . . . . . . . . . . . . . . . . . -Vehicles with ABS 90 . . . . . . . . . . . . . . . . . . . . . . CHASSIS SELF-LEVELLING, LIFTING AND LOWERING 91 . . . . . . . . . . . . . . . . . . . . . . . . . . -Operation 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN SYSTEM COMPONENTS 91 . . . . . . . . . . . . PNEUMATIC SUPPLY UNIT 91 . . . . . . . . . . . . . . . -Specifications and data 91 . . . . . . . . . . . . . . . . . . ELECTRONIC CONTROL UNIT 91 . . . . . . . . . . . . -ECU programming/setting 92 . . . . . . . . . . . . . . . . LEVEL SENSOR 92 . . . . . . . . . . . . . . . . . . . . . . . . . -Level sensor replacement 92 . . . . . . . . . . . . . . . . -Removal 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Level sensor adjustment 92 . . . . . . . . . . . . . . . . . AIR SPRING 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Air spring replacement 93 . . . . . . . . . . . . . . . . . . -Removal 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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82 REAR AIR SUSPENSIONS D AILY E URO 4 Print 603.93.651 Base - March 2006 Page LOAD SENSING VALVE 93 . . . . . . . . . . . . . . . . . . -Load sensing valve replacement 94 . . . . . . . . . . . . -Removal 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Load sensing valve adjustment on vehicle 94 . . . . REAR SUSPENSION OVERHAUL 95 . . . . . . . . . . . LEAF SPRING 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBERS 95 . . . . . . . . . . . . . . . . -Removal 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR STABILIZER BAR 95 . . . . . . . . . . . . . . . . . . . -Removal 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANHARD REACTION BAR 96 . . . . . . . . . . . . . . . -Removal 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Pneumatic system pipe leaks or breakage. NO 1 POOR OR IRREGULAR PNEUMATIC SYSTEM SUPPLY Tighten or replace loosen or damaged connections. Replace broken or damaged pipes. Electrocompressor malfunctioning. Overhaul or replace. Pneumatic suspension main failures: 1 -Poor or irregular pneumatic system supply; 2 -Vehicle irregular conditions. 2 YES NO Pneumatic system pipe leaks or breakage. Tighten or replace loosen or damaged connections. Replace broken or damaged pipes. Faulty pneumatic and/or electric connections. Find and reset faulty connections. YES Level sensor malfunctioning. Adjust levers and replace level sensor if required. NO YES ECU malfunctioning. Replace ECU. NO VEHICLE IRREGULAR CONDITIONS YES YES YES REAR AIR SUSPENSIONS 83 D AILY E URO 4 Print 603.93.651 Base - March 2006 DIAGNOSTIC Print 603.93.281

Page 768

These pneumatic suspensions show high flexibility and significant vibration damping. Their main characteristic is that the distance between chassis and road level, irrespectively of vehicle load, remains constant due to the effect of the automatic adjustment of the system. Electronic-control pneumatic suspensions are activated automatically when starting the vehicle. Electronic-control pneumatic suspensions enable, through the proper push buttons located in the cab, to change manually the distance between chassis and road level and therefore the height of the vehicle load bed. The following two types of pneumatic suspensions are currently adopted: -WABCO pneumatic suspensions for 29L - 35S vehicles -Streparava pneumatic suspensions for 35C - 40C - 45C -50C - 60C - 65C vehicles. PNEUMATIC SUSPENSIONS - WABCO TYPE (for 29L - 35S vehicles) WABCO system in addition to known advantages offered by pneumatic suspension, enables the following: -significant air consumption reduction; -ready response to the different adjustment processes; -friendly systems; -high safety performance; -complete system diagnostic. The WABCO system controls automatically the rated level of vehicle pneumatic suspensions. The above mentioned operations are bound to preset operating conditions and to the relevant system safety requirements. The ECU controls automatically the chassis level (distance from road level), through the real values provided by sensors and compares these values to the rated ones stored in its memory. If the driving position is changed, the electronic control unit governs the electro-pneumatic assemblies, by means of which the actual level is corrected in relation to the nominal level set or saved by the driver. Figure 94 62350 84 REAR AIR SUSPENSIONS D AILY E URO 4 Print 603.93.651 Base - March 2006 GENERAL

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Figure 95 62349 REAR AIR SUSPENSIONS 85 D AILY E URO 4 Print 603.93.651 Base - March 2006 SPECIFICATIONS AND DATA Air system components COMPONENT Pneumatic supply unit -Type: WABCO 415 403 402 0 Operating temperature Max. operating pressure Rated voltage Pressure control - 30ºC to 65ºC 12.7 bar 12V DC 14 to 17.1 bar Level sensors -Type: WABCO 441 050 012 0 ECU -Type: WABCO 446 055 450 0 Rated voltage 12V Double circuit load sensing valve (vehicles without ABS) -Type : BOSCH NM/FV/98-347 (ref. 796803) Ratio 0.15 Pneumatic actuator -Type : ELLENA EE6492 Operating temperature Operating pressure - 20ºC to 80ºC max 8 bar Air tank (litres) 31 Rear air spring (Mod. 29 L - 35 S) Max. diameter Min. length Max. length 171 mm 350 mm 150 mm

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86 REAR AIR SUSPENSIONS D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear leaf spring mm N o 2 Spring length (measured between eye centre and air spring connection) 1073 ± 6 Leaf thickness (measured at the securing point to rear axle) 24 ± 0.3 Leaf width 80 ± 0.5 Bush seat inner diameter 40 - 0,05 - 0,2 D = bush outer diameter 40.2 -0 - 0.15 d = bush inner diameter 16.5 + 0.2 − 0 Rear shock absorbers Mannesmann Sachs ARVIN MERITOR Length between eye centres: Open mm 460 ± 3 460 ± 3 480 ± 3 Closed mm 315 ± 3 315 ± 3 315 ± 3 Stroke mm 145 145 165 Stabilizer bar Models: 29 L - 35 S Stabilizer bar diameter (mm) 20 Levelling and height values Suspension condition Distance between upper chassis edge and road level (mm) Max. distance (mm) Max. height 620 + 40 Self-levelling 580 -Min. height 520 - 60

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Figure 96 20000 Battery 25926 Relay for enabling suspension lifting and stopping the lowering function 25927 Relay for enabling suspension lowering and stopping the lifting function 42354 Pneumatic suspension system failure switch 52090 Suspension levelling switch 52502 Key switch 53051 Suspension lifting control switch 53052 Suspension lowering control switch 58713 Failure warning led 58918 Board with 32 optical indications plus instruments 78233 Vehicle lifting solenoid valve unit 86023 Vehicle lifting/lowering control unit Legend 61099 REAR AIR SUSPENSIONS 87 D AILY E URO 4 Print 603.93.651 Base - March 2006 ELECTRIC SYSTEM WABCO (ECAS)

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Figure 97 1 -ECU (ECAS). 2 -Manual chassis levelling control switch. 3 -Chassis lifting control switch. 4 -Chassis lowering control switch. 5 -Warning light ECAS. 6 -Stop light switch. 7 -Speedometer - tachograph. 8 -Right air spring. 9 -Right level sensor. 10 -Hydraulic load sensing valve*. 11 -Load sensing valve control pneumatic cylinder*. 12 -Left level sensor. 13 -Left air spring. 14 -Electrocompressor and distribution valve unit. 15 -Right chassis control solenoid valve. 16 -Left chassis control solenoid valve. 17 -Choke valve. 18 -Drier filter 19 -Air spring discharge solenoid valve. 20 -One-way valve. 21 -Compressor. 22 -One-way valve 23 -Intake filter. 24 -Compressor motor 25 -Motor control relay 26 -Diagnosis socket * For vehicles without ABS only. Legend 000216T Electronic-control Vehicles: 29 L - 35 S 88 REAR AIR SUSPENSIONS D AILY E URO 4 Print 603.93.651 Base - March 2006 PNEUMATIC SYSTEM WABCO (ECAS)

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Figure 98 1 - Warning light 2 - Right level sensor 3 - Right air spring 4 - Chassis lowering control button 5 - Manual chassis levelling control button 6 - Electronic control unit 7 - Chassis lifting control button 8 - Hydraulic brake corrector 9 - Corrector control pneumatic cylinder 10 - Left air spring 11 - Pneumatic feeding unit 12 - Left level sensor 13 - Central diagnosis connector Legend 112174 REAR AIR SUSPENSIONS 89 D AILY E URO 4 Print 603.93.651 Base - March 2006 Print 603.93.281 PNEUMATIC SYSTEM ON VEHICLE Vehicles without ABS

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Figure 99 1 - Warning light 2 - Right level sensor 3 - Right air spring 4 - Chassis lowering control button 5 - Manual chassis levelling control button 6 - Electronic control unit 7 - Chassis lifting control button 8 - Left air spring 9 - Pneumatic feeding unit 10 - Left level sensor 11 - Central diagnosis connector Legend 112175 90 REAR AIR SUSPENSIONS D AILY E URO 4 Print 603.93.651 Base - March 2006 Vehicles with ABS

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The system consists of the following: -Pneumatic supply unit (electrocompressor, solenoid valve unit); -One ECU; -Two level sensors; -Two air springs; -Three levelling push buttons (1, 2, 3); -One warning light (4). Level sensors send to ECU the signals corresponding to chassis-road distance. The ECU processes these signals, generates accordingly activation signals and sends them to the electrocompressor. Turn the ignition key to ”MAR” and depress push buttons (1, 2, 3) for lifting, lowering or activating the self-levelling function of the chassis. This system enables vehicle running up to 20 km/h under whatever height and level condition. When this speed is exceeded, chassis automatic levelling is activated. Variation operations are indicated by warning light (4) blinking. 62356 This unit produces the compressed air required to supply the pneumatic system and enables to bleed air from the pneumatic system to lower the load bed. 62357 The ECU is the mastermind of the system. It controls every logic function of suspensions under both static and dynamic stage. ECU receives signals from the control switches set in the cab and lifts and lowers the load bed accordingly. It also receives signals from the level sensors and controls the electrocompressor and the air spring to keep the vehicle in the self-levelling condition. ECU indicates any system failure through the dedicated warning light set on the instrument panel. Figure 100 Operation MAIN SYSTEM COMPONENTS 790560 PNEUMATIC SUPPLY UNIT Specifications and data Type Wabco Lubrication Dry operation Max. operating pressure 12.7 bar Operating temperature -30 C ° to 65 ° C Rated voltage 12V DC Figure 101 Figure 102 766175 ELECTRONIC CONTROL UNIT CHASSIS SELF-LEVELLING, LIFTING AND LOWERING 112176 REAR AIR SUSPENSIONS 91 D AILY E URO 4 Print 603.93.651 Base - March 2006

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62460 Disconnect the electrical connection (2), loosen the screw ( ⇒ ) and disconnect the levers. Loosen the fastening screws and remove the level sensor (1). 62584 Operate on adjustment screws and set relay lever X value to 110 mm. Perform ECU setting as shown in the relevant paragraphs ”ECU programming/setting”. Figure 103 ECU programming/setting WABCO ECU is not requiring programming since it is supplied already programmed. Setting can be performed by MODUS, E.A.SY. and IT2000 diagnostic systems and shall be performed when replacing the following: -ECU; -level sensor; -level sensor levers. Connect the diagnostic tool to the 38-pin socket and proceed as follows to obtain correct setting: -check and adjust to 110 mm the level sensor lever length, if required; -lift the chassis by depressing the proper video push button (max. lifting); -Insert the special spacers provided (99346151) between the chassis and the rear axle measuring 65 mm; -lower the chassis completely by depressing the proper video push button (max.lowering); -set ECU by depressing the proper video push button. 62358 Level sensors inform constantly the ECU on distance changes between chassis and road level. Level sensors consists of a coil secured to the chassis and a small piston. When chassis height changes, a cam and a lever linked to the axle make the piston move inside the coil, thus modifying its inductance. These changes will be used by the ECU in the different stages of the system. 768822 LEVEL SENSOR Figure 104 Figure 105 Level sensor replacement Removal Refitting Reverse removal operations to perform refitting. Perform level sensor and ECU setting as shown in the relevant paragraphs ”ECU programming/setting” and ”Level sensor adjustment”. Level sensor adjustment Revi - February 2005 92 REAR AIR SUSPENSIONS D AILY E URO 4 Print 603.93.651 Base - March 2006 Print 603.93.281/A

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62361 Vehicles not fitted with ABS/EBS/ABD systems have been provided with the following components to obtain brakeforce distribution: -double circuit load sensing valve; -load sensing valve pneumatic actuator. The load sensing valve controls automatically the braking torque produced by brakes on the rear axle, according to the load applied on the rear axle, measured and transferred to the load sensing valve of the pneumatic actuator. The following diagram shows the brakeforce distribution ratio corresponding to 0.15 as a function of pneumatic pressure change inside air springs. Figure 106 Air spring is an elastic element dedicated to contain pressure air and to change its extension irrespectively of the applied load. 62360 Position the vehicle on level ground. Lift the rear part of the vehicle and rest the chassis on the proper stands. Use the hydraulic jack to support the rear axle. Bleed the system and disconnect the air spring (3) supply pipe (2). Loosen upper (1) and lower fastening nuts. Lower the rear axle and remove the air spring (3). Air spring replacement Removal Figure 107 Figure 108 Figure 109 500731 AIR SPRING Refitting Reverse removal operations to perform refitting. 784310 LOAD SENSING VALVE Legend A Hydraulic output pressure in bar; B Hydraulic control pressure in bar; C Pneumatic control pressure in bar; D Characteristic curves, 0.15 ratio (without load); E 1:1 ratio (with load); F Pneumatic pressure/load characteristic curves. 62359 62362 REAR AIR SUSPENSIONS 93 D AILY E URO 4 Print 603.93.651 Base - March 2006 Print 603.93.281

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62578 -Loosen nut (1); -apply 5 kg to plate (3) in point (2); -start engine; -disconnect the pneumatic actuator (4); -with engine running at idle, depress the brake pedal gradually until obtaining 100 bar pressure read on the gauge set upstream connector. This value shall be constant and shall be read on vehicle with load and without load; -simulate the fully laden condition by lifting completely the relay lever (3) and the unloaded condition by lowering the lever completely; -read output pressure value under both vehicle conditions (laden and unloaded); obtained values shall comply with those indicated on the plate, otherwise replace the load sensing valve; -operate the relay lever (3) to check whether the load sensing valve piston is sliding smoothly into its seat, otherwise replace the load sensing valve; -reconnect the pneumatic actuator (4); -load the vehicle to obtain 1500 kg weight on the rear axle evenly distributed on the right and left side of the vehicle with ± 5 kg tolerance; -with engine running at idle and 100 bar pressure read on the gauge set upstream the connector, check whether the output pressure value read on the gauge set downstream the connector is corresponding to the values indicated on the plate, otherwise replace the load sensing valve; -stop the vehicle, tighten nut (1) to the specified torque and remove applied loads. Figure 110 Bleed the system, loosen the screws (3) and disconnect the pneumatic actuator (2). Loosen the fastening screws of the load sensing valve (1) and remove it including the pneumatic actuator (2). Load sensing valve replacement Removal Figure 111 Figure 112 Refitting Reverse removal operations to perform refitting. Perform load sensing valve adjustment as shown in the relevant paragraphs ”Load sensing valve adjustment on vehicle”. 62433 Load sensing valve adjustment on vehicle This device shall be checked and adjusted, if required, at regular intervals by checking the values indicated on the plate (Figure 111) located on the internal part of the engine hood. ! Should the plate or the relevant technical data be missing, ask the manufacturer for a duplicate specifying the following: -Vehicle type and wheelbase -Rear axle weight -Load sensing valve No. Perform required operations in the following sequence: -position the vehicle with the rear wheels set on the brake test bed 99336914; -connect gauges 99372269 or Modus to pressure control intakes set upstream and downstream connector; -should gauges not be fitted with valves for automatic bleeding, bleed air by loosening the suitable ring nuts ! Perform this check with gradually increasing pressure. To check the load sensing valve, every braking system component shall be in perfect operating conditions. When replacing the leaf spring for special set-up, a new plate is required with properly corrected values. -when tests are over, check brake performance. 62577 LOAD SENSING VALVE PLATE 94 REAR AIR SUSPENSIONS D AILY E URO 4 Print 603.93.651 Base - March 2006

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62365 Figure 113 Position the vehicle on level ground. Lift the rear part of the vehicle and rest the chassis on the proper stands. Use the hydraulic jack to support the rear axle. Bleed the system, remove the wheel, loosen the air spring lower fastening screw (1). Loosen shock absorber lower fastening nut (3) and disconnect it. Loosen nuts (2) and remove the U bolts (4) and the elements securing the leaf spring to the rear axle. Loosen and remove the pin (6) and remove the leaf spring (5). Figure 114 Figure 115 62363 500450 LEAF SPRING Removal 500940 REAR SHOCK ABSORBERS Removal Lift the rear part of the vehicle and use the jack to support the rear axle. Loosen the upper (3) and the lower (1) fastening nuts and remove the shock absorber (2). Refitting Reverse removal operations to perform refitting. Refitting Reverse removal operations to perform refitting. Refitting Reverse removal operations to perform refitting. 528960 REAR STABILIZER BAR Removal 62364 Operate on both vehicle sides. Loosen the screws (1) and the nut (3). Remove the stabilizer bar (4) including the joints (2). REAR AIR SUSPENSIONS 95 D AILY E URO 4 Print 603.93.651 Base - March 2006 500730 REAR SUSPENSION OVERHAUL

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62368 Figure 116 PANHARD REACTION BAR Removal Refitting Reverse removal operations to perform refitting. Loosen the ”Panhard” reaction bar (4) fastening screws (3 and 5) and remove it. Loosen the relay rod (2) fastening screws (1 and 6) and remove it. 96 REAR AIR SUSPENSIONS D AILY E URO 4 Print 603.93.651 Base - March 2006

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WHEEL AND TYRES 1 D AILY E URO 4 Print 603.93.651 Base - March 2006 SECTION 9 5025 Wheel and tyres Page DESCRIPTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . -Tyre pressure 4 . . . . . . . . . . . . . . . . . . . . . . . . . TOOLS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAULT DIAGNOSIS 5 . . . . . . . . . . . . . . . . . . . . . . STATIC BALANCING OF THE WHEELS 8 . . . . . . TYRE PRESSURE 9 . . . . . . . . . . . . . . . . . . . . . . . . . HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE 9 . . . . . . . . . . . . . . . . . . . . . . . .

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2 WHEEL AND TYRES D AILY E URO 4 Base - March 2006 Print 603.93.651

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The wheel rim represents the rigid structure of the wheel and is identified by the following dimensions: -diameter of the rim, measured at the base of the circumferential groove (i.e., on the surface on which the air chamber rests); -width of the circumferential groove in the wheel rim (i.e., the distance between the surfaces on which the cover rests). The tyre has the following functions: -to absorb the greater part of the jolts caused by roughness of the road surface by utilising the elasticity of air; -to generate on the ground the motive force supplied by the engine necessary for the vehicle to move; -to ensure the maximum grip and stability of contact between the tyre and the road, with satisfactory tyre life; -to withstand the forces generated by sudden braking, hard acceleration and by the thrust of centrifugal force on bends; -to ensure the stability of the vehicle even at high speeds; to ensure the steerability of the vehicle. 44928 Figure 1 1. Tyre section rated width (mm) 2. Tyre height-width ratio percentage e.g., H/S = 0,75 3. Tyre structure (R = Radial) 4. Wheel rim diameter in inches 5. Load and speed index symbols 113: tyre load index on simple axis: 1150 kg 111: tyre load index on paired axis: 1090kg Speed category (N= 140 km/h) 6. Manufacturer’s trade name: XC A tubeless (IL): tyres without inner tube. 44929 Figure 2 S = Tyre section rated width (mm) H = Tyre height D = Max. utilisation diameter (Rx2) R = Radius under load (static) Ø = Fitting diameter E = Min. distance between centres in case of paired tyres e = Tyre deflection CdR = Rolling circumference WHEEL AND TYRES 3 D AILY E URO 4 Print 603.93.651 Base - March 2006 DESCRIPTION

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4 WHEEL AND TYRES D AILY E URO 4 Base - March 2006 Print 603.93.651 Tyre pressure Tyre type Inflation pressure Tyre type 3,5 bar 4 bar 4,75 bar 195/65 R16 simple weight on front axle in kg 1410 1569 1800 TL102/104R TL102/104Q twin weight on front axle in kg 2663 2963 3400 195/75 R16 simple weight on front axle in kg 1527 1700 1950 TL105/107R TL105/107Q twin weight on front axle in kg 2898 3225 3700 205/65 R16 simple weight on front axle in kg 1527 1700 1950 TL105/107T twin weight on front axle in kg 2898 3225 3700 215/65 R16 simple weight on front axle in kg 1613 1795 2060 TL107/109R twin weight on front axle in kg 3055 3399 3900 225/65 R16 simple weight on front axle in kg 1754 1952 2240 TL110/112R twin weight on front axle in kg 3321 3695 4240 Tyre type Inflation pressure Tyre type 4 bar 4,5 bar 5,25 bar 225/75 R16 simple weight on front axle in kg 2124 2334 2640 TL116/118Q TL116/118R twin weight on front axle in kg 4022 4420 5000 The pressures indicated refer to cold tyres and an outside temperature of 20ºC. NOTE

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WHEEL AND TYRES 5 D AILY E URO 4 Print 603.93.651 Base - March 2006 TOOLS TOOL NO. DESCRIPTION 99305037 Electronic equipment for front wheel balancing on the vehicle FAULT DIAGNOSIS Main tyre malfunctions: 1 -Excessive wear. 2 -Irregular wear. 3 -Wehicle pulls to one side. 1 Excessive speed on particularly uneven ground Tyres pressures too high Reduce pressures Sudden variations in speed, violent or harsh braking Avoid all unnecessary acceleration or braking Excessive speed with tyre pressures too low Check tyre pressures cold Truck overloaded Consult data on loads permitted NO NO YES NO YES NO YES YES YES Reduce speed EXCESSIVE WEAR

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6 WHEEL AND TYRES D AILY E URO 4 Base - March 2006 Print 603.93.651 Difference in tyre pressures between one pair of wheels and the other Check pressure NO YES Tyre pressures too low; wear moreaccentuated onthe outsides of the tread than in the middle Increase tyre pressure NO YES Tyre pressure too high, with excessive wear in the middle of the tread Reduce pressure NO YES Insufficient toe-in of front wheels; substantial wear on the inside surfaces of the tread Check and adjust toe-in NO YES Front wheel geometry incorrect Restore normal wheel geometry NO YES Distortion of wheel rims causing imbalance If possible, repair the rims or replace; then balance the wheels Tyres incorrectly fitted to rims Fit the tyre correctly and balance the wheel NO YES YES 2 IRREGULAR WEAR

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WHEEL AND TYRES 7 D AILY E URO 4 Print 603.93.651 Base - March 2006 Rear axle out of parallel due to breakage of the leaf spring centre pin, or springs of different lengths, or bent springs Overhaul the suspension YES 3 VEHICLE PULLS TO ONE SIDE Front wheels out of balance Balance the wheels NO YES Front tyres at different pressures Check pressures ensuring that both are at the correct value NO YES Excessive difference in wear between a pair of tyres Replace excessively worn tyre YES Excessive toe-in of front wheels; excessive wear of the outside surfaces of the tread Check and adjust toe-in NO YES

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Turn up the spin switch (6) to the second speed and place the balancing machine against the tyre. While the wheel is being spun, it will be found that the stroboscopic effect on the wheel will make the reference mark appear stationary; the pointer of the instrument (1), moving from the value zero, reaches a maximum value on the scale and then returns to zero. When the pointer has begun to fall back, withdraw the balancing machine, turn off the spin-up switch (6) completely and brake the motor by means of the brake lever (7). The wheel continues to revolve due to inertia and the reference mark made on the tyre moves; the point to which the reference mark has moved should therefore be noted. Read off from the instrument (1) the value shown by the pointer, multiply it by 10, giving the value of the balance weight to be fitted to the rim. The front wheels can be balanced on the vehicle using the electronic unit 99305037; this has the advantage of balancing the wheel together with the other rotating masses. The operation must be carried out as follows: -Raise the front of the vehicle and make sure that the wheels are free to rotate -Position the imbalance detector (1) under the axle close to the wheel being examined, arranging the height so that the spin-up wheel of unit 99305037 (2) is in contact with the tyre; position a support stand under the opposite side of the axle and lower the hydraulic jack. 16998 Figure 3 Figure 4 23885 Figure 5 -Connect the cable (3) of the imbalance detector to unit 99305037 -Make a reference mark on the tyre by drawing a radial mark with chalk or using a strip of gummed paper -Turn switch (2) to the static balancing position and sensitivity switch (4) to notch no. 5 on the graduated scale -Turn on switch (5) for instrument light (1) and strobe lamp switch (8). -Turn the spin-up switch (6) of unit 99305037 to the first speed position so as to make the wheel rotate. 16997 Fit the balance weight calculated in this way as shown in the figure. If during the test, the pointer of the instrument (1, Fig. 4) remains in the green area of the box, the wheel is balanced. To correct the residual imbalance, repeat the operations already carried out as above; depending on the new reading of the instrument (1, Fig. 4), refer to the diagram in the figure and proceed as follows to adjust: Figure 6 If the weight required to balance the wheel is more than 60 ÷ 80 grams, divide the weight in half and position the two parts so formed with one half on the inside and one half on the outside of the rim, making sure that they are in the same position. NOTE 8 WHEEL AND TYRES D AILY E URO 4 Base - March 2006 Print 603.93.651 502511 STATIC WHEEL BALANCING

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-If the weight is in the zone marked with the letter A, this means that it is too light, and in that case weight must be added as indicated by the instrument (1, Fig. 4). -If the weight is in the bottom zone marked with the letter C, this means that it is too heavy and in that case the weight must be reduced as shown by the measuring instrument. -If the weight is found to be in the zones marked with the letters B or D, do not remove or add any weight but instead move it 5 cm upwards in the direction of the arrows, see Fig. 6. 502510 TYRE PRESSURE The tyre pressures must be checked with the tyres cold. Take great care that the pressure is correct since, if it is higher than required, a harsh ride and excessive wear of the centre of the tread will result, while if it is lower, the load is not distributed over the whole tread but is concentrated at either side, causing premature wear of these areas and also damaging the internal structure of the tyre. Unequal pressures between tyres affects the driving stability of the vehicle and impairs operating safety. Tyre abnormal wear can occur in different areas of tread. HOW TYRE BEHAVIOUR DEPENDS ON PRESSURE Schematic views to demonstrate how tyre behaviour and performance depend on pressure. Figure 7 Figure 8 Figure 9 - 40% EFFICIENCY 40% + 20% EFFICIENCY 90% EFFICIENCY 100% CORRECT The value shown inside each tyre indicates the level of pressure of the tyre, while the efficiency relates to the life of the tyre. NOTE WHEEL AND TYRES 9 D AILY E URO 4 Print 603.93.651 Base - March 2006

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10 WHEEL AND TYRES D AILY E URO 4 Base - March 2006 Print 603.93.651

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STEERING GEAR 1 D AILY E URO 4 Print 603.93.651 Base - March 2006 SECTION 10 5014 Steering gear Page STEERING GEAR 3 . . . . . . . . . . . . . . . . . . . . . . . . -General 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING SPECIFICATIONS AND DATA 4 -Steering gear 4 . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 5 . . . . . . . . . . . . . . . . . SPECIFIC TOOLS 5 . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTICS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING 11 . . . . . . . . . . . . . . . . . . . . . . -Description 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING TYPE TRW 12 . . . . . . . . . . . . . -Operation 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING TYPE ZF 14 . . . . . . . . . . . . . . . -Operation 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKS AND OPERATIONS ON THE VEHICLE 16 -Checking maximum pressure 16 . . . . . . . . . . . . . . -Checking hydraulic steering centre (for ”ZF” power steering only) 16 . . . . . . . . . . . . -Bleeding the air from the hydraulic system 16 . . . . SWIVEL HEADS 16 . . . . . . . . . . . . . . . . . . . . . . . . . PROTECTION CASINGS 16 . . . . . . . . . . . . . . . . . . STEERING GEAR CONTROL 16 . . . . . . . . . . . . . . -Vehicles equipped with an Air-Bag 16 . . . . . . . . . . SAFETY STANDARDS TO BE OBSERVED DURING REPAIR OR MAINTENANCE OPE- RATIONS ON VEHICLES EQUIPPED WITH AIR-BAG SYSTEM PROVIDED BY SUPPLIER 17 . . . . . . . . . . . . . . . . -Preliminary Standards 17 . . . . . . . . . . . . . . . . . . . . -Repairs and inspections required after an accident 17 -Accidents with or without Air-Bag module activation 17 . . . . . . . . . . . . . . . . . . . . . .

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2 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651 Page -Accidents with Air-Bag module activation 17 . . . . -Painting 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Risks for health 18 . . . . . . . . . . . . . . . . . . . . . . . . -Overexposure effects 18 . . . . . . . . . . . . . . . . . . . -Safety Standards to observe when handling Air-Bag modules 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Air-Bag module scrapping 19 . . . . . . . . . . . . . . . . -Safety Standards to observe when handling pretensioners 19 . . . . . . . . . . . . . . . . . . . . . . . . . -Pretensioners scrapping 20 . . . . . . . . . . . . . . . . . . -Operations on system components 20 . . . . . . . . -Removing and scrapping activated Air-Bag module and pretensioner from vehicle 20 . . . . . . . . . . . . . -Removing and scrapping non-activated Air-Bag module from a repairable vehicle 20 . . . . . . . . . . -Air-Bag module deployment Remote activation 21 . . . . . . . . . . . . . . . . . . . . . . -Activating Air-Bag modules and electronic pretensioners installed on unrecoverable vehicles 21 -Upper steering gear shaft removal 23 . . . . . . . . . . -For vehicles equipped with Air-Bag 23 . . . . . . . . . -For all vehicles 23 . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Lower steering gear shaft removal 24 . . . . . . . . . . -Refitting 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC POWER STEERING 25 . . . . . . . . . . . . . -Hydraulic power steering removal 25 . . . . . . . . . . -Refitting 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Steering linkage replacement 26 . . . . . . . . . . . . . -Removal 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Rubber bushing replacement procedure 26 . . . . . POWER STEERING PUMP 28 . . . . . . . . . . . . . . . . . . . -Power steering pump overhaul procedure 28 . . .

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It has two functions: -angle driving between spin axis of the steering control and the wheels’ steering axis. -gear down through the coupling ratio the resistant moment opposing the wheels under the steering effect. The value of this ratio and the wheel geometry characteristics (toe-in - camber - caster), determine the stress and the type of steering, more or less direct; this increases or decreases the driver sensitivity of the vehicle attitude on road; besides, it determines the steering caster action degree, that is, the spontaneous return to straight normal running when the steering wheel is released after steering. The tie rods joining the steering levers mounted on stub axles using knuckle heads are joined by ball joints at the end of the rack rod. Operating the tie rod the wheel camber is adjusted. The hydraulic pump is of the blade type: - on F1A engines, it is flanged to the alternator support; -on F1C engines, it is flanged onthe leftside ofthe enginebase. The pump incorporates the overpressure control valve. STEERING GEAR General Generally, the steering gear members consist of: a full steering gear control, a steering box, the linkage joining the driving wheels and, for the hydraulic-type steering box of: an hydraulic pump, an oil tank and oil piping. In vehicle system 35C-65C with F1C engine, there is installed a pipe coil (A) to cool oil. The rotary movement given to the steering wheel by the driver is transmitted to the steering box by three shafts joined one another by universal joints. The universal joints allow the transmission of the rotary movement on different planes. The upper shaft, on which the steering wheel is keyed, is housed and supported in the upper support by elastic bushes. In addition, the indicator automatic switch-off and the antitheft steering lock are keyed to the support. The steering box is of the type: pinion - rack rod with hydraulic power. 88735 Figure 1 STEERING GEAR DIAGRAM STEERING GEAR 3 D AILY E URO 4 Print 603.93.651 Base - March 2006

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4 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651 POWER STEERING SPECIFICATIONS AND DATA Steering gear Steering gear Hydraulic Hydraulic power steering Pinion and rack type Type ZF* TRW Operating pressure X 100 bar Maximum delivery volume -No. of steering wheel turns 3,8 R k l i b h i di i 180 1 5 Rack travel in both steering directions: 180  1 5 mm Rack travel in both steering directions: 180  1,5 mm Rack travel in both steering directions: 180  1,5 mm Type TEXAND F020 SHELL-ALVANIA LS00 Lube oil pinion side kg -0,060 pipe end side kg -0,030 Power steering pump blade type with pressure relief valve incorporated Motor FIA FIC Type ZF 7612 955117 ZF 7682 955133 Minimum RGM rpm 500 750 Maximum RGM rpm 8500 3500 Maximum pressure bar 100 + 10 115+10 Minimum delivery dm 3 /min --Adjusted delivery dm 3 /min 9 ± 0,75 9 ± 0,8 Turning circle (theoretical value) [m] Wheelbase [mm] MODELS 29 L - 35 S 35 C (1) 35 C (2) - 40 C - 45 C - 50 C 60 C - 65 C Tyres 205 - 225/70 R 15 195/65 R 16 195/75 R 16 225/75 R 16 3000 10,37 10,34 11,04 -3300 11,25 11,22 11,98 11,79 3450 11,69 11,66 12,46 12,25 3750 12,57 12,54 13,40 13,17 3950 13,15 13,12 14,03 13,78 4100 -13,56 14,50 (3) 14,24 4350 --15,29 (4) 15,01 4750 --16,55 (4) 16,24 (1) Front suspension with trasverse leaf spring. (2) Front suspension with torsion bar. (3) Models 35C-40C only (4) Models 45C-50C only

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52376 STEERING GEAR 5 D AILY E URO 4 Print 603.93.651 Base - March 2006 TIGHTENING TORQUES DESCRIPTION TORQUE DESCRIPTION Nm kgm 1 Screw, steering box fastening nut 50 ÷ 61 5 ÷ 6,1 2 Nut securing the jointed head to the steering box rod 70 ÷ 100 7 ÷ 10 3 Nut, ball joint to steering arm 68 ÷ 83 6,8 ÷ 8,3 SPECIFIC TOOLS TOOL NO. DESCRIPTION 99347074 Knuckle pivot extractor

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Main hydraulic power steering operating faults: 1 -Steering stiff when turning right and left; 2 -Steering stiff only when turning left or right; 3 -Steering stiff when the wheel is turned quickly; 4 -When steering, heavy jolts are felt at the wheel; 5 -Torsional vibration of the steering wheel; 1 YES NO YES NO YES NO YES NO YES STEERING STIFF WHEN TURNING RIGHT AND LEFT Insufficient oil in system Open tank and check oil level. With engine running, top up oil to upper mark on dipstick and bleed system. Air in hydraulic circuit Check suction tube and pump shaft seal for leaks. Bleed system and top up the oil Pump regulating valve jammed or blocked Replace the power steering pump Insufficient oil pump delivery Overhaul or replace pump. Universal joint not serviceable Make joint free to slide by moving it to and fro several times so that it tilts under its own weight 6 -Excessive play at the steering wheel; 7 -Loss of oil; 8 -Insufficient pressure in the circuit; 9 -The vehicle tends to move sidewards; 10 -Hydraulic power steering pilot light always lighted. NO Internal power steering failure YES Replace the power steering unit 6 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651 DIAGNOSTICS

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Check suction tube and pump shaft seal for leaks. Bleed system and top up the oil 2 YES STEERING STIFF ONLY WHEN TURNING LEFT OR RIGHT Incorrect position of hydraulic centre (when wheel is released, the steering returns to one end of travel by itself): (ZF steering case only). Replace the power steering unit YES NO YES NO YES 3 STEERING STIFF WHEN THE WHEEL IS TURNED QUICKLY Regulating valve in pump blocked Replace the power steering pump Insufficient pump delivery (gears worn) Replace the hydraulic pump Air in steering system YES Insufficient oil in system Top up oil and bleed system 4 YES NO YES NO WHEN STEERING, HEAVY JOLTS ARE FELT AT THE WHEEL Play in universal joint Fit a new seal Replace the power steering unit Internal failure of hydraulic power steering (Continue) STEERING GEAR 7 D AILY E URO 4 Print 603.93.651 Base - March 2006

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YES NO YES NO YES YES NO YES NO Front wheel geometry incorrect Check and adjust according to specifications in thesection ”Axles” Wheels out of balance Balance in accordance with instructions given in the section ”Wheels and tyres” Steering rod joints loose on the levers Replace any worn parts Irregular pump operation Replace pump Leakage of oil from hydraulic power steering circuit couplings Check coupling seals for serviceability, replacing any which are worn Adjust in accordance with characteristic data for described in the section ”Axles” Wrong wheel toe-in 5 YES NO YES TORSIONAL VIBRATION OF THE STEERING WHEEL YES NO Wheels out of balance Balance in accordance with instructions given in the section ”Wheels and tyres” Air in hydraulic system Check suction tube and pump shaft seal for leaks. Bleed system and top up the fluid. 8 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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Play in ball joints and/or elastic supports loosen Play in universal joint NO YES NO YES 6 EXCESSIVE PLAY AT THE STEERING WHEEL Secure the supports Replace the ball joints Replace universal joint Replace the power steering unit Internal failure of hydraulic power steering In any case it is necessary to determine the place and the reason why there is oil leakage, eliminate the cause, top up oil in the tank with the engine started up to the upper mark of the dipstick. 7 YES NO YES LOSS OF OIL Tank cover not secured Secure cover Seal gaskets worn Replace worn seal gaskets, top up oil and bleed YES 8 INSUFFICIENT PRESSURE IN THE CIRCUIT Hydraulic pump not operating correctly Replace the power steering pump YES (Continue) STEERING GEAR 9 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Oil leaking from couplings in power steering circuit YES NO YES Check coupling seals for serviceability, replacing any which are worn Insufficient oil level in the tank Top up level and bleed circuit 9 THE VEHICLE TENDS TO MOVE SIDEWARDS Replace the power steering unit Check the windings and in case replace oil pressure sender. Oil pressure sender malfunction 10 YES NO HYDRAULIC POWER STEERING PILOT LIGHT ALWAYS LIGHTED YES Hydraulic power steering oil level low Top up oil 10 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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The distributor consists of: -a drive shaft (1) (joined to the steering column); -a distributing valve (4); -a wrench bar (3); -a pinion (6). The drive shaft is elastically joined by the wrench bar to the pinion by means of the pin (2). The distributing valve, trigged on the drive shaft is integral with the pinion by means of a pin (5); it has holes and splines in order to receive and distribute the oil flow to the hydraulic cylinder. Besides, a stiff joint (A) ensures the mechanical working of the hydraulic power steering in case of failure of the hydraulic system, through a bayonet joint. 24103 Figure 2 The power steering system consists of: -a tank (A); -a blade pump (B) with delivery regulating valves (C); -a series of connecting pipings (D); -an hydraulic power steering (E). The oil tank, in the engine compartment, feeds the bladepump. This pump is able to provide a feeding pressure ranging from a minimum of approx. 4 bar to a maximum of approx. 80+10. The oil come to the steering box, which is similar to a mechanical steering as for general building features, from the pump. In fact, its operation is mechanical for pinion to rack coupling, The rack rod is joined to the wheels with two side tie rods. The system is self-bleeding; bleeding is performed by completely steering to the right or to the left with the engine started and the vehicle stopped. The oil level check must be performed with the engine started. 24104 Figure 3 The hydraulic part of the steering box consist of: -a distributor (3); -an hydraulic cylinder (1); -a double-acting piston (4) integral with the rack rod. The hydraulic connection between distributor and hydraulic cylinder is achieved using two stiff pipes (2). The distributor (3) is integral with the hydraulic power steering pinion. HYDRAULIC POWER STEERING SYSTEM DIAGRAM HIGH PRESSURE LOW PRESSURE A 6 1 3 2 4 5 1 2 3 4 E The description below concerns the TRW hydraulic power steering and due to their similarity, it also applies to the ZF hydraulic power steering. NOTE STEERING GEAR 11 D AILY E URO 4 Print 603.93.651 Base - March 2006 POWER STEERING Description

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HYDRAULIC POWER STEERING OPERATION DIAGRAM: NEUTRAL POSITION The hydraulic cylinder (1) is integral part of the hydraulic power steering, The double-acting piston (2) (integral with the rack rod) slides in the hydraulic cylinder and divides it into two separate chambers A and B. The power steering is obtained by sending oil under pressure into one of the hydraulic cylinder chambers and discharging it into the other one. The power generated by the oil pressure on the side surface of the piston causes the movement of the piston and, as a result, of the rack. The feeding of one of the two hydraulic cylinder chambers occurs when the torque applied to the steering wheel causes the wrench of the bar; in this condition, the port of the drive shaft and the relevant ports of the distributing valve are joined depending on the rotary direction of the steering wheel. If the amount of torque applied to the steering wheel does not cause the wrench of the bar (low wheel resistance), the power steering does not intervene and the steering operates as a mechanical one. 24105 24106 Figure 4 Figure 5 The oil coming from the pump through the joint (3) goes into the distributing valve, circulates in it and returns in the tank through the joint (4), simultaneously passing through the chambers (2) and (1). The drive shaft (A), since it is not subject to wrench, is centred with respect to the distributing valve (B) and drives the oil coming from the pump directly into the tank through the ports (C). The chokes caused by the shaft (A) position with respect to the distributing valve (B) cause a pressure of ~ 3.5 bar in the right and left chamber through the ports (D) and (E). HIGH PRESSURE LOW PRESSURE 12 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651 POWER STEERING TYPE TRW Operation

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HYDRAULIC POWER STEERING OPERATION DIAGRAM: RIGHT STEERING 24108 Figure 6 The oil coming from the pump through the joint (3) goes into the distributing valve and it is sent to the hydraulic cylinder chamber (1) causing the movement of the piston. This movement pushes the oil contained into the chamber (2), through the joint (4), into the tank, passing again in the distributing valve. The movement of the piston in the direction of the arrow shows a right steering. The drive shaft (A), rotating clockwise with respect to the distributing valve (B), drives the oil under pressure coming from the pump through the ports (C), to the left chamber along the ports (E) and joins the discharge and the right chamber circuit by means of the ports (D). HIGH PRESSURE LOW PRESSURE STEERING GEAR 13 D AILY E URO 4 Print 603.93.651 Base - March 2006

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The oil coming from the pump through the joint (3) goes into the distributing valve and it is sent to the hydraulic cylinder chamber (2) causing the movement of the piston. This movement pushes the oil contained into the chamber (1), through the joint (4), into the tank passing again in the distributing valve. The movement of the piston in the direction of the arrow shows a left steering. The drive shaft (A), rotating clockwise with respect to the distributing valve (B), drives the oil under pressure coming from the pump through the ports (C), to the left chamber along the ports (D) and joins the discharge and the right chamber circuit by means of the ports (E). HYDRAULIC POWER STEERING OPERATION DIAGRAM: NEUTRAL POSITION HYDRAULIC POWER STEERING OPERATION DIAGRAM: LEFT STEERING 24107 19594 Figure 7 Figure 8 POWER STEERING TYPE ZF Operation With the steering wheel positioned to straight running, the bush (2) is arranged so that the passage of both feeding and discharge oil of the operating cylinder is closed. The oil pressures in the right and left chamber of the operating cylinder are balanced. The oil under pressure coming from the power steering pump (4) through the piping (5) feeds the distributor (1) central grove, flows in the bush (2) splines, goes out from it and, through the piping (6) returns in the tank (3). The neutral position of the hydraulic power steering is obtained and, therefore, the vehicle straight ride. HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE 14 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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The oil under pressure coming from the power steering (4) pump, through the piping (5), feeds the distributor (1) passing in the central groove. The rotation of the steering wheel causes a semi-rotation of the bush (2), this one is positioned so that the oil flows in its three splines and is sent to: the distributor upper groove, incase ofright steering(figure 10),or in the distributor lower groove,in caseof leftsteering (figure 11). The latter sends it to the relevant feeding piping (depending on the steering direction) of the operating cylinder chambers. Meanwhile, the oil contained in the chamber opposite to the fed one returns in the distributor. From the latter one, it flows in the discharge grooves of the bush (2) then, through the piping (6), returns in the tank (3). In this way the hydraulic interlocking is obtained. 19595 19596 Figure 9 Figure 10 HYDRAULIC POWER STEERING OPERATION DIAGRAM: LEFT STEERING HYDRAULIC POWER STEERING OPERATION DIAGRAM: RIGHT STEERING HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE STEERING GEAR 15 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Join a pressure gauge (2) on the oil delivery piping on the power steering pump (1). Rotate the steering wheel up to the limit stop, speed up the engine and read on the pressure gauge the maximum pressure value, which mast be of 80 bar. Check the oil level in the tank, if necessary top up. Lift the front part of the vehicle, start the engine and make it idle for a certain period. Check that there is no oil leakage from the hydraulic circuit and check the tank level. Slowly rotate the steering wheel in the two steering directions so that the air contained in the hydraulic system goes out. Check again the oil level in the tank and, in case top up. Lift the front of the vehicle and put the wheels in the straight ride position. Start the engine and fully speed up; if the steering gear put itself in steering position, the hydraulic steering centre is wrong and the hydraulic power steering must be changed. 501430 Bleeding the air from the hydraulic system The only possible interventions on the power steering and mechanical steering systems are: replacement of ball joints, replacement of protective rubber boots, linkages and rubber bushings. Follow the instructions provided in the specific paragraphs. Replace the power steering system if problems referred to this system only are found. 19598 32875 Figure 11 Figure 12 CHECKS AND OPERATIONS ON THE VEHICLE Checking maximum pressure 520636 SWIVEL HEADS 501438 PROTECTION CASINGS Check that the protection casings of the knuckle heads are in perfect condition and that their pivots do not present play, otherwise replace them as described below. Loosen the nut (3) securing the knuckle head (2) to the tie rod (4). Remove the nut fixing the knuckle head to the steering gear lever and using the extractor (1) 99347074 remove the knuckle head. Unscrew knuckle head from the tie rod of the steering box noting down the number of turns needed to disassemble. Remove the fixing brackets (5) and extract the protection casing (6). In order to re-fit the assembly, perform the above operation in reversed order, sticking to the following instructions: -carefully clean the steering gear tie rod knuckle; -lubricate the protective boot seats on the power steering box to facilitate assembly; -screw up the knuckle head with the same number of turns used to disassemble it; -fit a new o-ring on the power steering box; -tighten the nuts of the prescribed torque; -Adjust toe-in as shown in the respective section. Checking hydraulic steering centre (for ”ZF” power steering only) 501410 STEERING GEAR CONTROL Vehicles equipped with an Air-Bag ! Before doing any work on steering gear control components: -steering wheel; -steering control lever system; -steering gear shaft Strictly observe the safety standards described in the following paragraphs for Air-Bag system components. NOTE 16 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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System components are designed to operate just on vehicles of the specified make and type. Air-Bags must therefore not be adapted, reused or installed on other vehicles. Mount and use them only on the vehicles for which they have been designed and produced. ! The following Standards shall be strictly observed when performing any type of repair or maintenance operations on vehicles equipped with Air-Bag safety system. ! Air-Bag modules shall be handled with the utmost care. Use, transport and storage of these components are governed by the handling procedures described in the following paragraphs. ! Component removal and refitting shall be performed EXCLUSIVELY by skilled and authorised personnel. Failure to comply with the following procedure can result in unintentional activation of the system, severe injury or repairs not required. IT IS ABSOLUTELY FORBIDDEN TO DISASSEMBLE Air-Bag MODULE COMPONENTS. ! Any reuse, adaptation or installation on a different type of vehicle can result in sever injury or death for passengers in case of collision. Repairs and inspections required after an accident ! Any safety system component damaged after an accident must be replaced. Do not attempt to repair the control unit, the coil cable or the Air-Bag modules. Accidents with or without Air-Bag module activation Certain system components must be inspected after any crash, whether the Air-Bag deployed or not. These components are the following: -steering column; -steering column support; -electronic control unit anchoring area and modules; -coil cable; -dashboard (in the area of the passenger Air-Bag). If any faulty condition is found, replace the faulty component. Accidents with Air-Bag module activation In case of front impact with total system activation, the following components must be replaced: -Air-Bag modules; -pretensioners; -electronic control unit; -coil cable. STEERING GEAR 17 D AILY E URO 4 Print 603.93.651 Base - March 2006 SAFETY STANDARDS TO BE OBSERVED DURING REPAIR OR MAINTENANCE OPE-RATIONS ON VEHICLES EQUIPPED WITH AIR-BAG SYSTEM PROVIDED BY SUPPLIER Preliminary Standards Before starting any bodywork repair operation, welding or whatever work requiring to remove the Air-Bags or the control unit, proceed as follows: -set ignition key to ”STOP” and take it out; -always disconnect the battery, i.e.: disconnect the two terminals from the relevant pole and insulate them properly by tape; -wait for at least 10 minutes before proceeding; -disconnect control unit connector. Store modules with the cover set upwards, inside a metallic key-locked cabinet that must be used just with this purpose and that must not contain other type of materials, especially if flammables. Adopted connectors wired to Air-Bag modules are provided with short-circuit clip. It is impossible to activate units accidentally until Air-Bag modules are connected to a power source with suitable properties. A system component not activated in case of collision is to be considered still ”live” (active). Live components that shall be removed from vehicles (due to defects, warranty expiry or other reasons) shall be returned to the suitable Centre using the following procedure.

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Inspect cables and connectors to find any burning, external insulation melting or damages due to excessive heat. If any faulty condition is found on coil cable, electronic control unit anchoring area and modules, replace the faulty component. Painting Since modules and pretensioners are designed to withstand the temperatures developed during standard baking operation on bodywork, no special safety requirement shall be observed during painting or baking. Do not use open flames when working near the modules. Electronic control units (including the Air-Bag one) shall always be removed when temperature in certain rooms is equal to or exceeds 85 ° C. Risks for health Precautions to be observed when handling live Air-Bag are the following: -wear protective polyethylene gloves and goggles; -wash hands and any exposed body part with water and soap after handling live modules. Overexposure effects Since system is completely sealed there is no potential danger of exposure to propelling gas. Propelling gas mixture is at solid state, it is therefore impossible to inhale gas even in case of gas generator cartridge breakage. There is no risk for health in case of gas leakage. Avoid in any case contact with the skin and do not swallow the propelling gas. In case of: -contact with the skin: rinse immediately with water and soap; -contact with eyes: rinse immediately with fresh water for 15 minutes at least; -inhalation: bring immediately the injured person to open air; -swallow: make the injured person vomit if conscious. Always call the doctor in any of the above cases. Safety Standards to observe when handling Air-Bag modules Driver and passenger Air-Bags usually activate in case of collision through the action of the electronic activation control. Gas (mainly nitrogen) produced under these conditions are not toxic. Personnel operating on safety system shall strictly observe the following safety standards. Personnel operating on these devices shall be suitably trained and must observe the following precautions: -when removing or replacing activated Air-Bags, wear protective polyethylene gloves and goggles and handle just one module at a time; -always place the Air-Bag module with the cover and exhaust hole upwards. Never put something on Air-Bag cover; -once servicing is over rinse hands with water and neutral soap, in case of eyes contact with residual powders rinse immediately with fresh water; -before starting servicing, disconnect both battery cables (first the negative one), insulate terminals by tape and wait at least 10 minutes before proceeding; -metal components of the Air-Bag are hot after explosion, avoid to touch these components for at least 20 minutes from module activation; -do not repair Air-Bags but send faulty modules to supplier. Do not heat the Air-Bag module by welding, percussion, drilling, mechanical machining, etc.; -never install on vehicle a damaged or fall Air-Bag module; -it is prohibited to store Air-Bag modules together with flammable material or fuels; -gas generators must not come into contact with acids, greases or heavy metals since contact can result in formation of poisonous, noxious gas or explosive compounds; -never use open flames when working near Air-Bag modules or system components. 18 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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Spare parts shall be stored in their original package and temporary storing shall follow the same procedure as for live modules disconnected from vehicle, i.e. storage intodedicated metallic key-locked cabinet (resistant to shocks and provided with grids to enable natural ventilation). Cabinet shall be provided with proper warning plates (RISK OF EXPLOSION -NO OPEN FLAMES -NO OPENING BY UNAUTHORISED PEOPLE). Air-Bag module scrapping Air-Bag modules must not be scrapped together with the vehicle, but must be previously removed and activated as described in the following pages. Air-Bag units must always be activated before scrapping. An Air-Bag module not exploded during an accident is to be considered still ”live”. Live materials MUST NOT BE ACTIVATED but must be sent to a specialised centre (in Italy to GECMA in Chivasso) specifying on the freight note: -Air-Bag DEVICE CONTAINING PYROTECHNIC CHARGE TO BE DEACTIVATED. Devices must be sent using their original packages only. Should the original package be not available, a new one shall be requested to SPARE PARTS. In case of Air-Bag device replacement, the original package shall obviously be kept in good conditions to send the non-activated device. FOREIGN MARKETS shall observe local current laws and regulations. ! Failure to observe these procedures can result in unintentional Air-Bag module activation and severe injury. Live Air-Bag units must NOT be disposed of using the common disposal procedure. Live Air-Bag units contain substances dangerous for health thatcan cause severe injury if the sealed container is damaged during disposal. Safety Standards to observe when handling pretensioners In case of front impact, driver and passenger pretensioners usually activate just a minute before Air-Bag modules Personnel operating on these devices shall be suitably trained and must observe the following precautions: -when handling activated pretensioners, i.e. with activated propelling gas, wear protective gloves and goggles; -once servicing is over rinse hands with water and neutral soap, in case of eyes contact with residual powders rinse immediately with fresh water; -disconnect both battery cables (first the negative one), insulate terminals by tape and wait at least 10 minutes before proceeding; -pretensioner produce heat during activation, it is therefore necessary to wait at least 10 minutes before operating; -protect pretensioners against fall or shock during handling or transport; damaged or fallen pretensioners must not be used and must be returned to supplier communicating the reason for; -never carry pretensioners by the seat belt; -pretensioners must be protected against sparks and open flames and must not stay in contact with surfaces with temperatures exceeding 100 ° C for more than 6 hours; -propelling gas not burnt is flammable, therefore generator components must never be disassembled, damaged or tampered; -it is prohibited to store pretensioners together with flammable material or fuels; -gas generators must not come into contact with acids, greases or heavy metals since contact can result in formation of poisonous, noxious gas or explosive compounds; -seat belts with pretensioners shall be stored in proper key-locked compartments or cabinets, suitably aerated and away from open flames and heat sources. STEERING GEAR 19 D AILY E URO 4 Print 603.93.651 Base - March 2006

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Pretensioners scrapping Non-activated pretensioners (not installed on vehicle) must always be activated before scrapping. Non-activated pretensioners installed on vehicle must not be scrapped together with the vehicle, but must be previously removed. Pretensioner not activated during an accident is to be considered still ”live” and therefore it is necessary to follow the procedure described in this manual. Operations on system components Once servicing operations are completed, the system shall be tested by Modus, I.W.T. or equivalent diagnostic equipment. Air-Bag components are provided at installation with a label with a removable part showing system and components date of installation. The removable part is detached and data are stored together with the test report provided by Modus, by the workshop that has installed the components. After 10 years from installation, unless prior replacement, a new Air-Bag system (cable and components) shall be installed. As said above components technical data and the date of installation will be filed. Removing and scrapping activated Air-Bag module and pretensioner from vehicle Always wear gloves and goggles when handling activated Air-Bag or pretensioner. Wash hands and exposed skin with water and neutral soap after handling activated Air-Bag or pretensioner. In case of exposure to secondary products, rinse eyes immediately with fresh water. Failure to observe these indications can result in severe injury. To remove and scrap activated Air-Bag module and pretensioner proceed as follows: -follow instructions contained in this manual to remove activated Air-Bag module and pretensioner; -disconnect Air-Bag module and pretensioner mechanical fixings; -disconnect component connector form Air-Bag wiring; -put Air-Bag module and pretensioner in the proper sealed nylon bag; -send to authorised collection/disposal centre; -dispose of, recycle or scrap deployed Air-Bag module and pretensioner using the suitable procedure. ! After any impact involving pretensioner activation, the seat belt is unserviceable and must be replaced. Propelling gas residues shall be considered with attention. These residues that are mostly concentrated on the generator body or in small amount in the bag can contain copper or chlorides (e.g. potassium chloride). Combustion residues are very alkaline and corrosive. Always wear skin protections and goggles. Activated Air-Bags must always be stored in dry and well ventilated places. ! Never cut the cables or tamper the connector between vehicle wiring and Air-Bag module. Connector contains a safety clip. Removing and scrapping non-activated Air-Bag module from a repairable vehicle If connector is cut or removed from Air-Bag unit, the safety clip is disabled and this can result in unintentional activation and severe injury. Air-Bag systems have a backup power supply located in the control unit. This power supply shall be deactivated by disconnecting the two battery terminals and waiting for at least 10 minutes before starting any operation on whatever Air-Bag component. Keep the bag and the external bag cover in opposite direction to body when handling a live Air-Bag module. When placing a live Air-Bag on the bench or some surface like that, set the bag and the cover facing upwards and far from people. Never place objects near a live Air-Bag, since in case of module deployment objects will be thrown away like shells. ! Always store live Air-Bag modules an pretensioners in fresh, dry, close and safe place. Do not expose to open flames or temperatures exceeding 150 ° C. Never cut, drill, solder or weld an Air-Bag module or its components. Failure to observe these indications can result in unit damages, fire, unintentional deployment and severe injury. 20 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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AIR-BAG MODULE REMOTE ACTIVATION DIAGRAM 8663 A C1 Lb B L C2 C2 +12V Damaged live Air-Bag modules and pretensioners (e.g. electric connection breakage), shall be store far from corrosive or oxidising substances. Failure to observe these indications can result in fire and/or severe injury. Air-Bag module deployment Remote activation General instructions: -activation procedure can be performed in open area, suitably defined and fenced, far from flammable materials, liquids or other substances and far from people. Set the Air-Bag module on a firm surface and lock it; -clean this area from any material (glass, instruments, parts, etc.) which could become like shells during deployment; -check whether connector C2 is disconnected from remote activation device (10 m). -connect electric connector C1, specified by vehicle manufacturer, to remote activation Air-Bag module; -connect connector C2 to remote activation device; -connect remote activation device to 12V circuit or equivalent device; -stand protected; -wear goggles and protective clothes; -depress double activation push-button; -wait for approx. 20 minutes before touching the activated Air-Bag module since it is hot; -dispose of, recycle or scrap, as required, activated Air-Bag modules as described in the relevant chapters. Activating Air-Bag modules and electronic pretensioners installed on unrecoverable vehicles This procedure is to be used when scrapping a vehicle with one or more live Air-Bag modules. This procedure is valid whether Air-Bag system and/or electronic pretensioners are sound or not. It is recommended to activate pyrotechnic charges on vehicles by directly connecting the electric connector of each module to remote activation device. ! Deployment procedure shall be performed outdoor, away from people and in a well defined area. Check for absence of objects and flammable fluids near modules and pretensioners. Do not remain on the vehicle during activation and remember to close the doors. Stand protected (e.g. behind a wall, a vehicle, etc.) against thrown-away objects, if any. Let generators and modules cool down after deployment (20 min. at least before proceeding). Failure to observe these indications can result in severe injury. C1 = Air-Bag module connector C2 = remote activation device connector (Air-Bag connector with safety clip, counterparts with male pins on Air-Bag side) Lb = braid length = approx. 1 m L = main cable, safety distance 10 m A fenced area B Remote activation device ! Air-Bag modules and pretensioners are provided with backup power supply giving the electrical pulse required to bag deployment when the accident damages the battery or the cables before the sensor activates the gas generator. Figure 13 STEERING GEAR 21 D AILY E URO 4 Print 603.93.651 Base - March 2006

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General instructions: -follow all WARNINGS, PRECAUTIONS and safety instructions reported in this manual; -bring the vehicle outside in the provided area; -remove from the area around the Air-Bag covering all materials and slugs (glasses, tools, components etc.) and make sure that no inflammable liquids are nearby; -disconnect the two battery cables (first the negative cable) and wait for at least 10 minutes before proceeding; -use a connecting braid (L= about 1 m) with specific terminal connector for the electric connection with the module to activate; -reach the electric module connection (Air-Bag or electronic pretensioner), following the instructions of this manual; -disconnect connector C1 of the pretensioner or Air-Bag module; -check whether connector C2 is disconnected from remote activation device; -connect the electric connector C1 of the pretensioner or Air-Bag module to the connecting braid of the remote activation device; -connect connector C2 to remote activation device; -place people in a safe place; -connect the remote control device to a 12 Volts circuit or equivalent device; -press the double activation push-button to activate all pretensioners and Air-Bag modules at the same time; -after activating the Air-Bag modules and pretensioners, leave them cooling before touching them (about 20 minutes); -after activating the Air-Bag modules and pretensioners, the vehicle can be scrapped - by squashing or crushing -and/or recycled, depending on the cases. ABG= driver Air-Bag ABP = passenger Air-Bag C2 = remote activation device connector C1 = specific pyrotechnic charge connector L = main cable, safety distance 10 m Lb = braid length PTG = driver pretensioner A. Remote activation device VEHICLE PYROTECHNIC CHARGES ACTIVATION DIAGRAM, SINGLE ACTIVATION 8664 ABP C1 Lb ABG PTG C2 C1 Lb Lb C2 C2 C1 C2 L +12V A Figure 14 22 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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62107 62108 62108 62109 Disconnect the battery (2) cables (1-3) first the negative cable (1) then the positive one (3) and insulate them taping the terminals. For vehicles without Air-Bag, remove the pressure-fit cover (2) on the steering wheel. For vehicles with Air-Bag, turn the steering wheel and position it as shown in the figure, in order to easily reach the screws (1 and 3) and remove them. -Lift the Air-Bag module (1) in order to disconnect connector (2); -Remove the Air-Bag module (1) from the steering wheel (3). Set front wheels in straight running and mark ( → ) steering wheel assembly position (1) on upper steering gear shaft (2) Remove the steering wheel (1) from the shaft (2). For vehicles with Air-Bag, make sure not to extract or damage coil device cable (3). ! After removal, non-activated Air-Bag modules must be stored with plate laying on the surface in a suitable key-locked cabinet. For all vehicles Remove fixing nut (4). For vehicles equipped with Air-Bag Follow the safety standards given in the relevant chapter and wait for 10 minutes before proceeding. Figure 15 Figure 16 Figure 17 Figure 18 STEERING GEAR 23 D AILY E URO 4 Print 603.93.651 Base - March 2006 541415 Upper steering gear shaft removal

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62110 102313 62112 Figure 19 Figure 20 Figure 21 Remove the two screws (2) and remove the upper protection (1). Remove the three screws (4) and remove the lower protection (3). Cut electric cable fixing clamps and disconnect connectors (9-10-13). On vehicles equipped with ESP, take off connector (14) of steering angle sensor (15) incorporated into the steering column stalk. Loosen screw (3) locking indicator switch retaining clamp to gear shaft (1). Remove the indicator switch (2) from the gear shaft (1). To remove steering angle sensor (15), you just need to take off cover (16) and unscrew the three screws (17) that secure it to the steering column stalk.Mark universal joint (6) assembly position on lower shaft (8) and loosen the fixing screw (7). Remove the screws (4-5) and disconnect the upper steering gear shaft (1) from the lower steering gear shaft (8). To replace or disassemble switch (12) it is necessary to unscrew screws (11) using a proper punch or drill them in order to eliminate the most of material to remove them. Make sure not to damage switch thread in case of reuse. At refitting, the new screws (11) must be tightened till the hexagonal head is sheared from its rod. Remove the upper steering gear shaft as described in the relevant chapter (operation 541415). Lift cover (1) from floor. Unscrew the three fixing screws (2) of lower shaft (3) support (4). ! Make sure that steering wheel removal has lifted the top cap of the coil device. If the top cap turns, it will be necessary to block it by bringing it to the outside. If you hear a ”click”, it means that the cap is blocked. For any removals of the winding device, meticulously observe what specified in “Electric System” section. Refitting For refitting reverse removal operations and observe the following recommendations: -reconnect shafts and refit steering wheel matching the marks made during removal operations; -at refitting, the self-braking nuts and the steering wheel fixing nut must always be replaced; -tighten nuts and screws to the prescribed torque; -after tightening steering wheel fixing nut to upper shaft, it is necessary to crimp the nut; -when refitting is completed, carry out operation test on indicator switch and horn. 541413 Lower steering gear shaft removal On vehicles equipped with ESP, the steering angle sensor is fitted inside the steering column stalk. In this case, you will have to carry out the functional checks as well as the calibration procedure described in the relevant chapter of the “Brakes” section (page 63). NOTE 24 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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62113 Figure 22 Mark universal joint (6) assembly position on hydraulic power steering (3) shaft. Loosen screw (7) and remove hydraulic power steering lower shaft. Refitting For refitting reverse removal operations, complying with upper steering gear shaft refitting operations. 5014 HYDRAULIC POWER STEERING 541413 Hydraulic power steering removal Proceed as follows to remove the hydraulic power steering: Loosen front wheel fixing screws or nuts. Lift the front part of the vehicle, support it by proper stands and brake rear wheels. Position tool 99321024 near the wheels, remove wheel fixing screws or nuts. Remove the wheels. Remove cap (1) from hydraulic power steering oil tank. Disconnect pipes (4-5) from hydraulic power steering (3) and drain system oil into a suitable container. Steer wheel hubs in both directions to drain out oil from the system. Remove nuts (8) fixing kingpins (10) to steering levers (9) and remove the latter using extractor 99347074. Loosen the screw (7) fixing the universal joint (6) to the hydraulic power steering shaft (3). Remove the fixing screws (2) and remove the hydraulic power steering (3). For refitting reverse removal operations and observe the following recommendations: -after refitting the hydraulic power steering to the front cross member or to the driving axle, turn the pinion up to bring the rack to the end of the stroke. Turn again the pinion to the opposite direction for a number of turns equal to half of the turns required to the rack to complete the whole stroke (approx. 2 turns); -in this position, set steering wheel in straight running condition and connect the elastic joint to hydraulic power steering pinion fork or the universal joint to the hydraulic power steering. -At refitting, the self-braking nuts must not be reused but replaced with new ones. -tighten screws and nuts to the prescribed torque; -fill hydraulic power steering system tank in and carry out the drainage as described in the relevant section; -check and adjust toe-in as described in the relevant section. The only repair operations to carry out on hydraulic power steering and mechanical steering are the following: joint head replacement and rubber boots replacement. In these cases, follow the operations described in the relevant section. If defects depending only on the hydraulic power steering are found, replace it. Refitting ! STEERING GEAR 25 D AILY E URO 4 Print 603.93.651 Base - March 2006

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86010 86011 86012 Use suitable pincers to loosen the retainer clamps (2 and 4), remove the protective boot (3) from the power steering box (1) and move it aside to access the steering linkage connection (5) to the rack rod. Tighten the rack rod (2) in a vice with lead covered jaws, loosen the joint (3) and remove the steering linkage (4). Remove the o-ring (1). Repeat the operations to remove the opposite steering linkage. Follow the removal/refitting operations described in the respective sections to reuse ball joints. Reassemble by reversing the disassembly sequence; observe the following precautions: -replace o-rings (1) and clamps (2 and 4) with new parts; -lubricate ( → ) protective boot (3) seats on power steering unit (10) to facilitate assembly of the boots; -tighten steering linkage joints (5) at 100 ± 10 Nm (10 ± 1 kgm). POWER STEERING SYSTEM SPARE PARTS 1. O-ring - 2. Clamp - 3. Protective boot - 4. Clamp -5. Steering linkage - 6. Nut - 7. Head - 8. Tube - 9. Tube -10. Power steering unit - 11. Rubber bushing. Figure 23 Figure 24 Figure 25 Do not take the rack rod (2) to end of stroke after removing the linkage (4) to avoid damaging the power steering o-rings. Refitting Rubber bushing replacement procedure Use a suitable ram to remove/refit rubber bushings (11). Steering linkage replacement Removal 26 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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89008 Figure 26 Operation of the power steering pumps for FIA/F1C engines is similar to that of 8140 engines. F1C engine power steering pump Power steering pump overhaul procedure Replace the power steering pump if poor operation is found. F1A engine power steering pump 86013 Figure 27 501450 POWER STEERING PUMP STEERING GEAR 27 D AILY E URO 4 Print 603.93.651 Base - March 2006

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28 STEERING GEAR D AILY E URO 4 Base - March 2006 Print 603.93.651

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HYDRO-PNEUMATIC SYSTEM - BRAKES 1 D AILY E URO 4 Base - March 2006 Print 603.93.651 SECTION 11 78 Hydro-pneumatic system 52 Brakes Page GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (MISCELLANEOUS AND GENERATORS) 5 . . GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES) 6 . . . . . . . . . . GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS) 12 . . . . . . . . GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALIPERS) 13 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALIPERS AND CYLINDERS) 14 . . . . . . . . . . . GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING HEADS) 15 . . . . GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES) 17 . . . . . . . . . GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES) 19 . . . . . . . . . . PIPES AND COUPLINGS 19 . . . . . . . . . . . . . . . . . . -General 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Re-flanging rigid pipes 19 . . . . . . . . . . . . . . . . . . . -Bending rigid pipes 20 . . . . . . . . . . . . . . . . . . . . . . -Cutting rigid pipes 20 . . . . . . . . . . . . . . . . . . . . . . -Replacing flexible hoses with threaded couplings 21 -Replacing flexible hoses with quick release couplings 22 BRAKING SYSTEM 24 . . . . . . . . . . . . . . . . . . . . . . . -Outline diagram for vehicles 29L - 35S without ABS 24 -Outline diagram for vehicles 29L - 35S with ABS 8 25 . -Outline diagram for vehicles 29L - 35S with ESP 8 26 . -Outline diagram for vehicles 35C - without ABS 27 -Outline diagram for vehicles 35C with ABS 8 28 .

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2 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651 Page -Outline diagram for vehicles 35C with ESP 8 29 . . -Outline diagram for vehicles 40C - 45C - 50C - 60C -65C with ABS 8 30 . . . . . . . . . . . . . . . . . . . . . . . . -Outline diagram for vehicles 35C with ESP 8 31 . . -Braking system main components layout 32 . . . . . -Location of the main brake system components on vehicles with ABS 34 . . . . . . . . . . . . . . . . . . . . . . . -Location of the main brake system components on vehicles with ESP 36 . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Service brake 37 . . . . . . . . . . . . . . . . . . . . . . . . . . -Emergency brake 37 . . . . . . . . . . . . . . . . . . . . . . . -Parking brake 37 . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKES 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Front and Rear disc brakes 37 . . . . . . . . . . . . . . . . FAULT DIAGNOSIS 38 . . . . . . . . . . . . . . . . . . . . . . -Diagnosis Instruments 38 . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 46 . . . . . . . . . . . . . . . . . . TOOLS 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA - HYDRAULIC SYSTEM 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS AND DATA - BRAKES 52 . . . . . . CHECKS 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Functional check of vacuum brake system 54 . . . . BRAKING SYSTEM MAIN COMPONENTS 55 . . . . -Vacuum pump 55 . . . . . . . . . . . . . . . . . . . . . . . . . -Vacuum servo brake 55 . . . . . . . . . . . . . . . . . . . . . -Bleeding air from the hydraulic circuit (vehicles not equipped with ABS) 56 . . . . . . . . . . . . . . . . . . . . . -Bleeding air from the hydraulic circuit with deaerator device (vehicles not equipped with ABS) 56 . . . . . Page -Air bleeding from the ABS/ESP system hydraulic circuit 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -ABS 8/ESP 8 system bleeding procedure sequence 58 -Mechanically controlled load sensing valve (vehicles 35C) 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Regulation of load proportioning valve on vehicle 59 . -Dual mechanically controlled load sensing valve (vehicles 29L - 35S) 60 . . . . . . . . . . . . . . . . . . . . . -Adjusting the load sensing valve 60 . . . . . . . . . . . . STABILITY CONTROL AND ANTI-SKID DEVICES 61 . . . ABS SYSTEM FUNCTIONS 61 . . . . . . . . . . . . . . . . . -Antilock braking system (ABS) 61 . . . . . . . . . . . . . -Electronic braking distribution device (EBD) 61 . . . -Electronic Stability Program (ESP) - Option 61 . . . FUNCTIONS INCLUDED IN THE ESP SYSTEM ONLY 61 -Acceleration drive control device (ASR) 61 . . . . . -Engine braking torque control (MSR) 61 . . . . . . . . -Hill holder control (HHC) 61 . . . . . . . . . . . . . . . . -Hydraulic Brake Assistant (HBA) 61 . . . . . . . . . . . -Electro-hydraulic modulator/control unit for 29L -35S vehicles ) 62 . . . . . . . . . . . . . . . . . . . . . . . . . . -Electro-hydraulic modulator/control unit for 29L -35S vehicles ) 63 . . . . . . . . . . . . . . . . . . . . . . . . . . -Rev sensor 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Phonic wheels 64 . . . . . . . . . . . . . . . . . . . . . . . . . ESP SYSTEM SENSORS 64 . . . . . . . . . . . . . . . . . . . .

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HYDRO-PNEUMATIC SYSTEM - BRAKES 3 D AILY E URO 4 Base - March 2006 Print 603.93.651 Page -Yaw sensor with built-in side acceleration sensor 64 . . -Longitudinal acceleration sensor 64 . . . . . . . . . . . . -Steering angle sensor 64 . . . . . . . . . . . . . . . . . . . . BRAKE REPAIR OPERATIONS 65 . . . . . . . . . . . . . . -Front brakes 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Replacing brake linings 65 . . . . . . . . . . . . . . . . . . . -Checks 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal/Re-fitting of brake calipers 67 . . . . . . . . . REAR BRAKES 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal/Refitting of brake calipers 68 . . . . . . . . . . -Checks 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal/Refitting brake calipers 70 . . . . . . . . . . . . OVERHAUL OF BRAKE CALIPERS 70 . . . . . . . . . . . -2x44 - 2x48 - 2x60 Brembo brake calipers 70 . . . -1x52 - 1x60 Brembo brake calipers 71 . . . . . . . . . OVERHAUL OF BRAKE DISCS 72 . . . . . . . . . . . . . . MACHINING AND GRINDING OF DISC BRAKES 72 . . . OVERHAULING PARKING BRAKE 73 . . . . . . . . . . . WHEEL NUT TIGHTENING SEQUENCE 73 . . . . . -Assembly 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Adjusting parking brake 75 . . . . . . . . . . . . . . . . . . STEERING ANGLE SENSOR 76 . . . . . . . . . . . . . . . . Page -Replacing 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE ESP COMPONENTS 76 . . . . . . . -Calibration 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . LONGITUDINAL ACCELERATION SENSOR 77 . . -Removal 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Calibration 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . YAW SENSOR 78 . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Calibration 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTROHYDRAULIC MODULATOR/CONTROL UNIT 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Removal 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Refitting 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Programming 79 . . . . . . . . . . . . . . . . . . . . . . . . . . -Calibration 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Bench overhauling 80 . . . . . . . . . . . . . . . . . . . . . . -Disassembly 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . -Assembly 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651

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32780 HYDRO-PNEUMATIC SYSTEM - BRAKES 5 D AILY E URO 4 Base - March 2006 Print 603.93.651 Print 603.43.671 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (MISCELLANEOUS AND GENERATORS) DESCRIPTION SYMBOL HYDRAULIC FLOW AIR FLOW ELECTRICAL LINE ABLE TO ROTATE CROSSOVER OF CONNECTED LINES PRESSURE TEST POINT QUICK-RELEASE COUPLING COCK COCK WITH OUTLET 1 2 SILENCER COMPRESSOR 0 2 ENERGY SAVING COMPRESSOR 0 2 4 VACUUM PUMP 3 2 HYDRAULIC PUMP 0 2 HYDRAULIC HAND PUMP

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32783 32782 6 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES) DESCRIPTION SYMBOL CONDENSATE SEPARATOR FILTER 1 2 DEHUMIDIFIER 1 2 DEHUMIDIFIER 21 1 22 4 DEHUMIDIFIER WITH BUILT-IN REGULATOR 21 1 22 23 AUTOMATIC CONDENSATION DRAIN VALVE CONTROLLED CONDENSATION DRAIN VALVE HAND CONDENSATE DRAIN VALVE CONTROLLED ANTI-ICING UNIT 1 2 7 AUTOMATIC ANTI-ICING UNIT 1 2 PRESSURE REGULATOR WITH INDEPENDENT CIRCUIT 21 22 1 23 24 PRESSURE CONTROLLER 21 1 PRESSURE CONTROLLER 21 1 23 PRESSURE CONTROLLER (GOVERNOR) 2 1 PRESSURE LIMITING VALVE 2 1

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32783 32784 32785 HYDRO-PNEUMATIC SYSTEM - BRAKES 7 D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES) DESCRIPTION SYMBOL PROPORTIONAL REDUCING VALVE 2 1 MATCHING VALVE 2 1 FOUR CIRCUIT PROTECTION VALVE 21 22 1 23 24 THREE CIRCUIT PROTECTION VALVE 21 22 1 23 TWO CIRCUIT PROTECTION VALVE 21 22 1 NON-RETURN AIR INLET VALVE 2 1 NON-RETURN AIR INLET VALVE 2 1 SAFETY VALVE CHECK VALVE 2 1 CHECK VALVE 2 2 1 DOUBLE SHUT-OFF VALVE 11 12 2 DIFFERENTIAL DOUBLE SHUT-OFF VALVE M S U THROTTLE VALVE WITH QUICK RETURN 1 2 THROTTLE VALVE CONTROL VALVE 2 1

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32786 8 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES) DESCRIPTION SYMBOL DUMP VALVE 2 1 BRAKE CONTROL VALVE 21 11 22 12 P A BRAKE CONTROL VALVE 21 11 BRAKE CONTROL VALVE 21 11 4 22 12 PARKING BRAKE CONTROL VALVE 22 11 21 PARKING BRAKE CONTROL VALVE 2 1 BRAKE VALVE 2 1 CONTROL VALVE 2 1 CONTROL VALVE 22 1 21 RETARDER CONTROL VALVE 23 13 R SERVO CONTROL VALVE 2 1 4

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32787 32786 HYDRO-PNEUMATIC SYSTEM - BRAKES 9 D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES) DESCRIPTION SYMBOL SERVO CONTROL VALVE 2 1 42 41 SERVO CONTROL VALVE FOR SINGLE LINE 2 1 4 TRAILER BREAKING TRIPLE CONTROL VALVE 2 1 42 41 43 TRAILER BREAKING TRIPLE CONTROL VALVE WITH BUILT-IN SERVO SWITCHING 22 11 42 41 43 12 LOAD PROPORTIONING VALVE 2 1 DUAL LOAD PROPORTIONING VALVE 21 11 22 12 LOAD PROPORTIONING VALVE WITH BY-PASS 21 12 11 LOAD PROPORTIONING VALVE WITH BUILT-IN RELAY 2 1 4 LOAD PROPORTIONING VALVE WITH BUILT-IN RELAY WITH AIR CONTROL 4 42 41 1 2

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32788 32787 10 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES) DESCRIPTION SYMBOL LOAD PROPORTIONING VALVE WITH AIR CONTROL 42 41 1 2 LOAD PROPORTIONING VALVE WITH AIR CONTROL 1 4 2 PROPORTIONAL REDUCING VALVE 1 2 SLAVED PROPORTIONAL REDUCING VALVE 1 4 2 SLAVED LIMITING VALVE 1 2 LEVELLING VALVE 1 21 22 LEVELLING VALVE 1 2 HAND OPERATED SUSPENSION RAISING CONTROL VALVE 11 21 12 23 LEVELLING VALVE WITH BUILT-IN TRAVEL LIMITER 24 23 21 22

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32788 HYDRO-PNEUMATIC SYSTEM - BRAKES 11 D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES) DESCRIPTION SYMBOL PROPORTIONAL CONTROL VALVE 1 2 41 42 HAND OPERATED SUSPENSION CONTROL VALVE WITH ELECTRICAL MONITORING 21 11 12 22 13 1 3 ELECTROPNEUMATIC VALVE 1 2 ELECTROPNEUMATIC VALVE 1 2 ELECTROPNEUMATIC VALVE 1 21 22 HYDRAULIC MODULATOR FOR ABS HL HR HZ1 VL VR HZ2 ABS AUGMENTER VALVE 1 4 2

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32789 12 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (TANKS AND ACCUMULATORS) DESCRIPTION SYMBOL COMPRESSED AIR TANK BRAKE FLUID RESERVOIR AIR SPRING

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32791 32790 HYDRO-PNEUMATIC SYSTEM - BRAKES 13 D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CONVERTERS, CYLINDERS AND CALIPERS) DESCRIPTION SYMBOL VACUUM SERVO BRAKE VACUUM SERVO BRAKE DUAL CIRCUIT MASTER CYLINDER SINGLE CIRCUIT MASTER CYLINDER AIR/HYDRAULIC CONVERTER AIR/HYDRAULIC CONVERTER HYDRAULIC BRAKE CYLINDER SLAVE CYLINDER BRAKE CYLINDER SPRING CYLINDER COMBINED BRAKE CYLINDER FIXED DISK BRAKE CALIPER

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32791 14 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (CALIPERS AND CYLINDERS) DESCRIPTION SYMBOL FLOATING DISK BRAKE CALIPER FLOATING DISK BRAKE CALIPER WITH PARKING MECHANICAL FLOATING DISK BRAKE CALIPER SERVO CLUTCH SERVO CLUTCH

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32793 32792 HYDRO-PNEUMATIC SYSTEM - BRAKES 15 D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING HEADS) DESCRIPTION SYMBOL ”ISO” SEMICOUPLING A M ISO VERSION ”ISO” SEMICOUPLING A M VERSIONWITHISOCOUPLINGS ”CUNA” SEMICOUPLING A B ITALIAN VERSION ”CUNA” SEMICOUPLING M A ”NATO” SEMICOUPLING A M NATO VERSION

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32793 16 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (SEMI-COUPLINGS AND COUPLING HEADS) DESCRIPTION SYMBOL SEMI-COUPLING 1 2 3 5 4 V A Z SINGLE LINE VERSION SEMI-COUPLING V A Z A M SINGLE LINE VERSION SEMI-COUPLING 4 2 12 22 SINGLE LINE VERSION SEMI-COUPLING 4 2 12 22 M A 1 SINGLE LINE VERSION

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32794 HYDRO-PNEUMATIC SYSTEM - BRAKES 17 D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (INDICATORS AND SWITCHES) DESCRIPTION SYMBOL PRESSURE GAUGE PRESSURE GAUGE PRESSURE TRANSMITTER LAMP MECHANICAL OPERATED SWITCH PRESSURE SWITCH LOW PRESSURE SWITCH AUDIBLE WARNING SENSOR

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32795 18 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651 GRAPHIC SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES) DESCRIPTION SYMBOL SINGLE CYLINDER HYDRAULIC BRAKE TWIN CYLINDER HYDRAULIC BRAKE DUAL SERVO HYDRAULIC BRAKE DUAL SERVO HYDRAULIC BRAKE WITH PARKING BRAKE SINGLE CAM OPERATED BRAKE TWIN DUAL CAM OPERATED BRAKE

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The pipes in the braking systems of commercial vehicles are currently of two types: -Flexible nylon hose with single or two-ply structure and in the following diameters ( ∅ 6-8-10-12-16 mm) supplied as spares in metre lengths. -Rigid metal pipes of the following diameters ( ∅ 4.75-6.35-8-10-12 mm). Pipes from ∅ 4.75 to ∅ 10 mm are supplied as spares in straight lengths of 4, 5 and 6 m, while those which are over 10 mm diam. are supplied as spares ready cut, bent and flared. Figure 1 A B C TYPES OF RE-FLANGING OF RIGID PIPES A Type re-flanging General Deburr pipe (1), insert union fitting (2) on this and position it between blocks (3) bearing against pin (5). Lock pipe (1) with screw (4). 31971 31974 31973 Move pin (4) to neutral position. Tighten screw (1) until matrix die (2) comes up against blocks (3), thus forming the end of the pipe (5). 31972 31975 Position of press 99386523 (3) the blocks (1) so that the stamped numbers indicating the diameter of the pipes to be worked are facing towards the due (2). The choice of the matrix die (2) depends on the diameter of the pipe to be re-flanged. Additionally, the diameter of the pipe that can be re-flanged is stamped on the matrix die. Fix matrix die (2) to press 99386523 (1). For re-flanging follow the instructions given above for A Type re-flanging. Re-flanging rigid pipes B Type re-flanging Figure 2 Figure 3 Figure 4 Figure 5 HYDRO-PNEUMATIC SYSTEM - BRAKES 19 D AILY E URO 4 Base - March 2006 Print 603.93.651 799512 PIPES AND COUPLINGS

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Fit union fitting (2) and tighten so that ring (3, Figure 6) is locked over the pipe (1). Bending rigid pipes C Type re-flanging 31979 Fit nut (2) and ring (3) over the pipe (1). Position pipe (1) in tool (3) and bend the pipe by acting on lever (2). 31976 31977 31980 To remove the pipe (2) from the tool (3) use lever (1). 31978 31981 Fit tool (1) 99386523 and select components (2) and (3) according to the diameter of the pipe to be bent. Position pipe (2) in tool (3) 99386523 and tighten screw (1). By holding the pipe (2) still, rotate the tool (3) until the pipe has been completely cut. Cutting rigid pipes Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 20 HYDRO-PNEUMATIC SYSTEM - BRAKES D AILY E URO 4 Base - March 2006 Print 603.93.651

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-Re-flange the support ring when fitted on the vehicle or at the test bench on a union fitting. -The pressure and the final distance of the pressure ring front edge from the reinforcement bush should be in accordance with those shown in the table below. When the hose is incorrectly fitted, do not reuse the hose once the bush and support ring have been removed. Replacing flexible hoses with threaded couplings Twin-layer -Only use type approved hoses; -Check the condition of the new hose, that must be free from cracks, cuts or scores; -Cut the hose at 90 ° , with respect the to axis, to the required length by means of pipe-cutter pliers 99387050; Fit the following in the specified order over the hose: -Nut (3), pressure ring (2) (the thickest part should be facing the nut (3) and the reinforcement bush (1); -The bush must be in perfect condition (it must be free from deformation or hammer dents); Carefully follow the instructions below: 10397 10398 10399 -Fit the reinforcement bush with tool 99372219 ensuring contact between its flange and end of the hose; -Make sure that the end of the hose penetrates into the rake throat of the flange; 1. Reinforcement bush - 2. Pressure ring - 3. Nut -4. Union fitting - 5. Hose - h. Distance between bush edge and ring edge (see table) After having cut the pipe, deburr and shape the ends as described previously. ASSEMBLY OF REINFORCEMENT BUSH A = CORRECT ASSEMBLY B = INCORRECT ASSEMBLY Hose mm Distance between bush edge and ring edge mm (*) Fitting pressure (N/mm 2 ) 6 x 1 8 x 1 10 x 1,5 12 x 1,6 16 x 2,34 0,040 0,050 0,050 0,060 0,060 Introduce the end of the prepared hose into the union fitting until the reinforcement bush flange rests in the appropriate seat: -To lock the nut on the union fitting, tighten this up by hand and then by means of a box wrench and dynamometric wrench; this must tightened up to the required driving torque. Single layer (*) See reference h, Fig. 14 Figure 12 Figure 13 Figure 14 By turning tool (3) around the pipe (2), screw (1) becomes loose. To completely cut the pipe, you must tighten the screw (1) as soon as it becomes loose. da 1 a 1,5 da 2 a 2,5 da 2 a 2,5 da 2 a 2,5 da 3 a 3,5 NOTE NOTE HYDRO-PNEUMATIC SYSTEM - BRAKES 21 D AILY E URO 4 Base - March 2006 Print 603.93.651

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-When hoses run through chassis members or metal parts, make sure that the holes through which they pass are fitted with rubber grommets, and that these are in good condition; -Avoid sliding the hose along sharp edges which might cause cuts; -When the hose has to be attached to existing pipe work, take into account of the additional heat to which it may be subjected (power steering pipe work). In this case the hose must be protected with shields; -When the hose has been connected, check that it is not under tension between the attachment points, instead leaving it slightly slack to take up the more substantial variations in temperature, especially for short lengths; -Before fitting, thoroughly clean the hoses by blowing compressed air through them to safeguard operation of the system. -Protect the hoses if grinding or welding operations are carried out on the vehicle. A notice is fitted in the cabin indicating the precautions to be observed to avoid damage. Figure 15 Replacing flexible hoses with quick release couplings When fitting is finished, check that all seals (unions, couplings, etc.) are completely free from leaks. When fitting the hose to the vehicle, some important points should be borne in mind: -Bends must comply with minimum radii, so as to avoid constrictions Minimum radius of curvature mm Diameter of pipe mm 13132 6 x 1 8 x 1 10 x 1,5 12 x 1,6 16 x 2,34 ~ 40 ~ 50 ~ 60 ~ 75 ~ 100 Screw the coupling into the threaded seating provided on the air valve, and tighten it to the driving torque indicated in the table. -Check that the seal ring (1) is in its seal; -Tighten the coupling until the seal gasket is in contact with the valve; -Direct the valve correctly and, by keeping the moveable part still, lock the hexagonal nut to the driving torque