Iveco 682 Service Manual

682
Repair Manual
I
Print notes
Product: 682
Construction
● F2CFE611
● F3B
Language: ENG
Name: printed 603.95.857 – base 02/2015 - 2nd ED. ENG
Publication status: 07.05.2015
IVECO S.p.A.
Lungo Stura Lazio 15/19
10156 Torino
Italy
Images and text: IVECO S.p.A. 2015

All rights reserved.
– printed 603.95.857 – base 02/2015 - 2nd ED.

Contents II
Repair Manual 1
General information 2
Engine 3
Clutch 4
Gearbox 5
Propeller shafts 6
Rear axles 7
Axles 8
Suspensions 9
Wheels and tyres 10
steering 11
Pneumatic system - Brakes 12
Bodywork and chassis 13
Scheduled maintenance 14
Electric/electronic system 15
III Contents
682 ‒ Repair Manual
Contents 1
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Contents

INTRODUCTION 3
Contents
Contents
SYMBOLS - WARNINGS . . . . . . . . . . . . . . . . . . . 5
SYMBOLS - SERVICE OPERATIONS . . . . . . . . . . . . 6
PRODUCT CODE . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . 8
GENERAL WARNINGS REGARDING THE

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . 9
Grounding and screening . . . . . . . . . . . . . . . . . . . 11
Optional electrical and mechanical parts

installations . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Conversions between the main units of measurement

of the international system and the most commonly
used derived sizes . . . . . . . . . . . . . . . . . . . . . . . 12
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Revolutions per time unit . . . . . . . . . . . . . . . . 12
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Temperature . . . . . . . . . . . . . . . . . . . . . . . . 13
Update data . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 INTRODUCTION

INTRODUCTION 5
SYMBOLS - WARNINGS
INTRODUCTION
"This document provides data, characteristics, instructions and methods to perform repair interventions on the vehicle and its com-
ponents. Anyhow, this document is addressed to qualified and specialised personnel. Iveco commercial and assistance network
personnel as well as all Iveco authorised points of assistance are specifically qualified and equipped to perform the repair inter-
ventions that are indicated in this document. Before performing any intervention, check to have available the document relating
to the vehicle model on which the intervention is being performed and also make sure that all accident prevention devices, such
as, a rough guide, goggles, helmet, gloves, shoes, as well as work equipment, lifting and transport equipment, etc., are available and
efficient, and further make sure that the vehicle is in safety conditions for intervention. Making interventions strictly observing the
indications given here, as well as using specific equipment indicated, assures a correct repair intervention, execution timing observ-
ance and operators' safety. Each repair intervention must be finalised to the recovery of functionality, efficiency and safety condi-
tions that are provided by Iveco. Each intervention on the vehicle that is finalised to a modification, alteration or anything else which
has not been authorised by Iveco, involves the exclusion of any liability by Iveco, and, in particular, where the vehicle is covered by a
warranty, each intervention involves an immediate waiver of the warranty. Iveco declines any liability for repair work. Iveco is avail-
able to provide any information necessary for the implementation of the interventions and to provide instructions for any cases and
situations not covered in this publication.
Data and information contained in this publication may be outdated as a result of changes adopted by Iveco, at any time, for tech-
nical or commercial reasons or due to the need to adapt the vehicle to the legal requirements of different countries. In the event
of discordance between the information in this manual and the actual vehicle, please contact the Iveco network before performing
any interventions.
The complete or partial reproduction of the text or illustrations herein is forbidden.
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated in
the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, Transmission, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections - disconnections of
units to/from the vehicle, overhauls at the bench and relative troubleshooting.
On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, wiring
diagrams, electric characteristics of components, component codes and troubleshooting relative to the control units specific to the
electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of
symbols has been defined to classify warnings, while another set has been specified for service operations.
SYMBOLS - WARNINGS
Danger for persons

Failure to comply with these prescriptions can result in the risk of serious injury.
Risk of serious damage to the vehicle

Partial or complete non observance of these prescriptions can lead to serious damages to the vehicle and can sometimes result in the
guarantee being voided.
General danger
Includes the dangers of both above described signals.
Environmental protection
Indicates correct behaviour in order that vehicle use is as environmentally friendly as possible.
NOTE Indicates an additional explanation for a piece of information.

6 INTRODUCTION
SYMBOLS - SERVICE OPERATIONS
SYMBOLS - SERVICE OPERATIONS

Removal
Intake
Disconnect
Refitting
Exhaust
Connect
Disassembly
Operation
Disassembly
Assembly
Compression ratio
Composition
Tolerance
Tighten to the specified torque
Weight difference
Tighten to the specified torque + angle value Rolling torque
Press or caulk Rotation
Adjustment Angle
regulation Angle value
Visual inspection
Preload
Assembly position check
Measurement
Value to be measured Revolutions per time unit
Check
Tools Temperature
Surface for machining

Pressure
Machined finished product
Oversized
Interference
Greater than ...
Forced assembly
Maximum
Undersized
Thickness
Lesser than ...
Clearance
Minimum
Lubricate Selection
Dampen Classes
Grease Oversizes
Temperature < 0 °C
Sealant
Cold
Glue
Winter
Temperature > 0 °C
Air bleeding Hot
Summer
Replacement
Original spare parts

INTRODUCTION 7
PRODUCT CODE
PRODUCT CODE
AABBCC
● A A B B C C ‒ Product Code
Note The first and second figures identify the PRODUCT within motor vehicle.
50 Chassis
52 Axles
53 Gearbox
76 Electric system
● A A B B C C ‒ Unit code
Note The third and fourth digit identify the UNIT within the PRODUCT.
01 Chassis
02 Bumper-underrun
03 Alternator
● A A B B C C ‒ Sub-assembly Code
Note The fifth and sixth digit exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT.
40 Chassis cross members

13 Rotor

8 INTRODUCTION
GENERAL WARNINGS
GENERAL WARNINGS
The warnings shown may not be representative of all the dangerous situations that may occur. Therefore, supervisors should be contacted
whenever a dangerous situation that has not been described occurs.
Use the specific and general equipment according to that prescribed in the respective use and maintenance handbooks. Check the working
condition and suitability of tools not subject to periodic review.
Manual handling of loads must be previously appraised regarding the weight, size and path.
Handling with mechanical equipment must be done using appropriate lifts and hoists, in terms of weight, shape and volume. Hoisters, ropes
and hooks used must show clear indications regarding maximum acceptable carrying capacity. The use of such tools is strictly permitted by
authorised personnel only. Stay at a safe distance from the load and never below it.
In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out from accidentally
striking workshop personnel.
Shop activities performed by two technicians must always been executed with caution; avoid operations that may be dangerous for any
collaborators due to lack of field of vision or incorrect position.
Keep any personnel not assigned to the operations clear of working area.
Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it.
Scrupulously observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Upon completing repair work,
before starting the vehicle, perform all checks indicated in the "Checks by the user" paragraph of the Use and Maintenance handbook.
In case of poor visibility when manoeuvring the vehicle, assign a person at ground level to assist. Do not leave the vehicle in motion unat-
tended during repair work.
Keep the vehicle stationary using appropriate chocks.
When working on a vehicle off the ground, make sure that it is resting firmly on the appropriate supports and that the manual/automatic
safety devices are activated in the event of lifting with a hydraulic ramp.
When working on vehicles fuelled with natural gas, in addition to the instructions given in the document, also observe all the specific safety
regulations provided.
Remove the expansion tank cap only when the engine is cold, unscrewing it carefully to allow the residual pressure in the system to es-
cape.
Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 16 point cards of harmful
materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks, in order to prevent
sudden fires/explosions. Suitably store flammable, corrosive and pollutant fluids and liquids in accordance with current regulations. Strictly
avoid using containers for food to store harmful liquids. Avoid drilling or burning pressurised containers and discard cloths impregnated
with inflammable substances into suitable containers.
Worn out, damaged or consumable parts must be replaced with original Iveco spare parts.
During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and stains of liquids and
oils. Electric sockets and electrical equipment necessary to perform repair operations must meet safety rules.
For operations on the vehicle's hydraulic, pneumatic, air conditioning and airbag systems (if so equipped), carefully comply with the indica-
tions provided in the relevant sections of the manual.
Wear, where required by the operation, garments and protection provided for by accident prevention rules; contact with moving parts can
cause serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc.
Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside.
Do not breathe fumes from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated areas. Wear an appro-
priate respirator in the presence of paint dust.
Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. Avoid direct contact with
liquids and fluids inside vehicle systems; consult the 16 remedy points sheet if accidental contact occurs.

INTRODUCTION 9
GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM
Clean the units or assemblies removed from the vehicle and carefully check their integrity before overhauling. Place in an orderly fashion
and in appropriate containers the parts removed or disassembled with their respective fixing elements (screws, nuts, etc.).
Check the integrity of the parts that prevent the loosening of screws: split washers, split pins, clips, etc. Self-locking nuts with nylon inserts
must always be replaced.
Avoid contact of rubber with diesel fuel, petrol or other incompatible substances.
Before pressure washing mechanical parts, protect electrical connectors and any control units.
The tightening of screws and nuts should always be carried out according to directions; IVECO's sales and assistance network is available to
provide any clarifications necessary to carry out any repair work not covered by this document..
Before welding:
● Disconnect all electronic control units and unplug the power cable from the battery's positive terminal (connecting it to the chassis
ground) and connectors.
● Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
● Wait approximately 15 minutes before proceeding with welding.
● Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable materials flow when
welding.
Should the vehicle be subjected to temperatures exceeding 80 °C (dryer ovens), remove the electronic control units.
The disposal of all liquids and fluids should be carried out in strict compliance with specific regulations in force.
When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the chassis ground cable
first of all from the negative terminal of the battery.
Before connecting the batteries to the system, make sure that the system is suitably insulated.
Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from the battery termin-
als.
Do not cause sparks to verify the presence of voltage in a circuit.
Do not use a test bulb to check the continuity of a circuit. Only use the appropriate testing devices.
Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding, grounding, etc.)
conform with the IVECO system and that they are carefully restored after repair or maintenance work.
When working on electronic control units, plug connections and electrical connections to the components, measurements can be made
only on suitable testing lines, by means of special plugs and plug-type bushes. Never use improvised equipment like metal wires, screw-
drivers, pins or similar. In addition to the risk of causing a short circuit, this might damage plug-type connections and this would then give
rise to contact problems.
Before changing an electronic control unit, check the wiring and if necessary contact the market T.H.D. (Technical Help Desk) for author-
isation or advice about the possible operations to perform before changing the ECU.
For current drawing carefully follow the indications given in the section Electrical/Electronic system of this manual. It is absolutely forbidden
to draw current from unauthorised points.

10 INTRODUCTION
Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries or special truck.
Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries) may lead to their
destruction.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening torque.
Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.
Do not directly supply current to components served by electronic control units with nominal vehicle voltage.
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.
Key storage procedures are affected by electromagnetic disturbances such as cell phones and the like. Therefore, during key storage:
1. Make sure there are no sources of disturbance near the keys or in the cab.
2. Keys not inserted in the panel must be at least 1 metre away.
Note The connectors are viewed from the cable side. Connector views contained in the manual are representative of cable side.
For fuse identification and rating, comply with the indications present in the vehicle, since their identification or rating may be
subject to changes.
In order to prevent damage or short-circuiting of the on-board electronic control units, the following operations must be always carried
out before starting any welding operation on the chassis.
When doing arc welding on the vehicle, isolate the electrical system as follows:
1. disconnect the power supply cable from battery positive terminal and connect the cable to chassis ground;
2. disconnect the power supply cable from battery negative terminal;
3. disconnect the connectors from electronic control units and ward off touching control unit connector pins with your hands.
Moreover:
1. Should the control unit be close to the part to be welded, take the control unit off its position;
2. where possible, connect the welding machine ground directly to the piece to be welded.
In the case of vehicles equipped with a DTCO digital tachograph, do not disconnect the battery leads and then connect them by jumpers
to reset the electronic systems.
This operation should be avoided, as it could cause permanent damage to the DTCO tachograph CARD or other on-board electronic
systems.
To reset the electronic system without running risks, disconnect the vehicle battery and wait for 10 minutes.
It is strictly forbidden to carry out any modifications or connections to the electronic control unit wiring. In particular, the data line
between the control units (CAN line) is to be considered untouchable.
Diagnostic and maintenance operations can only be carried out by authorised personnel with IVECO approved equipment.

INTRODUCTION 11
Grounding and screening
Grounding and screening
185272 Figure 1
The negative conductors connected to a system grounding point must be as short as possible and connected in a "star pattern", as
well as being tightened down correctly and as specified ref. (M).
d
C
d
C
88039 Figure 2
The following precautions must be observed regarding the electronic components:
● electronic control units must be connected to the system ground when equipped with metal housings.
● Electronic control unit negative cables must be connected to a system ground point, such as the dashboard compartment
ground (avoiding "serial" or "chain" connections), as well as to the negative terminal of the battery/is.
● Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have optimal isolation.
Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
● The metal braid of the shielded circuits must be in contact only at the control unit side to which the signal is to be sent.
● In the case of junction connectors the unshielded section (d), near to the latter, must be as short as possible.
● The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.

12 INTRODUCTION
Optional electrical and mechanical parts installations
Optional electrical and mechanical parts installations

Installation of accessories, additions and modifications to the vehicle must be carried out in compliance with the IVECO assembly
directives (the specific publication "Directives for conversion and set-ups" is available from the Service Network workshops).
It is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional)
sockets in order to simplify and normalise the electrical intervention by fitters.
For any exception to mounting instructions, IVECO's authorisation is necessary.
Lack of observance of above described prescriptions involves guarantee lapse.
▶ It is strictly forbidden to carry out any modifications or connections to the electric control unit wiring. In particular,
the data line between the control units (CAN line) is to be considered untouchable.
Conversions between the main units of measurement of the international system and the most
commonly used derived sizes
Power
1 kW=1.36 CV
1 kW=1.34 HP
1 CV=0.736 kW
1 CV=0.986 HP
1 HP=0.746 kW
1 HP=1.014 CV
Torque
1 Nm = 0.102 kgm
1 kgm=9.81 Nm
Revolutions per time unit

1 rad/s = 1 rpm x 0.1047
1 rpm = 1 rad/s x 9.5493
Pressure
1 bar=1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly required:
● the unit Nm is converted into kgm for simplicity according to a 10:1 ratio
1 kgm = 10 Nm;
● the unit bar is converted into kg/cm2 for simplicity according to a 1:1 ratio
1 kg/cm2 = 1 bar.

INTRODUCTION 13
Update data
Temperature
0 °C = 32 °F
1 °C = (1x1.8+32) °F
Update data
Section Description Page Revision date

14 INTRODUCTION

682 ‒ General information
Contents 1
Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3

2 Contents

GENERAL INFORMATION 3
Contents
Contents
VEHICLE IDENTIFICATION DATA . . . . . . . . . . . . . 5

Vehicle identification plate . . . . . . . . . . . . . . . . . 5
Vehicle identification number (V.I.N.) punched on
the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMMERCIAL CODES . . . . . . . . . . . . . . . . . . . . 7
DECODING VCB EURO III VEHICLE . . . . . . . . . . . 8
DECODING VCB EURO IV VEHICLE . . . . . . . . . . . 9
COMPOSITION OF EURO III MODELS . . . . . . . . . 10
COMPOSITION OF EURO IV MODELS . . . . . . . . . 11
REFUELLING . . . . . . . . . . . . . . . . . . . . . . . . . . 11
International lubricants and fuels designation . . . . 12

4 GENERAL INFORMATION

VEHICLE IDENTIFICATION DATA
GENERAL INFORMATION
200103 Figure 1
The type and number of engine, type and number of chassis and manufacturer's plate comprise the vehicle identification data.
Vehicle identification plate

The data plate is located on the back of the vehicle, on the chassis cross member.

707852 Figure 2
The vehicle identification plate shows the following information:
1. The vehicle VIN

2. The GVW (gross vehicle weight)
3. The GCW (gross combination weight)
4. Weight allowed on 1st axle
5. Weight allowed on 2nd axle
6. Weight allowed on 3rd axle
7. Model
8. The engine model and wheelbase. In some cases the wheelbase between the first and second axle and the tandem wheelbase
(distance between the second and third axle)
9. Engine power and number of axles
10. Headlight position parameters
Vehicle identification number (V.I.N.) punched on the chassis

The vehicle identification number (V.I.N.) punched on the chassis is made up of 17 alphanumeric characters assigned by the manu-
facturer to the individual vehicle. This number definitively identifies each vehicle for a period of 30 years.
Location
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Positions 1-2-3: Manufacturer identification
Positions 4-5-6-7-8-9: General vehicle characteristics (vehicle type, total weight, engine rating, type-approval, engine type)
Location 10: Year of manufacture (conventionally 0)
Location 11: Chassis manufacturer

COMMERCIAL CODES
Positions 12-13-14-15-16-17: Progressive production number
COMMERCIAL CODES
SC 430 G 34 H T S
● SC 430 G 34 H T S ‒ Cab type

DC Short cab (Day cab)
SC Long cab (Sleeper cab)
● SC 430 G 34 H T S ‒ Total ground

190 4x2 trucks
260 6x4 Trucks - 6x4 Tippers
330 6x4 Tippers
410 8x4 Tippers
430 4x2 Tractors
600 4x2 - 6x4 Tractors
● SC 430 G 34 H T S ‒ Iveco range code 682

● SC 430 G 34 H T S ‒ Engine power
29 290 HP C9 E3
34 340 HP C9 E3
35 350 HP C9 E4
38 380 HP C9 E3
39 390 HP C9 E4
43 430 HP C13 E3
48 480 HP C13 E3
● SC 430 G 34 H T S ‒ Type of use

– ON ROAD
H OFF ROAD
● SC 430 G 34 H T S ‒ Version
− Truck
T Tractor
● SC 430 G 34 H T S ‒ Type of rear axle

− double reduction (HR)
S single reduction (SR)

DECODING VCB EURO III VEHICLE
DECODING VCB EURO III VEHICLE
AAABBCCD
● A A A B B C C D ‒ ENABLED'
F 682
● A A A B B C C D ‒ AXLE CONFIGURATION - TOTAL GROUND MASS

2 Chassis cab 4x2 (18 ton)
4 Tractors 4x2 (18 ton)
6 Chassis cab 6x4 (25 ton)
7 Tractors 6x4 (25 ton)
9 Tippers 6x4 (25 ton)
A Tippers 8x4 (31 ton)
● A A A B B C C D ‒ MOTOR UNIT
A 290 HP C9 E3
B 340 HP C9 E3
C 380 HP C9 E3
E 430 HP C13 E3
G 480 HP C13 E3
● A A A B B C C D ‒ TYPE OF REAR AXLE - TYPE OF SUSPENSION

Note H.R. = Double reduction axle
S.R. = Single reduction rear axle
A Mechanical - SR
B Mechanical - HR
● A A A B B C C D ‒ VERSION
1 Truck
2 Tractor
3 Tipper
● A A A B B C C D ‒ WHEELBASE
Note □ = Cab vehicles
● = Tractors
ο = Tippers
1 6x4 (●) 3300+1350; 6x4 (ο) 3325+1350; 4x2 (●) 3650; 8x4 (ο) 4500
2 6x4 (ο) 3625+1350; 8x4 (ο) 4825
3 6x4 (□) 3825+1350; 6x4 (ο) 3825+1350
4 6x4 (ο) 4225+1350; 4x2 (□) 4600; 8x4 (ο) 5425
5 6x4 (□) 4425+1350; 6x4 (ο) 4425+1350;
6 6x4 (ο) 4725+1350; 6x4 (□) 5025+1350
7 4x2 (□) 5600
8 6x4 (□) 5925+1350
● A A A B B C C D ‒ GEARBOXES

DECODING VCB EURO IV VEHICLE
A 9M
B 12M
● A A A B B C C D ‒ CAB TYPE - STEERING - BRAKE COMBINATION

A AS-C - RH - Drum/Drum
1 AS-C - LH - Drum/Drum
D AS-L - RH - Drum/Drum
4 AS-L - LH - Drum/Drum
DECODING VCB EURO IV VEHICLE
AAABBCCD
● A A A B B C C D ‒ ENABLED'
K 682
● A A A B B C C D ‒ AXLE CONFIGURATION - TOTAL GROUND MASS

2 4x2 Tractors
5 6x4 Tractors
6 6x4 Tippers
● A A A B B C C D ‒ MOTOR UNIT
B 350 HP C9 E4
C 390 HP C9 E4
● A A A B B C C D ‒ TYPE OF REAR AXLE - TYPE OF SUSPENSION

Note H.R. = Double reduction axle
S.R. = Single reduction rear axle
A Mechanical - SR
B Mechanical - HR
● A A A B B C C D ‒ VERSION
2 Tractor
3 Tipper
● A A A B B C C D ‒ WHEELBASE
Note ● = Tractors
ο = Tippers
1 6x4 (●) 3300+1350; 6x4 (ο) 3325+1350; 4x2 (●) 3650

2 6x4 (ο) 3625+1350
3 6x4 (ο) 3825+1350
● A A A B B C C D ‒ GEARBOXES
B 12M
● A A A B B C C D ‒ CAB TYPE - STEERING - BRAKE COMBINATION

1 AS-C - LH - Drum/Drum
4 AS-L - LH - Drum/Drum

COMPOSITION OF EURO III MODELS
COMPOSITION OF EURO III MODELS

MODELS TRACTOR TRUCK TIPPER
(CH64) 6x4
(CH84) 8x4
(CSTZ) 6x4
(CST2) 4x2
(CS42) 4x2
(CS64) 6x4
PF
SC/DC 330 G 34 H
SC/DC 330 G 38 H
SC/DC 330 G 43 H
SC/DC 410 G 38 H
SC/DC 410 G 43 H
SC/DC 190 G 29 S
SC/DC 260 G 34 S
SC 430 G 34 TS
SC 430 G 38 TS
SC 430 G 48 TS
SC 600 G 34 TS
SC 600 G 38 TS
SC 600 G 43 TS
SC 600 G 48 TS
DC 260 G29 H
SC 260 G 38 S
SC 600 G 34 T
SC 600 G 38 T
SC 600 G 43 T
SC 600 G 48 T
GROUPS
CURSOR 9 - 290 HP ● ●
CURSOR 9 - 340 HP ● ● ● ● ●
CURSOR 9 - 380 HP ● ● ● ● ● ●
CURSOR 13 - 430 HP ● ● ● ●
CURSOR 13 - 480 HP ● ● ●
17" single disc ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
9 JS 135 T-B ● ●
12 JSD 160 T ● ●
12 JSD 160 TA ● ● ● ●
12 JSD 180 T ● ●
12 JSD 180 TA ● ● ●
12 JSD 220 T ● ●
12 JSD 220 TA ● ● ● ● ●
CF7140 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
Single reduction rear axle (SR) ● ● ● ● ● ● ● ● ● ●

Double reduction rear axle (HR) ● ● ● ● ● ● ● ● ● ●
ZF 8098 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
Front mechanical ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
Parabolic ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
Rear mechanical
Semi-elliptic ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

COMPOSITION OF EURO IV MODELS
COMPOSITION OF EURO IV MODELS

MODELS TRACTOR TIPPER
4x2 6x4 6x4
PF
CST3 CST5 CH54
SC/DC 330 G 35 H
SC 430 G 39 TS
SC 600 G 39 TS
SC 600 G 39 T
GROUPS
CURSOR 9 - 350 HP ●
CURSOR 9 - 390 HP ● ● ●
17" single disc ● ● ● ●
12 JSD 180 T ●
12 JSD 180 TA ● ● ●
CF7140 ● ● ● ●
Single reduction rear axle (SR) ● ●

Double reduction rear axle (HR) ● ●
ZF 8098 ● ● ● ●
Front mechanical ● ● ● ●
Parabolic ● ● ● ●
Rear mechanical
Semi-elliptic ● ● ● ●
REFUELLING
Quantity
IVECO RECOMMENDED LUBRICANTS PARTS TO BE REFILLED
litres kg
Urania FE 5W30 (1) F2C engine
Urania LD7 Total capacity of 1st filling 26 23.4
F3B engine
Urania FE 5W30 (1)
Total capacity of 1st filling 35 31.9
Urania LD7
Replacement capacity (including oil filter) 28 25.5
Gearbox
9 JS 135 T-B 12.5 11.5
12 JSD 160 T 17 16
Tutela Transmission 12 JSD 160 TA 17 16
W90/M_DA 12 JSD 180 T 18.5 17.5
12 JSD 180 TA 18.5 17.5
12 JSD 220 T 18.5 17.5
12 JSD 220 TA 18.5 17.5
Tutela Truck FE-Gear
total power take off
Tutela ZC 90

REFUELLING
Quantity
IVECO RECOMMENDED LUBRICANTS PARTS TO BE REFILLED
litres kg
Single reduction intermediate rear axle SR 22.4 (20 + 1.2x2) 20.5
Single reduction rear axle SR (4x2 vehicles) 17 15.6
Tutela Transmission
Single reduction rear axle SR (6x4 vehicles) 24.4 (22 + 1.2x2) 22.4
W140/M-DA (2)
Double reduction rear axle (HR) 10 (6 + 2x2) 9.2
Double reduction intermediate axle (HR) 12.3 (8.2 + 2x2) 11.3
HYDRAULIC CAR
Power steering 12 10.9
32HVI
Tutela TRUCK DOT SPE-

Clutch circuit 0.5 0.45
CIAL
Cooling system
Total capacity*
Water+Paraflu¹¹ 45 40.5
* = Protective antifreeze (50% concentration freezing
point -35°C)
HYDRAULIC CAR
Cab tilting system 0.6 0.54
32HVI
R134A Air conditioning system –
(1) IVECO recommends using these oils to obtain benefits in terms of "fuel economy". The vehicle is already equipped by IVECO with these types of lubric-
ants (also suitable for cold climates with minimum temperatures of up to -30°C).
(2) Suitable for hot or temperate climates
International lubricants and fuels designation
International lubricants and fuels designation Original products

ENGINE OIL
Meets specifications:
ACEA E4/E7 with fully synthetic base URANIA FE 5W30 (1)
SAE 5W 30
Qualification IVECO Standard 18-1804 Class TFE (C.T.R.. I023.M01)
Mineral based ACEA E5/E7 Urania LD7
SAE 15W 40
Qualification IVECO STANDARD 18-1804 Class T2 E7 (C.T.R. I517.F06)
OIL FOR MECHANICAL GEARBOXES
API GL5 with a mineral base Tutela Transmission W90/M - DA
SAE 80W 90
Qualification IVECO STANDARD 18-1805 Class RAM 1 (C.T.R. N. I009.G87)
OIL FOR DIFFERENTIAL AND WHEEL HUBS
API GL5 with a mineral base SAE 85W 140 Tutela Transmission W140/M-DA (2)
Qualification IVECO STANDARD 18-1805 class RAM2 (C.T.R. I014.N87) (C.T.R. I014.N87)
OIL FOR POWER STEERING AND HYDROSTATIC TRANSMISSIONS
Meets specifications: HYDRAULIC CAR 32 HVI
ISO VG32
HYDRAULIC CAB TILTING SYSTEM OIL
Meets specifications: HYDRAULIC CAR 32 HVI
ISO VG32
SPECIFIC GREASE FOR WHEEL HUB BEARINGS
with lithium soap base, N.L.G.I. consistency no. 2 Tutela MR 2
Qualification IVECO STANDARD 18-1810 Class 1 (C.T.R. I007.C89)
Qualification IVECO STANDARD 18-1810 Class 1 (C.T.R. I002.I90)

REFUELLING
International lubricants and fuels designation Original products

GREASE FOR GENERAL GREASING
Qualification IVECO STANDARD 18-1810 Class 1 (C.T.R. I007.C89)
FLUID FOR CLUTCH CONTROL
Compliant with N.H.T.S.A. standards N 116, ISO 4925, Std. SAE J 1703
● N.H.T.S.A. 116 DOT 4 Tutela TRUCK DOT SPECIAL
● ISO 4925 (C.T.R. I002.F99)
● Std. SAE J 1704
Qualification IVECO STANDARD 18-1820
WINDSCREEN WASHER LIQUID
Tutela Professional SC 35
mixture of alcohol and surfactants CUNA NC 956-11
(C.T.R. I005.B00)
GREASE FOR CENTRAL LUBRICATION SYSTEMS
Tutela COMAR 2 (3)
with a synthetic base containing lithium soaps of NLGI grade 2
(C.T.R. I001.G95)
Qualification IVECO STANDARD 18-1810 class X
CONCENTRATED PROTECTIVE FLUID FOR RADIATORS
Paraflu11 (4)
based on ethylene glycol containing corrosion inhibitors
(C.T.R. I002.C00)
REFRIGERANT FOR AIR CONDITIONING
R134a
1. IVECO recommends using these oils in order to obtain benefits in terms of "fuel economy". Suited for cold climates as well (minimum temperat-
ure down to -30°C).
2. Suitable for hot or temperate climates.
3. Working temperatures: from -30 °C to +140 °C
4. To be used diluted with water at 50%.
IVECO guarantees optimum engine performance when genuine lubricants are used.
If non-original products are used, lubricants with minimum ACEA performance are acceptable for the Diesel engines specified in the table. Using
products with inferior characteristics to these ACEA specifications could cause engine damage not covered by warranty.


682 ‒ Engine
Contents 1
Contents
MAIN REPAIR OPERATIONS ON VEHICLE . . . . . . . 3
F2C ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 103
F3B ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 267
DENOX SYSTEM . . . . . . . . . . . . . . . . . . . . . . 445
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 471

682 ‒ Engine
2 Contents

682 ‒ Engine
MAIN REPAIR OPERATIONS ON VEHICLE 3
Contents
Contents Change filter and clean horizontal air filter

casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MAIN FUEL SUPPLY SYSTEM REPAIRS . . . . . . . . . . . 5 Change filter and clean vertical air filter
Replacing the vehicle electro-injectors (F2C casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Replacement of intercooler on the vehicle . . . . . . 51
Replacing the vehicle electro-injectors (F3B
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MAIN REPAIRS ON LUBRICATION SYSTEM . . . . . . 51
Replacing the vehicle hydraulic accumulator (rail) Replacement oil sump on vehicle . . . . . . . . . . . . 51
(F3B Engines) . . . . . . . . . . . . . . . . . . . . . . . . 12 Replacement of the engine oil on vehicle . . . . . . . 52
Replacing the vehicle EDC control unit (F2C Replacing the vehicle heat exchanger (F2C
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacing the vehicle EDC control unit (F3B
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 MAIN REPAIRS ON COOLING SYSTEM . . . . . . . . 54
High pressure pump replacement on the vehicle Replacement of fan on the vehicle . . . . . . . . . . . 54
(F2C engines) . . . . . . . . . . . . . . . . . . . . . . . . 18 Replacement of viscostatic coupling on the
High pressure pump replacement on the vehicle vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
(F3B engines) . . . . . . . . . . . . . . . . . . . . . . . . 18 Replacement of radiator on the vehicle . . . . . . . . 55
Fuel pre-filter replacement on the vehicle . . . . . . 34 Replacing the thermostat on the vehicle (F2C
Fuel pre-filter support replacement . . . . . . . . . . 34 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Sediment filter replacement . . . . . . . . . . . . . . . 35 Replacing the vehicle thermostat (F3B

Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Replacing the vehicle fuel filter (F2C Engines) . . . . 35
Replacing the water pump on the vehicle (F2C
Replacing the vehicle fuel filter (F3B Engines) . . . . 36 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fuel tank replacement. . . . . . . . . . . . . . . . . . . 36 Replacing the water pump on the vehicle (F3B
Bleeding air from the fuel circuit . . . . . . . . . . . . 38 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cooling system air bleeding . . . . . . . . . . . . . . . 64
MAIN REPAIRS ON BOOSTER SYSTEM . . . . . . . . . 39
Exhaust piping replacement . . . . . . . . . . . . . . . 39 MAIN REPAIRS ON BELTS AND AUXILIARY
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Silencer replacement . . . . . . . . . . . . . . . . . . . 39
Replacement of the air conditioner compressor
Silencer replacement (versions with vertical
drive belt on the vehicle . . . . . . . . . . . . . . . . . 65
exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Replacement of the water pump/alternator belt on
Replacing the engine brake device on the
the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 66
vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Replacement of the belt tensioner on vehicles . . . . 66
Replacing the turbocharger (F2C Engines) . . . . . . 43
Replacement of A/C compressor on the
Replacing the vehicle turbocharger (F3B
vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Replacement of alternator on the vehicle . . . . . . 67
Replacing the exhaust manifold on vehicle (F2C
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
MAIN REPAIRS ON DISTRIBUTION PARTS . . . . . . 69
Replacing the exhaust manifold on vehicle (F3B
Replacement of rocker cover on vehicle . . . . . . . 69
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacing the rocker arm cover on vehicle (F3B
Replacing the SNORKEL engine air vent (8x4
8x4 Versions) . . . . . . . . . . . . . . . . . . . . . . . . 69
vehicles - F3B engines) . . . . . . . . . . . . . . . . . . 48
Replacing the vehicle rocker arm shaft (F2C
Replacing the air filter casing on the vehicle. . . . . . 48
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacing the vehicle rocker arm shaft (F3B
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

682 ‒ Engine
4 MAIN REPAIR OPERATIONS ON VEHICLE
Contents
Replace the cylinder head on the vehicle (F2C

engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Replacing the vehicle camshaft (F2C Engines) . . . . 85
Replacing the vehicle camshaft (F3B Engines) . . . . 85
MAIN REPAIRS ON ENGINE PARTS . . . . . . . . . . . 89

Replace rod-piston on vehicle (F2C Engines) . . . . 89
Replace cylinder liners on vehicle (F2C
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
MAIN REPAIRS ON SERVICE PARTS . . . . . . . . . . . 95

Replacement of starter motor on the vehicle . . . . 95
Replacing the power steering pump on the vehicle
(F2C Engines) . . . . . . . . . . . . . . . . . . . . . . . . 96
Replacing the power steering pump on the vehicle
(F3B Engines) . . . . . . . . . . . . . . . . . . . . . . . . 97
Replacing the vehicle air compressor (F2C
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Replacing the vehicle air compressor (F3B
Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

682 ‒ Engine
MAIN FUEL SUPPLY SYSTEM REPAIRS
MAIN REPAIR OPERATIONS ON VEHICLE

.775010. Replacing the vehicle electro-injectors (F2C Engines)
Tightening torques
Injector retainer screws 21 ±3 N⋅m
Caution!
High-pressure fuel pipes Replacement
▶ Each time the high pressure fuel pipes are removed they must be replaced with new ones.
Note Drain the fuel in the cylinder heads before replacing the injectors.
Main action
.775010. Removing the vehicle electro-injectors (F2C Engines)
1. Remove the rocker cover as described in the relevant chapter (Removing the rocker arm cover on vehicle ( ➠ Page 69)).
2. Remove the electric connections (1) from injectors.

3. Remove the HP fuel pipe, followed by the fuel supply pipe (2)
from the rail HP pump, the fuel return pipe (5) and the 6 fuel
pipes (6) between the rail and injector.
4. Remove the injector wiring (7) from the head. The wiring has
to be removed from the front.
5. Loosen the couplings (3) and remove the oil pipe (4) connec-
ted to the engine brake cylinder and engine brake solenoid cyl-
inder.
173805 Figure 1

682 ‒ Engine
6. Unscrew the retaining screws (1) and remove the rail (2).
7. Remove the rocker arm shaft as described in the relevant
chapter (Removing the vehicle rocker arm shaft (F2C Engines)
( ➠ Page 71)).
8. Remove and mark the bridges on the valve stem.
173806 Figure 2
9. Undo the fixing screw (1) and remove the injector fixing
bracket (2).
169527 Figure 3
10. Position tool 99342157 (1) as in the figure and remove the
injectors (2) from the head.
169826 Figure 4

682 ‒ Engine
.775010. Refitting the vehicle electro-injectors (F2C Engines)

11. Install the injectors (1) along with brackets and gaskets (2) into
the cylinder head seats.
169828 Figure 5
12. Position the injectors (2) so that the distance X between inject-
ors and valve springs (1) is equal on both sides.
13. Tighten the injector fixing screws (1) to the prescribed torque.
Tightening torque
173807 Figure 6
Caution!

682 ‒ Engine
14. Refit the rocker arm shaft as described in the relevant

chapter ( Refitting the vehicle rocker arm shaft (F2C Engines)
( ➠ Page 72)).
15. Secure the rail to the head by screwing the fixing screws to the
specified torque.
16. Fit the glow plug wiring (7).
17. Refit the oil pipe (4) connected to the engine brake cylinder
and engine brake solenoid valve cylinder and tighten the coup-
lings to the specified torque.
18. Refit the HP fuel pipes (2), (5) and (6) and tighten couplings to
the specified torque.
19. Reconnect the electric connections (1) to the electro-injectors
and retain the wiring to the fuel pipes (7) using cable clamps.
20. Adjust the intake and outlet rocker arm play as in the relative
chapter (541230 Intake and exhaust rocker arm clearance ad-
justment ).
21. Refit the rocker cover as described in the relative chapter
(540630 Refitting the rocker arm cover on vehicle
( ➠ Page 69)).
22. Reprogram the control unit. 173805 Figure 7
.775010. Replacing the vehicle electro-injectors (F3B Engines)
Tightening torques
High-pressure pipe couplings (supplier CHESINI) 60 ±2.5 N⋅m
High-pressure pipe couplings (supplier TI) 42 ±2.5 N⋅m
Electrical connection M4 nut 1.5 ±0.25 N⋅m
Main action
.775010. Replace the vehicle electro-injectors (F3B Engines)
1. Remove the rocker arm shaft as described in the relevant chapter (Removing the vehicle rocker arm shaft (F3B Engines)
( ➠ Page 74)).

682 ‒ Engine
216008 Figure 8
2. Disconnect the electrical connections from the electro-injectors by unscrewing the nuts (1).
3. Disconnect the electrical connection (3) on the engine brake solenoid valve.
4. Disconnect the electrical connection (8) from the rail fuel pressure sensor.
5. Remove the retainers (→) and free the head cables (7) from the HP fuel pipes (2).
Note The high pressure fuel pipes must be replaced at each disassembly.
6. Unscrew fittings (4) and (5) and remove the HP fuel pipes (2) between rail (6) and injectors.
7. Remove and mark the bridges on the valve stem.
8. Undo the fixing screw (1) and remove the injector fixing
bracket (2).
169827 Figure 9

682 ‒ Engine
9. Use a suitable tool (1) to pull out the injectors (2) from the
head.
169826 Figure 10
.775010. Refitting the vehicle electro-injectors (F3B Engines)

10. Install the injectors (1) along with brackets and gaskets (2) into
the cylinder head seats.
Note Mount the electro-injectors in the same position when
removed.
169828 Figure 11
11. Position the injectors (2) so that the distance (X) between
injectors and valve springs (1) is equal on both sides.
173807 Figure 12
Caution!

682 ‒ Engine
216008 Figure 13
12. Connect the HP fuel pipes (2) starting from cylinder 1 and respecting the sequence 1st-2nd-3rd-6th-5th-4th, tightening the
couplings by hand.
Note Before tightening the couplings to torque make sure that the pipes (2) are not touching each other.
13. Tighten the injector fixing screws to the prescribed torque.
Tightening torque
14. Complete assembly of HP fuel pipes (2) by first tightening the injector side couplings (4) and then those on the rail side (5).
Tightening torque
15. Mount the injector wiring (7) retaining it to the HP fuel pipes where indicated (→).
16. Connect the fuel pressure sensor for the rail (8) and engine brake solenoid valve (3).
17. Connect the electrical connections to the injectors by tightening the nuts (1) to the torque specified.
Tightening torque
Electrical connection M4 nut (1) 1.5 ±0.25 N⋅m
18. Refit the rocker arm shaft as described in the relevant chapter ( Refitting the vehicle rocker arm shaft (F3B Engines)
( ➠ Page 76)Operation 541230).

682 ‒ Engine
.774510. Replacing the vehicle hydraulic accumulator (rail) (F3B Engines)
Tightening torques
Rail fixing screws 23.5 ±2.5 N⋅m
Screws fixing the high pressure fuel supply pipe support brackets to the head 23.5 ±2.5 N⋅m
Fuel return coupling from the rail. 50 N⋅m
Main action
.774510. Removal of the vehicle hydraulic accumulator (rail) (F3B Engines)
Note The high pressure fuel pipes cannot be re-used but must be replaced each time they are removed.
1. Cut off the power supply from the electrical system by opening the main current switch and by disconnecting the cables from
the batteries.
2. Remove the vehicle rocker arm shaft. ( ➠ Page 74)
183458 Figure 14
3. Unscrew the fixing screws of the high pressure fuel delivery pipes supports (8).
4. Unscrew the fittings and remove the high pressure fuel supply pipes (8).
5. Unscrew the fittings from the rail and the injectors and detach the high pressure fuel pipes (1, 2, 3, 4, 5 ) and (6) the fuel
return pipe (7) from the head.
6. Disconnect the electrical connection from the pressure sensor (11).

682 ‒ Engine
.774510. Refitting of the vehicle hydraulic accumulator (rail) (F3B Engines)
216010 Figure 15
8. Fit the rail (6) onto the head and tighten the fixing screws (5) to the specified torque.
Tightening torque
Rail fixing screws (5) 23.5 ±2.5 N⋅m
Caution!
9. Connect the HP fuel pipes (3) starting from cylinder 1 and respecting the sequence 1st-2nd-3rd-6th-5th-4th, tightening the
couplings by hand.
10. Connect the rail supply high pressure fuel pipes (2).
Note Before tightening the couplings to torque make sure that the pipes (3) and (2) are not touching each other.
11. Complete assembly of HP fuel pipes (3) by first tightening the injector side couplings and then those on the rail side.
Tightening torque
12. Tighten the couplings of the high pressure fuel pipes (2), tightening the couplings to the required torque.
Tightening torque
13. Fix the fuel supply pipe support brackets, tightening the screws (1) to the required torque.

682 ‒ Engine
216010 Figure 15
Tightening torque
Screws fixing the high pressure fuel supply pipe support brackets to the 23.5 ±2.5 N⋅m
head (1)
14. Connect the electrical connection to the fuel pressure sensor (8) and clamp the injector wiring (7) retaining it to the HP fuel
pipes where indicated (→).
15. Connect the fuel return pipe (4) from the rail and tighten to the prescribed torque.
Tightening torque
Fuel return coupling from the rail. 50 N⋅m
16. Refit the rocker arm shaft as described in the relevant chapter ( Refitting the vehicle rocker arm shaft (F3B Engines)
( ➠ Page 76)Operation 541230).
.766161. Replacing the vehicle EDC control unit (F2C Engines)
Caution!
Danger of injury. Possible unexpected movement of the vehicle
▶ The vehicle could move during the procedure. Take the utmost care.

682 ‒ Engine
Note Before replacing the control unit, ensure that:

The diagnostic instruments are adequately charged (if not connected to mains power);
The instrument has an active Internet connection;
The vehicle batteries are adequately charged;
The diagnostic instrument does not become disconnected when reading and programming;
The old control unit (being replaced) is properly connected: this is to allow the internal parameters to be read by the dia-
gnostic instrument:
Note Before proceeding with replacement of the control unit, be sure you have the vehicle's VIN number available.
Main action
1. Before removing the control unit, connect the diagnostic instru-
ment to the diagnostic socket (1) and start the replacement
procedure.
Note For the IVECO Service Network:
- in Teleservices mode, select the item for control unit
replacement with the relevant vehicle range;
- select the control unit to be replaced;
– if requested, enter the Programming Card code for
the new control unit;
- select the key mode (manual - automatic).
2. Continue to remove the control unit as indicated below.
215771 Figure 16
.766161. Removal of the EDC ECU (F2C Engines)

3. Lift the cab.
4. Remove the three electrical connectors (1) that connect to the
EDC ECU (2).
5. Remove the delivery and return fuel pipes (4) acting on the
retaining couplings (3).
6. Remove the retainers (5) of the EDC ECU (2) that connect it
to the engine block (6).
7. Remove the EDC ECU (2) from the vehicle.
173596 Figure 17
.766161. Refitting of the EDC ECU (F2C Engines)

8. To refit, carry out the operations described for removal in reverse order.

682 ‒ Engine
.766161. Replacing the vehicle EDC control unit (F3B Engines)
Caution!

gnostic instrument:
Main action
ment to the diagnostic socket (1) and start the replacement
procedure.
Note For the IVECO Service Network:
- in Teleservices mode, select the item for control unit
replacement with the relevant vehicle range;
- select the control unit to be replaced;
– if requested, enter the Programming Card code for
the new control unit;
- select the key mode (manual - automatic).
2. Continue to remove the control unit as indicated below.
215771 Figure 18

682 ‒ Engine
.766161. Removing the vehicle EDC control unit (F3B Engines)

3. Disconnect the negative cable from the battery.
178187 Figure 19
4. Lift the cab.

5. Working from the right of the engine to make it easier to ac-
cess the control unit, disassemble the power steering oil tank,
the engine ignition push button panel and the intake manifold.
Note It may not be necessary to disassemble some parts
depending on the vehicle in question.
194561 Figure 20
6. Disconnect the electrical connections from the engine control

unit (1).
7. Unscrew the screws fixing the control unit (1) to the engine
and remove it from its seat.
217715 Figure 21
.766161. Refit the vehicle EDC control unit (F3B Engines)

8. To refit, repeat the operations described for the removal process in reverse order, tightening the mounting screws to the
specified torque.

682 ‒ Engine
9. Conclude replacement by following the instructions provided by the diagnostic tool.

10. Using the diagnostics tool, perform the "new ECM ECU recognition" operation.
Note The user is promoted to insert the electronic code during this phase.
11. Finally, carry out a faults memory reading to verify that there are no errors.
.771010. High pressure pump replacement on the vehicle (F2C engines)
Work material
Extraction tool for cartridge filters 99363280
Main action
.771010. High pressure pump removal on the vehicle (F2C engines)
1. To remove the HP pump (1) remove the fuel filter (2) by
unscrewing it with the specific tool.
Tool / Material Product
code
Extraction tool for cartridge filters 99363280
2. Remove the air sleeve (3) from air filter pipe (4) to com-
pressor (5).
3. Disconnect the two fuel delivery and return piping acting on the
couplings (6).
4. Disconnect the water pump electrical connection (7) of the HP
pump (1).
5. Remove the four fasteners (8) of the HP pump (1) and re- 173598 Figure 22
move it.
.771010. High pressure pump refitting on the vehicle (F2C engines)

.771010. High pressure pump replacement on the vehicle (F3B engines)
Work material
Tool for rotating the flywheel 99360321
Spacer (to be used with 99360321) 99360325
Tool for engine T.D.C. positioning 99360612
Main action
.771010. High pressure pump removal on the vehicle (F3B engines)
Conditions
● 8x4 versions

682 ‒ Engine
▶ Unscrew the screws (2) and remove the sheet metal

guard (1).
▶ Slacken the retainer collar (5) and from the mounting
plate (3) remove the power steering oil reservoir (6)
and set it aside, making sure that no oil spills out from the
inside.
▶ Loosen the screws (4) and remove the plate (3).
216005 Figure 23
▶ Unscrew the retaining screws (4) and free the pipes (5)
from the plate (3).
▶ Loosen the nuts (1) and remove the plate (3) from the
vehicle.
▶ Undo the screws (7) and free the engine brake actuator
pneumatic pipes (CEB) from the cross-member (6).
▶ Unscrew the retaining screws (2) and remove the cross
member (6).
217887 Figure 24
1. Loosen the collars (6) and (2) and disconnect the air intake
pipes (1) from the elastic sleeves.
2. Disconnect the compressor air intake hose from the pipe (1).
3. Undo the fixing screws and remove the support brackets (3)
and remove the pipe (1).
4. Undo the screws (5) and remove the engine oil vapour
breather pipe (4).
216011 Figure 25

682 ‒ Engine
5. Unscrew the screws (1) and remove the timing gear cover (2).
216012 Figure 26
6. Remove the flywheel rpm sensors (1).
194224 Figure 27

682 ‒ Engine
7. Apply the specific tool (6) and the specific spacer (7) to the
gear casing (3).
code
Note The arrow shows the direction of rotation of the en-

gine when running.
8. Using the above-mentioned tool, turn the engine flywheel (1)
in the direction of engine rotation so as to take the piston of
cylinder no. 1 to 54° before T.D.C. in the phase of compression
(cylinder 6 in discharge phase).
Note This condition is verified when the hole with two
notches (5) on the engine flywheel (1) is visible
through the small inspection window (2).
216019 Figure 28
9. Check that the specific tool (1) is inserted in the hole (3)
present in the engine flywheel (4) through the seat (2) of the
engine speed sensor; in this condition, the flywheel is located in
the reference position (piston no. 1 to 54° before T.D.C.).
code
10. If this condition does not occur, turn and adjust the flywheel (4)
appropriately.
71774 Figure 29

682 ‒ Engine
11. Fit a suitable pin (1) through the HP pump drive gear hole (3)
and fit it into the corresponding hole on the gearbox.
12. Unscrew the fastening nut (2).
13. Remove the pin (1).
14. Remove the gear (3) using a suitable extraction tool.
216013 Figure 30
Conditions
● 8x4 versions
▶ Position a suitable container below the vehicle, disconnect

the hose (3) from the power steering pump and drain the
oil from the tank.
▶ Undo the screws (2) and remove the power steering
circuit oil supply pipe (1).
216014 Figure 31

682 ‒ Engine
15. Undo the fixing screw (2) of the supply pipe (1).
16. Undo the coupling(3) on the air delivery pipe (1) from the
compressor.
216016 Figure 32
216015 Figure 33
17. Unscrew the coupling (8), disconnect the air delivery pipe from the compressor and remove it.

682 ‒ Engine
216015 Figure 33
18. Disconnect the electrical connection (6) from the flow regulator.
19. Disconnect the electric connection (9) from phase sensor.
20. Disconnect and remove the compressor (10) air intake hose.
21. Unscrew couplings (7) and from the pump (11) disconnect the fuel pipes (low pressure).
22. Unscrew the coupling (4) and from the pump (11) disconnect the fuel supply pipe that is attached to the filter.
23. Act on the quick snap coupling (3) to disconnect the fuel return to tank pipe.
Caution!
24. Remove retainers (5) and remove the high pressure fuel delivery pipes (2).
25. Unscrew the fitting (1) and disconnect the pump lubrication pipe.

682 ‒ Engine
216017 Figure 34
26. Remove screws (4) and free the fuel return pipe from the plate (6).
27. Use a screwdriver to pry away the clamp and release the electric cable (2) from the plate (6).
28. Undo screws (1) and (5) and remove the HP pump support plate (6).

682 ‒ Engine
29. Undo the screws (2), remove the HP pump (1) from its cradle
and remove it from the vehicle.
216018 Figure 35
.771010. High pressure fuel pump refitting on the vehicle (F3B engines)
engine speed sensor and that the hole with two notches can
be seen from the bottom hole of the flywheel case (5); in this
condition, the flywheel is located in the reference position
(piston no. 1 to 54° before T.D.C.).
code
appropriately.
185523 Figure 36

682 ‒ Engine
32. Position the high pressure pump (1) into its cradle and tighten
the fixing screws (2).
216018 Figure 37
33. Direct the HP pump drive shaft so that the key (2) faces the
hole (1) on the distribution gearbox.
216020 Figure 38

682 ‒ Engine
34. Mount the gear (2) aligning the key on the pump shaft with its
seat on the gear seat.
Note In this condition, the pump and phonic wheel/timing
sensor are timed with the drive axle.
36. Screw the fastening nut (3).
38. If there is interference between the drive gear teeth of the
pump (5) and (2) proceed as follows.
◁ Unscrew the screws (6) and remove the blow-by filter
(7).
◁ Slacken the screws (4) and, taking advantage of the slots,
turn the gear (5) so that it is possible to mount, without
any interference between teeth, the gear (2) and fit the
pin (1) through the hole on the gear into the gearbox seat.
◁ Tighten the fixing screws (4) and nut (3) of the pump 217692 Figure 39
gear (2) to torque.
◁ Replace the blow-by filter (7).
◁ Remove the pin (1).

682 ‒ Engine
216017 Figure 40
39. Remove the fixing plate (6) and tighten the screws (1) and (5).
40. Use the screw (4) to fix the fuel return pipe (3) to the plate (6).
41. Fix the electric cable (2) to the plate (6) with the snap-on clamp.
Caution!

682 ‒ Engine
216015 Figure 41
42. Fit the high pressure fuel pipes (2), tightening the couplings to the required torque.
43. Secure the pipes (2) to the support bracket by tightening the retainers (5).
44. Connect the low pressure fuel pipes to the pump (11), tightening the couplings (7).
45. Connect the fuel supply pipe attached to the filter to the pump (11) by screwing in the coupling (4).
46. Act on the quick snap coupling (3) to connect the fuel return to tank pipe.
47. Connect the pump lubrication pipe by screwing in the coupling (1).
48. Refit the compressor air intake hose (10).
49. Connect the electrical connection (6) to the flow regulator.
50. Connect the electrical connection (9) to the timing sensor.
51. Connect the compressor air delivery pipe to the compressor by tightening the coupling (8).

682 ‒ Engine
52. Refit the compressor air delivery pipe (1) by tightening the
coupling (3) and securing the pipes with a screw (2).
216016 Figure 42
53. Position the gasket, mount the distribution gear cover (2) and
screw the fixing screws (1).
216012 Figure 43
54. Connect the engine oil vapour breather pipe (4) and connect it
to the engine crankcase with the screws (5).
55. Mount the air intake pipe (1) and fix it to the elastic sleeves by
tightening collars (6) and (2).
56. Mount the brackets (3) that support the pipes (1).
57. Connect the compressor air intake hose to the pipe (1).
216011 Figure 44

682 ‒ Engine
58. Fit the flywheel rpm sensor (1).
194224 Figure 45
Conditions
● 8x4 versions
▶ Mount the power steering circuit oil supply pipe (1) and
tighten the fixing screw (2).
▶ Connect the hose (3) to the power steering pump.
216014 Figure 46

682 ‒ Engine
▶ Mount the cross-piece (6) and fix using the screws (2).
▶ Mount the plate (3) and fix to the cross-piece using nuts
(1).
▶ Fix the pipes (5) to the plate (3) tightening the clips (4).
217887 Figure 47
▶ Mount the plate (3) securing it to the cab support cross-

member with screws (4) .
▶ Secure the power steering tank (6) to the support plate
(3) by tightening the fixing collar (5).
▶ Fill the power steering circuit with the quantity and quality
of oil specified.
▶ Before refitting the sheet guard (1) bleed the air from the
power steering circuit as in the relative chapter Bleeding
air from the power steering circuit ( ➠ Page 18) (opera-
tion 501430).
▶ Complete installation by fixing the sheet guard (1) with
screws (2).
216005 Figure 48

682 ‒ Engine
.773110. Fuel pre-filter replacement on the vehicle
Main action
.773110. Fuel pre-filter removal on the vehicle
1. Remove the water detector sensor electrical connection (2).
2. Unscrew prefilter (1) using the suitable tool from the support
(3).
215756 Figure 49
.773110. Fuel pre-filter refitting on the vehicle

4. Before refitting the new fuel prefilter, moisten the seal with diesel or engine oil.
5. Screw the new prefilter on by hand, taking care to check that the rubber seal and the mating surface are clean and in a perfect
state of repair. Tighten the cartridge 3/4 turn.
6. Bleed air from fuel system as described in the relevant section Bleeding air from the fuel circuit ( ➠ Page 38) (operation
542011);
.773114. Fuel pre-filter support replacement
Main action
.773114. Fuel pre-filter support removal on the vehicle
1. Remove the fuel prefilter (8) as described in the relevant
chapter (773110 Fuel pre-filter removal on the vehicle
( ➠ Page 34)).
2. Remove the fuel heater (2) electrical connection (1).
3. Remove the two fuel delivery and return pipes (5) acting on
the couplings (6).
4. Undo the two retainers (7) and remove the fuel prefilter (9)
support.
173829 Figure 50

682 ‒ Engine
.773114. Fuel pre-filter support refitting on the vehicle

5. To refit, carry out the operations described for removal in reverse order, while observing the following precautions: Tighten
the screws and couplings to the prescribed torque.
6. Refit the fuel prefilter as described in the relating chapter Fuel pre-filter refitting on the vehicle ( ➠ Page 34) (Operation
773110).
7. Bleed air from fuel system as described in the relevant section Bleeding air from the fuel circuit ( ➠ Page 38) (operation
542011);
.773120. Sediment filter replacement

Main action
1. Place a suitable container under the filter body, unscrew the
plug (4) and drain the fuel and water into it.
2. Undo the pin (2) and remove the cover (1).
3. Extract the filter (3) and replace it.
4. After cleaning the filter from any impurities, insert the new filter
and fit the cover (1).
5. Bleed the fuel supply circuit as in the relative chapter Bleeding
air from the fuel circuit ( ➠ Page 38) (operation 542011).
217713 Figure 51
.542011. Replacing the vehicle fuel filter (F2C Engines)

Main action
1. Unscrew the fuel filter using a suitable tool (1).
2. Before refitting the new cartridge make sure that the gasket and
sealing surface are clean and in perfect condition, moisten the
seal with diesel or engine oil.
3. Screw the cartridge on by hand until it is in contact with the
mounting and then tighten by 3/4 of a turn to the required
tightening torque.
4. bleed air from fuel system as described in the relevant section
(operation 542011);
119972 Figure 52

682 ‒ Engine
.542011. Replacing the vehicle fuel filter (F3B Engines)

Main action
tightening torque.
(operation 542011);
216003 Figure 53
.507220. Fuel tank replacement.
Tightening torques
Tank retainer pins. 18+5
+0 N⋅m

682 ‒ Engine
Main action
.507220. Fuel tank removal
173603 Figure 54
1. Remove the side guard (1) by acting on the retainers (2).
2. Remove the fuel couplings of the fuel supply and return pipes (3) from the tank (7) acting on the clamps (5).
3. Remove the electrical connection of the fuel level sensor (4).
4. Remove the retainer belts (6) of the tank (7) acting on the retainers (8).
5. Remove the tank (7) from the vehicle.
.507220. Fuel tank refitting

6. Place the tank on the supporting brackets making sure that the
rear and lower walls are correctly aligned and in contact with
the brackets (4).
7. Fit the straps (2) and for each one tighten the top screw (1) by
just a few turns so that the screw enters the nut by approxim-
ately 2 mm.
8. Secure the straps (2) at the bottom and for each one tighten
the bottom screw (3) by approximately 4 turns so that the
screw enters the nut by approximately 7-8 mm.
9. For each strap, tighten the top screw (1) until it protrudes from
the nut by 2-4 mm.
10. In the same way, tighten the bottom screw (3) until it protrudes
from the nut by 2-4 mm.
11. For each strap, tighten the screws (1) and (3) to the prescribed 222096 Figure 55
torque.

682 ‒ Engine
Tightening torque
Tank retainer pins. (1,3) 18+5
+0 N⋅m
12. Refit the float and connect the fuel pipes working on the quick-
fit couplings.
13. Connect the electric connection on the fuel level sensor.
14. Refit the side guards if present.
15. Make sure that the lower drain plug is tightened correctly be-
fore refuelling.
222096 Figure 55
.542011. Bleeding air from the fuel circuit
Tightening torques
Fitting for bleeding 18 ±2 N⋅m
Note Do not bleed the fuel system using the vehicle ignition device otherwise the HP pump will run dry and cause damage to it
or, in worst case scenarios, breakage.
Main action
1. Open the breather (3) on prefilter.
2. Pump using the hand pump (1) on the prefilter until the fuel
supply system contains no more air. Close breather (3).
3. Open the bleeder screw (2) located in the diesel filter, con-
necting it to a pipe to direct the residues to suitable containers.
4. Manually pump the pump (1) located on the prefilter until fuel
with no air bubbles comes out of the bleeder screw (2). Re-
tighten the screw when the operation is complete (2).
Tightening torque
Fitting for bleeding 18 ±2 N⋅m
5. Start the engine and let it run idle for a few minutes to remove
any residual air.
Note Make sure that the outflow fuel is captured in a suitable
container.
Note Make absolutely sure that the fuel does not soil the 217881 Figure 56
drive belt: alternator, water pump, etc.

682 ‒ Engine
MAIN REPAIRS ON BOOSTER SYSTEM

.507122. Exhaust piping replacement
Main action
.507122. Exhaust piping removal
1. Undo the screws (1) and disconnect the exhaust gas pipes (3)
from the engine brake throttle device.
Note Secure the engine brake throttle device appropriately
so that after removing the pipe (3) it does not come
free and fall off.
2. Slacken the collar (2) and remove the pipe section (3).
217707 Figure 57
.507122. Exhaust piping refitting

.507110. Silencer replacement
Tightening torques
Collars for silencer pipes 6 N⋅m to8 N⋅m

682 ‒ Engine
Main action
.507110. Silencer removal
1. Slacken clamps (3) and remove hose (4).
2. Support the silencer (2) adequately and slacken the clamps (1).
3. Remove the silencer (2) from the vehicle.
173808 Figure 58
.507110. Refitting the silencer

Tightening torque
Collars for silencer pipes 6 N⋅m to8 N⋅m

682 ‒ Engine
.507110. Silencer replacement (versions with vertical exhaust)
Main action
.507110. Silencer removal (versions with vertical exhaust)
217706 Figure 59
1. Remove the exhaust gas tail pipe (9) as follows:
◁ Unscrew the screws (1) and remove support rod (2).

682 ‒ Engine
217706 Figure 59
◁ Unscrew the screws (5) and remove support rod (3).
◁ Loosen the collar (8) and remove the exhaust gas tail pipe (9) from the silencer (7).
2. Remove the silencer (7) as follows:
◁ Disconnect the exhaust gas intake pipe from silencer (7) by slackening the collar (4).
◁ Support silencer (7) in an appropriate manner, slacken the clamps (6) and remove the silencer (7).
.507110. Silencer refitting (versions with vertical exhaust)


682 ‒ Engine
.543710. Replacing the engine brake device on the vehicle.
Main action
.543710. Removing the engine brake device on the vehicle.
1. Disassemble the air pipes (2) from the actuator cylinder (3).
2. Release and remove the clamp (7) from the ball joint (8).
3. Unscrew locking nut (1) of the engine brake cylinder (3).
4. Loosen the screws (4) to allow support plate to rotate and
remove the engine cylinder brake (3).
5. Undo locking screws (5) and disconnect exhaust pipe (6) from
engine brake device (9).
6. Remove engine brake device (9).
173809 Figure 60
.543710. Refitting the engine brake device on the vehicle.

.542410. Replacing the turbocharger (F2C Engines)
Tightening torques
Screws and nuts securing the turbocharger 1. Pre-tightening Tightening sequence: 1 - 4
35 ±5 N⋅m
2. Tightening Tightening sequence: 1 - 4
46 ±2 N⋅m
Caution!
Turbocharger Checks in case of replacement/overhaul.
▶ If the turbocharger is overhauled and/or replaced, make sure all air pipes are whole, clean and free from foreign
bodies.
▶ Furthermore, check sealing gaskets for inefficiency and connection sleeves for fastening, checking that the intake
ducts, air filter and radiators (intercooler) are not clogged.
▶ Check that the oil circulation pipes are not broken nor clogged: otherwise replace them or fix the problem.

682 ‒ Engine
Main action
.542410. Removing the turbocharger (F2C Engines)
1. Slacken collar (3) and disconnect the exhaust pipe (4) from the
turbocharger (5).
2. Remove fixing screws (1) disconnect sleeves (2) and (6) and
remove the air pipe (7).
173810 Figure 61
3. Slacken collar (1) disconnect the intercooler pipe (4) from the
turbocharger (2).
4. Undo screws and remove intercooler pipe (4) from the
bracket (3) that secures to the chassis.
173811 Figure 62
5. Remove the oil return (5) and delivery (3) pipes from the
turbocharger (4).
6. Support the turbocharger (4) appropriately, undo the fixing
screws (1) and remove from the exhaust manifold (6).
173812 Figure 63

682 ‒ Engine
.542410. Refitting the turbocharger (F2C Engines)

7. To refit, carry out the operations described in the removal process in reverse order, tightening the nuts and/or bolts to the
specified torque.
Tightening torque
Screws and nuts securing the turbocharger 1. Pre-tightening
Tightening sequence: 1 - 4
35 ±5 N⋅m
2. Tightening
46 ±2 N⋅m
8. Replace the gasket (2) between turbocharger (4) and exhaust manifold (6).
9. Replace all gaskets removed during removal.
10. Check engine oil level and if needed top up.
11. Check conditions of oil return to sump pipe (5).
.542410. Replacing the vehicle turbocharger (F3B Engines)
Caution!
Turbocharger Checks in case of replacement/overhaul.
▶ If the turbocharger is overhauled and/or replaced, make sure all air pipes are whole, clean and free from foreign
bodies.
▶ Furthermore, check sealing gaskets for inefficiency and connection sleeves for fastening, checking that the intake
ducts, air filter and radiators (intercooler) are not clogged.
▶ Check that the oil circulation pipes are not broken nor clogged: otherwise replace them or fix the problem.

682 ‒ Engine
Main action
.542410. Removing the turbocharger on the vehicle (F3B Engines)
217698 Figure 64
1. Undo the screws (10) and remove the support bracket (11).
2. Loosen the collars (1) and (7) and disconnect the air intake pipes (9).
3. Remove the bracket (2) from head.
4. Slacken collar (5) disconnect the exhaust gas pipe (4) from the turbocharger (3).
5. Slacken collar (6) disconnect the air intake (8) from the turbocharger (3).
6. On Tipper versions, disconnect the cab support cross-member to make disassembly easier.
7. Undo screws (2) and from the turbocharger (6) disconnect the
oil intake pipe (3).
8. Undo screws (5) and from the turbocharger (6) disconnect the
oil to sump return pipe (3).
9. Support suitably the (7) outlet manifold-turbocharger (6) unit
and loosen the fastening screws (1) and remove it as a block
from cylinder head.
10. Place the exhaust manifold complete with turbocharger onto
the bench.
11. Unscrew the locking nuts (1) and (4) and remove the tur-
bocharger (3) from the exhaust manifold (2).
217699 Figure 65

682 ‒ Engine
.542410. Refitting the turbocharger on the vehicle (F3B Engines)

12. To refit, carry out the removal operations in reverse order, according to following instructions: Tighten the nuts or screws to
14. Check engine oil level and if needed top up.
15. Check for oil leaks from the oil inlet and return to sump couplings disconnected during removal.
.540720. Replacing the exhaust manifold on vehicle (F2C Engines)
Tightening torques
Gasket retaining screws 1. Pre-tightening torque 35 N⋅m to45 N⋅m
2. Tightening torque 65 N⋅m to75 N⋅m
Main action
.540720. Removing the exhaust manifold on vehicle (F2C Engines)
1. Remove the turbocharger as described in the relevant chapter ( Removing the turbocharger (F2C Engines) ( ➠ Page 44)).
2. Undo the fixing screws and remove exhaust manifold (1) along
with its gaskets.
169821 Figure 66
.540720. Refitting the exhaust manifold (F2C Engines)

3. Fit the exhaust manifolds with new gaskets and tighten the 1 48 1 1
fastening screws to specified torque as shown in the figure.
Tightening torque
Gasket retaining screws 1. Pre-tightening torque 6 3 2 7 6 3 4 7 6 3 2 7
35 N⋅m to45 N⋅m 45359 Figure 67
2. Tightening torque
65 N⋅m to75 N⋅m
4. Refit the turbocharger as described in the relative chapter

(542410 Refitting the turbocharger (F2C Engines)
( ➠ Page 45)).

682 ‒ Engine
.540720. Replacing the exhaust manifold on vehicle (F3B Engines)

Main action
▶ To replace the exhaust manifold see operation Replacing the vehicle turbocharger (F3B Engines) ( ➠ Page 45) (operation
542410).
.554010. Replacing the SNORKEL engine air vent (8x4 vehicles - F3B engines)
Main action
.554010. Removal
1. Remove central tie (1) that supports the engine air pipe
(snorkel) (2) acting on the retainer (5).
2. Remove the bottom metal fixing clamp (4) of the engine air
pipe (snorkel) (2) ; acting on the retainer (3).
3. Remove the engine air pipe (snorkel) (2) from vehicle along
with top air filter (6).
217720 Figure 68
.554010. Refitting
4. To refit, carry out the operations performed in the removal process in reverse order, tightening all retainers.
.505110. Replacing the air filter casing on the vehicle.
Main action
.505110. Removing the air filter casing on the vehicle.
Conditions
● Vertical air filter

682 ‒ Engine
▶ Remove clamps (3) and disconnect the hose (6).

▶ Loosen clamp (2), then disconnect pipe (5) from air filter
casing.
▶ Disconnect the electrical connection from the air filter
clogged sensor (1).
▶ Remove the screws (4), then remove the air pipe (5).
174178 Figure 69
Conditions
● Horizontal air filter
▶ Remove the screws (2) and detach the bracket (1) from
the filter casing (3).
▶ Unscrew the retaining screws (4) and remove the filter
casing (3).
174179 Figure 70
.505110. Refitting the air filter casing on the vehicle.

1. To refit the filter casing, carry out the operations described for removal in reverse order.

682 ‒ Engine
.505111. Change filter and clean horizontal air filter casing.

Main action
174177 Figure 71
1. Undo the nut with tabs (1) and remove the cover (2).
2. Remove the nut with tabs (3) and remove air filter (4) from the filter casing.
3. Remove the nut (5) and remove air filter (6) (if any) from the filter casing.
4. Undo the retainers (8) and disconnect the cover (7), drain the water and clean filter casing from dust and grime build-up.
5. Refit cover (7) screwing in retainers (8) and refit the filter cartridges (4) and (6) with new ones.

682 ‒ Engine
MAIN REPAIRS ON LUBRICATION SYSTEM
.505111. Change filter and clean vertical air filter casing.

Main action
1. Undo the nut with tabs and remove the cover (2).
2. Remove the nut (3) and remove air filter (2) from the filter
casing (1).
3. Drain water contained and clean the filter casing from dust and
grime build-up.
4. To reassemble, repeat the above mentioned procedure back-
wards.
200104 Figure 72
.506050. Replacement of intercooler on the vehicle

Main action
▶ To replace intercooler see operation 506010 Replacement of radiator on the vehicle ( ➠ Page 55).

.540430. Replacement oil sump on vehicle
Main action
.540430. Removal of oil sump on vehicle
1. Pull out the engine oil level control rod.
2. Drain engine oil in a suitable container.

682 ‒ Engine
3. Loosen the screws (2) and remove the engine oil sump (1)
with the spacer (3) and the seal gasket.
155857 Figure 73
.540430. Refitting of oil sump on vehicle

4. Refit carrying out operations described in the removal process in reverse order, tightening the nuts in the specified sequence
and at the specified torque.
Note Replace all gaskets removed during disassembling.
5. Fill in engine oil in the specified quantity.
6. Check the engine oil level using the level control rod.
.543070. Replacement of the engine oil on vehicle

Main action
1. Remove the oil filter (1).
Note The oil filter contains approximately 1 kg of engine oil
inside.
Position a suitable container to collect the oil.
It is possible to empty the filter of Cursor 13 engines
through the lower plug.
119976 Figure 74

682 ‒ Engine
Caution!
Engine oil drainage. The engine oil is highly pollutant and harmful.
▶ In case of contact with skin wash thoroughly with water and detergent.
▶ Adequately protect skin and eyes; take measures as set forth by safety regulations.
Caution!
Disposal Engine oil
▶ The engine oil is highly pollutant and harmful.
▶ Dispose of residuals in an adequate manner that complies with laws in force.
2. Before refitting the new cartridge, moisten the seal with engine oil.
3. Screw on the oil filter (1) by hand until there is contact with the mounting and then tighten by 3/4 of a turn to the required
torque.
4. Re-screw the plug under the pan and tighten it at the prescribed torque.
5. Fill in with the prescribed oil quantity and quality from the filler as in the relative chapter.
.543110. Replacing the vehicle heat exchanger (F2C Engines)
Main action
.543110. Remove the vehicle heat exchanger (F2C Engines)
1. Refit the cooling system, as described in the relevant chapter.
2. From the water pump (2) remove the pipe (1) that is attached
to the heater.
3. Remove the fixing bracket (3) of the (4) air compressor pipe.
4. Remove the fixing screws (5) from the cover (6) of the heat
exchanger and remove it.
5. Remove the internal body of the heat exchanger acting from
below the vehicle.
173602 Figure 75
.543110. Refitting the vehicle heat exchanger (F2C Engines)

7. Fill up the engine cooling circuit and carry out the bleeding procedure as described in the relevant chapter (operation
543210).

682 ‒ Engine
MAIN REPAIRS ON COOLING SYSTEM

.543420. Replacement of fan on the vehicle
Main action
.543420. Removing of fan on the vehicle
1. Remove bracket fixing screws (2) and (5) to free the A/C
system pipes (3) from the pipe (4).
2. Remove the intercooler left hose (6) and right hose.
3. Slacken the nuts that secure the radiator to the chassis and
move the complete radiator assembly forward.
4. Remove the 4 screws (7) and remove the viscostatic coupling
along with fan by disconnecting it from the pulley (1).
173822 Figure 76
5. Remove the fan (3) from the viscostatic coupling (1) by undo-
ing the fixing screws (2) while on the bench.
Note The fan must be upright.
200105 Figure 77
.543420. Refitting the fan on the vehicle


682 ‒ Engine
.543422. Replacement of viscostatic coupling on the vehicle

Main action
▶ To replace the viscostatic coupling follow the instructions in the chapter Replacement of fan on the vehicle ( ➠ Page 54) (op-
eration 543420).
.506010. Replacement of radiator on the vehicle
Main action
.506010. Removal of radiator on vehicle
173824 Figure 78
1. Drain the engine coolant.
2. Drain the A/C system using the specific tools.
3. On the left, remove the screws of the brackets (3), (4) and (6) that secure the pipes (2) of the A/C system.
4. Unscrew the nut (11) and remove the condenser pipes (13).
5. Unscrew the nut (12) fixing the pipe bracket (10).
6. Disconnect the intercooler air hose (5).
7. Undo the clamps and remove the coolant pipes (1).
8. Disconnect the breather pipes (7) from the radiator.
9. Undo the screws (9) and remove the bracket (8) that supports the pipes and set aside.

682 ‒ Engine
174172 Figure 79
10. From the right side , remove the screws (2) and the A/C pipes mounting bracket (1).
11. Undo the coupling (12) and disconnect the pipes (1) from the A/C compressor (13).
12. Remove the elastic coupling and intercooler pipe (11).
13. Lift the front radiator grille, undo the screws (5) and move the oil dipstick away from the radiator assembly (3).
14. Disconnect the hoses (6) from the pipes (4).
15. Remove the screws (7) and free the pipes (4) from the mounting bracket.
16. Remove the screws (8) and remove the support bracket (9) for pipes (4) from the intercooler (10).
17. Move the pipes (4) and bracket (9) away from the radiator assembly.
18. Remove the viscostatic coupling along with fan as described in the relevant chapter (operation 543422).
19. From under the vehicle, remove the clamps (15) and remove the water pipe (14).
20. Remove the screws (14) that secure the radiator assembly (15) to the chassis on both the RH and LH sides.
21. Secure the radiator assembly (15) to a hoist appropriately.
22. Lift the radiator assembly (15) along with the condenser, intercooler (10), radiator and air conveyor from the chassis to re-
move it.
.506010. Refitting of radiator on vehicle

23. To refit the radiator assembly carry out the operations described for removal in reverse order, following the instructions
below.
24. Check the conditions of the auxiliary and drive parts belts of the climate control compressor and replace if worn or damaged.

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25. Tighten the screws and/or nuts to the specified torque.

26. Replace all gaskets removed during removal with new ones.
27. Fill the cooling system with the specific fluid, then bleed air out of the cooling system as described in the relevant chapter (op-
eration 506010).
28. Recharge the A/C system as in the relevant chapter (operation 553230).
.553232. Condenser removal-refitting

Main action
1. Undo the screws (1) and remove the bracket (2) and con-
denser (3) from the radiator assembly (4).
2. To refit, carry out the operations described for removal in re-
verse order.
174173 Figure 80
.506050. Intercooler removal-refitting

Main action
1. Remove and refit the condenser as described in the relevant chapter (553232 Condenser removal-refitting ( ➠ Page 57)).

682 ‒ Engine
2. Undo the screws (2) and (3) and remove the intercooler (3)
from the radiator (1).
verse order.
174175 Figure 81
.506017. Air conveyor removal-refitting

Main action
1. Loosen the screws (2) and remove the external plate of the
conveyor (1).
2. Loosen screws (3) and remove air conveyor (4) from the radi-
ator (5).
verse order.
174176 Figure 82

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.543251. Replacing the thermostat on the vehicle (F2C Engines)
Tightening torques
Thermostat fixing screws 22 N⋅m to27 N⋅m
Main action
.543251. Removing the thermostat on the vehicle (F2C Engines)
2. Disconnect the hose (5) and pipe (1) from the thermostat (2).
3. Disconnect the electric connection (4) from temperature
sensor.
4. Unscrew the five fixing screws (3) and remove the thermostat
body (2) together with the gasket.
174174 Figure 83
.543251. Refitting the thermostat on the vehicle (F2C Engines)

5. To refit, carry out the operations described in the removal process in reverse order, tightening the thermostat fixing screws
to the specified torque.
Tightening torque
Thermostat fixing screws 22 N⋅m to27 N⋅m
543210).

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.543250. Replacing the vehicle thermostat (F3B Engines)
Main action
.543250. Removing the thermostat on the vehicle (F3B Engines)
1. Unscrew the cap under the radiator and drain the engine
coolant into a suitable container.
2. Disconnect the electrical connection (1) and free the thermo-
stat body cable (2).
3. Disconnect the hose from the thermostat body (2).
4. Undo the fixing screws (3) and disconnect the thermostat body
(2) from the vehicle.
217704 Figure 84
159408 Figure 85
5. Disconnect the flange (2) and spring (1) by pressing on the flange (2) and turning it at the same time.

682 ‒ Engine
159409 Figure 86
6. Undo the screws (1) and remove the thermostat cover (2).
7. Remove the gasket (3) and replace it.
8. Remove the thermostat (1) from its saddle on the thermostat

body (2) and replace it.
217705 Figure 87
.543250. Refitting the thermostat on the vehicle (F3B Engines)

9. For refitting, carry out the steps described for removal in reverse order, observing the following:
◁ Replace the gaskets removed with new parts.
◁ After completing assembly, fill and bleed the engine cooling air circuit as in the relative chapter Cooling system air bleed-
ing ( ➠ Page 64).
◁ Check thermostat efficiency by checking work temperature of the engine on the cluster indicator.
◁ Check for any water leaks from the parts removed.

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.543210. Replacing the water pump on the vehicle (F2C Engines)
Tightening torques
Screws securing water pump 20 N⋅m to24 N⋅m
Main action
.543210. Removing the water pump on the vehicle (F2C Engines)
2. Remove the viscostatic coupling as described in the relevant chapter (operation 543422).
3. Remove the water pump/alternator drive belt as described in the relevant chapter (543411 Replacement of the water
pump/alternator drive belt on the vehicle ( ➠ Page 30)).
4. Undo the screws (1) and remove the water pump (2) and
pulley (3).
125702 Figure 88
.543210. Refitting the water pump on the vehicle (F2C Engines)

5. To refit, carry out the operations for removal in reverse order, tightening the water pump fixing screws to the specified tight-
ening torque.
Tightening torque

543210).
8. During the first hours of work make sure that there are no coolant leaks.

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.543210. Replacing the water pump on the vehicle (F3B Engines)
Main action
.543210. Removing the water pump on the vehicle (F3B Engines)
1. Open the cap under the radiator and drain the engine cooling circuit into a suitable container.
2. Acting on automatic belt tensioner (2), slacken belt tension (1),

and pry free from the pulley without removing it.
217702 Figure 89
3. Unscrew the screws (1) fixing the water pump.

4. Screw 2 reaction screws into the threaded holes (→) and re-
move the pump (2) from its seat.
217701 Figure 90

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.543210. Refitting the water pump on the vehicle (F3B Engines)

5. Thoroughly clean the pump seat on the crankcase from rust or
filth.
6. Replace the O-ring seal on the pump and lubricate with a thin
layer of suitable grease to simplify mounting.
7. Install the oil pump (2) into its cradle on the crankcase and
tighten the retaining screws (1).
8. Refit the water pump drive belt, as described in the relevant
chapter Replacement of the water pump/alternator drive belt
on the vehicle (operation 543411).
9. Fill and bleed the engine cooling air circuit as in the relative
chapter Cooling system air bleeding ( ➠ Page 64)506010.
10. Check for any coolant leaks from the pump.
167112 Figure 91
.506010. Cooling system air bleeding
Technical data
Thermostat start of opening 85 ±2 ℃
Caution!
Air bleeding General warnings
▶ To avoid burns to the operator or damage to the engine, since the pressurization of the cooling system is created
only with the heating of the liquid starting from the condition of a cold engine, do not remove the cap closing the
filler in the expansion tank until the system liquid has completely cooled. Any topping up must only be done with the
engine cold.
Main action
Conditions
● For vehicles equipped with an additional heater
▶ Turn on the heater.
1. Start the engine and keep the revs just above the minimum for 5 min.
Note If the tank empties completely during these first few minutes, stop and engine and top the tank up at a slower rate
than before.
Restart the engine.
2. After 5 min running, top up the level of fluid in the expansion tank, if needed.
3. Close the expansion tank filler union with the relevant cap (2).
4. Bring the engine up to full speed so that the coolant quickly reaches the temperature of full thermostat opening (approx.
90°C) and keep it in this condition, until air is fully bled out of the system.
Note You can inspect this checking that no foam or air bubbles are in the tank.
5. Wait for the system to fully bleed the air: approx. 15 min. from the moment that the thermostat is opened.

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MAIN REPAIRS ON BELTS AND AUXILIARY PARTS
Technical data

.543910. Replacement of the air conditioner compressor drive belt on the vehicle
Work material
Guide for fitting rubber belt 99360192
Main action
1. Tighten screws (1) and remove the viscostatic coupling with the
fan (3) from the drive pulley (2) and move them towards the
radiator.
217703 Figure 92
2. Cut the air conditioner compressor drive belt (1), as it must

not be used again.
173819 Figure 93
Caution!
Elastic belt assembly Prescriptions
▶ The specific tool must be used for fitting the air conditioner compressor elastic belt. Different methods may cause
tension thus damaging the elastic belt.

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3. Apply the specific tool to the gear case.

code
4. Fit the elastic belt (3) on the crankshaft pulley. Fit the chock (2)
onto the compressor pulley (1) of the air conditioner. Position
the elastic belt (3) in the recess of the specific tool.
code
5. Use a suitable tool to rotate the crankshaft in the direction of

the arrow (→) until the elastic belt (3) is correctly positioned on
the compressor pulley (1).
Tool / Material Product 178158 Figure 94
code
Note While working, keep the specific tool (2) in contact

with the pulley and, at the same time, guide the elastic
belt (3) to prevent it from twisting.
Caution!
Spring belt Precaution during disassembly
▶ The flexible belt must be replaced with a new one every time it is removed from the vehicle.
6. Refit the viscostatic coupling as described in the relevant chapter Replacement of viscostatic coupling on the vehicle
( ➠ Page 55) (operation 543422).
.543411. Replacement of the water pump/alternator belt on the vehicle

Main action
▶ To replace the water pump and alternator belt on the vehicle refer to the sections Replacement of the water
pump/alternator drive belt on the vehicle ( ➠ Page 30) and Replacement of the water pump/alternator drive belt on the
vehicle ( ➠ Page 78) (Operation 543411).
.543417. Replacement of the belt tensioner on vehicles

Main action
▶ For replacement of the automatic belt tensioner see the chapter Replacement of the belt tensioner on vehicles (operation
543417).

682 ‒ Engine
.553239. Replacement of A/C compressor on the vehicle
Tightening torques
Compressor retaining screws 22 N⋅m to27 N⋅m
Main action
.553239. Removal of A/C compressor on the vehicle
1. Drain the A/C system using the adequate tool.
2. Remove the bracket (2) that secures the pipes (1) of the A/C
system.
3. Disconnect the pipes (1) from the compressor by acting on the
retainers (3).
4. Remove the electrical connection (6) that drives the com-
pressor (5).
not be used again.
6. Remove the fastenings (7) of the compressor (5) and remove
it.
173597 Figure 95
.553239. Refitting the A/C compressor on the vehicle

7. Reposition the compressor support (5) and tighten the fixing screws (7) to the specified torque.
Tightening torque
Compressor retaining screws 22 N⋅m to27 N⋅m
8. Connect the pipes (1) of the A/C system to the compressor (5) tightening the fastenings (3).
9. Remove bracket (2) that clamps the pipes (1).
10. Refit the A/C compressor belt (4) as in the relative chapter (543910 Replacement of the air conditioner compressor drive
belt on the vehicle ( ➠ Page 65)).
11. Recharge the A/C system as in the relevant chapter.
.760310. Replacement of alternator on the vehicle

Tightening torques
Alternator top fixing screws 40 N⋅m to48 N⋅m
Alternator bottom fixing screws 22 N⋅m to27 N⋅m
Main action
1. Disconnect the negative battery pole.

682 ‒ Engine
2. Remove the intercooler air intake pipe (6) by loosening the

metal fasteners.
3. Pry the belt (2) free from the alternator (3) by acting on the
belt tensioner (1) without removing the drive belt (4) of the
climate control compressor.
4. Remove the fastenings (5) of the alternator (3).
217718 Figure 96
5. Disconnect the electrical connection (1) from the alternator

(2).
6. Remove the alternator (2) from the vehicle.
7. To refit, carry out the operations for removal in reverse order,
tightening the locking nuts to tightening torque.
Tightening torque
Alternator top fixing screws 40 N⋅m to48 N⋅m
Alternator bottom fixing screws 22 N⋅m to27 N⋅m
217719 Figure 97

682 ‒ Engine
MAIN REPAIRS ON DISTRIBUTION PARTS

.540630. Replacement of rocker cover on vehicle
Main action
.540630. Removing the rocker arm cover on vehicle
1. Unscrew retaining screws (3) and take off rocker cover (1).
2. Replace the rubber gasket removing it from the tappet cover.
173801 Figure 98
.540630. Refitting the rocker arm cover on vehicle

3. Refit carrying out operations described in the removal process in reverse order, tightening the nuts in the specified sequence
and at the specified torque.
.540630. Replacing the rocker arm cover on vehicle (F3B 8x4 Versions)
Main action
.540630. Removing the rocker arm cover on vehicle (F3B 8x4 Version)
1. Unscrew the screws (2) and remove the sheet metal guard (1).
2. Slacken the retainer collar (5) and from the mounting plate (3)
remove the power steering oil reservoir (6) and set it aside,
making sure that no oil spills out from the inside.
3. Loosen the screws (4) and remove the plate (3).
216005 Figure 99

682 ‒ Engine
216004 Figure 100

4. Unscrew the retaining screws (8) and free the pipes (10) from the plate (9).
5. Loosen the nuts (6) and remove the plate (9) from the vehicle.
6. Undo the screws (12) and free the engine brake actuator pneumatic pipes (CEB) from the cross-member (11).
7. Unscrew the retaining screws (7) and remove the cross member (11).
8. Unscrew the retainers (11) and (3), remove the mounting plate (2) and set in place the climate control pipes (1).
9. Undo the perimeter screws (4) and remove the rocker arm cover (5) from the cylinder head.
.540630. Refitting the rocker arm cover on vehicle (F3B 8x4 Version)
10. To refit follow removal operations in reverse order and observe the instructions below:
◁ Carefully clean the mating surface between cylinder head and rocker arm cover;
◁ check gasket and replace if worn.

682 ‒ Engine
.541230. Replacing the vehicle rocker arm shaft (F2C Engines)
Work material
Tool for rocker arm shaft assembly and fitting 99360558
Set of gauges for angle tightening with square connection 99395216
- 1/2" and 3/4"
Tightening torques
Fastening screws for rocker arm shaft 1. 1st stage, with torque 80 N⋅m
wrench
2. 2nd stage, angle tightening 60°
using the specific tool (3)
Main action
.541230. Removing the vehicle rocker arm shaft (F2C Engines)
2. To make the operations easier, remove the suction duct (3) after disconnecting it from turbocharger and air filter.
3. Remove the rocker cover as described in the relevant chapter (Removing the rocker arm cover on vehicle ( ➠ Page 69)).
4. Undo the fixing screws and remove the thermostat (3) from
the cylinder head.
5. Remove the oil vapour relief pipes (2) from the Blow-by cover
(1) slackening the retainer clamp.
6. Unscrew the screws and remove the Blow-by cover (1).
173802 Figure 101

682 ‒ Engine
7. Release the check springs (2) of the engine brake lever.

8. Unscrew the fastening screws (1) of the rocker-arm shaft .
173803 Figure 102
9. Apply the specific tool (2) to the rocker arm shaft (1) and
remove the shaft on the cylinder head.
code
155847 Figure 103
.541230. Refitting the vehicle rocker arm shaft (F2C Engines)

10. Before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws have been fully unscrewed.
Note Replace all gaskets removed during removal.
11. Apply the specific tool (1) to the rocker arm shaft (2) and mount the shaft on the cylinder head.
Tool / Material Product code

682 ‒ Engine
12. Screw in the screws (1) (2) and (3) until the rocker arms are
brought to contact relating seats on cylinder head, tighten the
screws according to sequence indicated in figure operating in
two steps as indicated in successive figure.
70567A Figure 104

DIAGRAM OF TIGHTENING SEQUENCE FOR
ROCKER SHAFT FASTENING SCREWS
13. Lock the screws (2) fixing the rocker arm shaft as follows:
Tightening torque
Fastening screws for rocker 1. 1st stage, with torque wrench
arm shaft 80 N⋅m
2. 2nd stage, angle tightening using the
specific tool (3)
60°

code
Set of gauges for angle tightening with square connection - 99395216
1/2" and 3/4"
14. Fit the engine brake lever retainer springs.

15. Adjust intake and exhaust rocker arm clearance as well as pump
injector control rocker arm pre-load as described in the relev- 0050320t Figure 105
ant chapter (541230 Intake and exhaust rocker arm clearance
adjustment ( ➠ Page 257)).
16. Refit the Blow-by cover (1) screwing the fixing screws to the
specified tightening torque.
17. Refit the thermostat (3) following the order and specified tight-
ening torque of the fixing screws.
18. Connect the oil vapour relief pipe (2) to the Blow-by cover (1).
( ➠ Page 69)).
20. Fasten the intake duct (3) connecting it to turbocharger and to
air filter and tightening the fastening screws.
21. Fill up the engine cooling circuit and carry out the bleeding pro-
cedure as described in the relevant chapter (operation 543210).
173802 Figure 106

682 ‒ Engine
.541230. Replacing the vehicle rocker arm shaft (F3B Engines)
Work material
Tightening torques
Fastening screws for rocker arm shaft 1. Until in contact Tightening sequence: 1 - 7
25 N⋅m
2. Tightening sequence: 1 - 7
60 N⋅m
80 N⋅m
60°
Main action
.541230. Removing the vehicle rocker arm shaft (F3B Engines)
1. Remove the rocker arm cover on vehicle ( ➠ Page 69)
2. Undo the screws (4) and remove the support bracket (5).
pipes (3).
216009 Figure 107

682 ‒ Engine
4. Remove the engine brake lever check spring (2) from the actu-
ator on the solenoid valve (3).
Note Undo the fixing screw (1) to simplify the operation.
216006 Figure 108
216007 Figure 109

5. Release the check springs (1) of the engine brake lever on the remaining actuators.
6. Unscrew the intake and exhaust valve registers (2).
7. Unscrew the screws (4) proceeding gradually, following the opposite sequence as to what is described for assembly in order
to avoid deforming the rocker arm shaft (3).

682 ‒ Engine
remove the shaft on the cylinder head.
code
155847 Figure 110
.541230. Refitting the vehicle rocker arm shaft (F3B Engines)

mount the shaft on the cylinder head.
code
155847 Figure 111

682 ‒ Engine
216007 Figure 112

10. Tighten the screws (4), fixing them progressively until the rocker shaft (3) comes into contact with the head; this prevents
deformation of the rocker shaft (3) due to the thrust of the valve springs.
Note Before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws (2) have been fully un-
screwed.
11. Connect the engine brake lever check springs (1) to the engine brake actuators.
12. Screw the engine brake solenoid valve fixing screws if removed previously.
13. Tighten the screws in four phases to the required torques.

Tightening torque
Fastening screws for rocker 1. Until in contact
arm shaft Tightening sequence: 1 - 7
25 N⋅m
60 N⋅m
80 N⋅m
60°
14. Carry out the intake and exhaust rocker arm clearance adjust- 183461 Figure 113
ment. ( ➠ Page 257)
15. Refit the rocker arm cover on vehicle ( ➠ Page 70)

682 ‒ Engine
16. Position the air intake pipe (3) connecting it to the flexible
sleeves and tightening the retainer collars (1) and (2).
17. Complete refitting by installing the support bracket (5) and
tightening the screws (4).
216009 Figure 114
.540610. Replace the cylinder head on the vehicle (F2C engines)
Consumables
LOCTITE 5970
Work material
Tool for timing of phonic wheel on timing gear 99360613
- 1/2" and 3/4"
Gauge for camshaft timing 99395223
Tightening torques
Pre-tightening the cylinder head using a torque 1. 1st step 50 N⋅m
wrench 2. 2nd step 100 N⋅m
Angle tightening 1. Tightening sequence: 3rd step
120°
2. Tightening sequence: 4th step
60°
Shoulder plate locking screws 16 N⋅m to22 N⋅m
Tightening the gear - camshaft bolts 1. Tightening sequence: 1st step
25 N⋅m
2. Tightening sequence: 2nd step
45°
Tightening the phonic wheel - camshaft bolts 1. Tightening sequence: 1st step
10 N⋅m
25 N⋅m to32 N⋅m

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Main action
.540610. Remove the cylinder head on the vehicle (F2C engines)
173813 Figure 115

2. Remove the air intake pipe (12) to the compressor.
3. Disconnect the air pipe (14).
4. Remove the EDC ECU as described in the relevant chapter (766161 Removal of the EDC ECU (F2C Engines) ( ➠ Page 15)).
5. Partially disconnect the engine wiring (1) by disconnecting the electrical connections and freeing it from the clips.
6. Remove the fuel filter (15).
7. Disconnect the fuel pipes from the fuel filter support (16) and from the pressure pump (13).
8. Undo the fixing screws and remove the fuel filter support (16) from the cylinder head.
9. Disconnect the fuel inlet pipe (2) to the rail from the cylinder head .
10. From the compressor (11) disconnect the air supply pipe (3) and detach it from the support brackets (4) by unscrewing the
fixing screws.
11. Remove the power steering oil tank (6) from the intake manifold (8) by unscrewing the fixing screws (5).
12. Remove the engine ignition pushbutton pad (10).
13. Disconnect the intake manifold (8) from the intercoooler by removing the flexible sleeve.
14. Remove the fixing screws (7) and remove the intake manifold (8).
15. Disconnect the (9) fuel return pipe.

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16. Remove the air conditioning compressor as described in the

relevant chapter (553239 Removal of A/C compressor on the
vehicle ( ➠ Page 67)).
17. Remove the support (5) of the A/C compressor from the
cylinder head.
18. Remove the pipes (2) from the Blow-by cover.
19. Disconnect the hose (6) and breather pipe (3) from the ther-
mostat (4).
20. Remove the fixing screws and remove the thermostat (4) from
the cylinder head.
21. Disconnect the breather pipe (1).
22. Remove the turbocharger as described in the relevant
chapter ( 542410Removing the turbocharger (F2C Engines)
( ➠ Page 44)). 173814 Figure 116
23. Remove the exhaust manifold as described in the relevant
chapter (540720 Removing the exhaust manifold on vehicle
(F2C Engines) ( ➠ Page 47)).
24. Remove the rocker cover as described in the relevant
chapter (540630 Removing the rocker arm cover on vehicle
( ➠ Page 69)).
25. Remove the rocker arm shaft as described in the relevant
chapter (541230 Removing the vehicle rocker arm shaft (F2C
Engines) ( ➠ Page 71)).
26. Remove the injectors as described in the relevant chapter
(775010 Removing the vehicle electro-injectors (F2C Engines)
( ➠ Page 5)).
27. Remove the hydraulic accumulator (rail) as described in the
relevant chapter (774510 Rail removal ( ➠ Page 194)).
28. Undo the screws (2) and remove the cover (1).
200106 Figure 117

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29. Unscrew the screws (1) and remove the gear (3) fitted with
pulser ring (2).
173815 Figure 118
30. Unscrew the screws (1); tighten one of them in a reaction hole
and remove the thrust plate (2), remove the gasket.
173816 Figure 119
31. Unscrew the cylinder head fastening screws and remove the
cylinder head (1).
32. Remove the seal gasket (2).
33. Place the cylinder head on the bench.
34. Extract the camshaft.
35. Perform "Cylinder head overhaul" as described in the
relative chapter (540610CYLINDER HEAD OVERHAUL
( ➠ Page 230) ).
60515 Figure 120
.540610. Refitting the cylinder head on the vehicle (F2C engines)

36. Fit the camshaft in its seat.
37. Check that pistons 1-6 are at the T.D.C. and insert specific tool through the engine rpm sensor saddle into the engine flywheel
hole.
38. Clean thoroughly the bearing surfaces both on the cylinder head and on the crankcase.

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39. Put the gasket (2) on the crankcase.
Caution!
Sealings Prescriptions
▶ Replace all gaskets removed during removal.
40. Place the cylinder head on the engine and tighten the fastening screws in the specified sequence and torque.
Caution!
Retaining screws Prescriptions
▶ The cylinder head fastening screws are to be replaced each time you remove them.
▶ Lubricate the thread of the screws with engine oil before assembly.
41. Diagram showing the cylinder head fixing screws tightening

order.
61270 Figure 121
42. Pre-tightening with the torque wrench (1).

Tightening torque
Pre-tightening the cylinder 1. 1st step
head using a torque wrench 50 N⋅m
2. 2nd step
100 N⋅m
60565 Figure 122
43. Angle tightening with specific tool (1).

Tightening torque
Angle tightening 1. Tightening sequence: 3rd step
120°
2. Tightening sequence: 4th step
60°

code
1/2" and 3/4"
60566 Figure 123

682 ‒ Engine
44. Fit the camshaft (3), positioning it with the reference marks (→)
as shown in the figure.
45. Lubricate the seal (2) and fit it on the thrust plate (1).
46. Clean the contact surfaces between the head and thrust plate
(1).
47. Apply the prescribed sealant (6) onto the thrust plate (1) on
the gear housing as shown in the figure.
Tool / Material
LOCTITE 5970
114267 Figure 124
Caution!
Sealings Prescriptions
▶ Do not apply sealant inside the gasket (5).
48. Mount the thrust plate (1) with gasket (5) within 10 minutes of
sealant application and tighten the screws (4) to the specified
torque.
Tightening torque
Shoulder plate locking screws 16 N⋅m to22 N⋅m
49. Mount the specific tool (1) on the cam shaft using 2 screws
M8x1.25 (2) and position the pin (3) into the corresponding
hole on the head.
116053
code
116053 Figure 125
50. Position the gear (1), without fully tightening the screws (5),
on the camshaft, positioning it so that the 4 eyelet holes are
centred with regard to the camshaft fastening holes.
51. Arrange the spokes (4) of the gear (1) as in the figure.
52. This is necessary in order to properly set the phonic wheel
which can be fitted in only one mounting position in relation
to the gear.
53. Tighten bolts (3) to prescribed torque.
Tightening torque
Tightening the gear - cam- 1. Tightening sequence: 1st step
shaft bolts 25 N⋅m
45° 117691 Figure 126

682 ‒ Engine
54. Mount the phonic wheel (4) so that the notch indicated by the
arrow (→) is aligned with the sensor (2).
55. To make sure that the position is correct, fit the specific tool
(1) into the sensor saddle (2).
code
56. Tighten the bolts (3) to the specified torque.

Tightening torque
Tightening the phonic wheel - 1. Tightening sequence: 1st step
camshaft bolts 10 N⋅m
25 N⋅m to32 N⋅m
57. Refit the injectors as described in the relative chapter 173817 Figure 127
(775010 Refitting the vehicle electro-injectors (F2C Engines)
( ➠ Page 7)).
58. Refit the rocker arm shaft as described in the relevant chapter
(541230 Refitting the vehicle rocker arm shaft (F2C Engines)
( ➠ Page 72)).
59. Adjust the intake and outlet rocker arm clearance as in the rel-
ative chapter (541230 Intake and exhaust rocker arm clearance
adjustment ).
60. Adjust clearance between the gears (5) and (6) as described in
the relevant chapter.
61. Check and put in timing phase as described in the relevant
chapter (541210 Camshaft and phonic wheel timing
( ➠ Page 251)).
62. Check the phonic wheel timing as described in the relevant
chapter (541215 Pulser ring timing ( ➠ Page 256)).
63. Fit again the timing gear cover after replacing the gasket.
( ➠ Page 69)).
65. Refit the exhaust manifold as described in the relevant
chapter (540720 Refitting the exhaust manifold (F2C Engines)
( ➠ Page 47)).
66. Refit the turbocharger as described in the relative chapter
(542410 Refitting the turbocharger (F2C Engines)
( ➠ Page 45)).

682 ‒ Engine
.541210. Replacing the vehicle camshaft (F2C Engines)

Main action
▶ Replace the camshaft in accordance with operation 540610 Replace the cylinder head on the vehicle (F2C engines)
( ➠ Page 78).
.541210. Replacing the vehicle camshaft (F3B Engines)
Work material
Main action
.541210. Camshaft of distribution removal
1. Remove the vehicle rocker arm shaft. ( ➠ Page 74)
pipes (1) from the elastic sleeves.
3. Disconnect the compressor air intake hose from the pipe (1).
4. Undo the fixing screws and remove the support brackets (3)
and remove the pipe (1).
5. Undo the screws (5) and remove the engine oil vapour
breather pipe (4).
216011 Figure 128
6. Unscrew the screws (1) and remove the timing gear cover (2).
216012 Figure 129

682 ‒ Engine
7. Remove the flywheel rpm sensors (1).
194224 Figure 130
8. Position the crankshaft with the pistons (1 - 6) and at the top

dead centre (T.D.C.).
code
Note This situation occurs when:

The hole with one reference mark (5) of the engine
flywheel (4) can be seen through the inspection win-
dow.
The specific tool (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the flywheel (4).
9. If this condition does not occur, turn the flywheel (4) appropri-
ately.
10. Remove the specific tool (1).
code 182251 Figure 131

682 ‒ Engine
11. Unscrew the screws (7) and remove the blow-by filter (8).
13. Unscrew the fastening nut (3).
15. Remove the gear (2) using a suitable extraction tool.
16. Unscrew the screws (4) and remove the gear (5) as well as
gear (6).
217882 Figure 132
17. Unscrew the screws (1); tighten the reaction screws in the
holes (→) and remove the shoulder plate (2) together with
the gasket.
193167 Figure 133
18. Remove the camshaft (1) from the engine case rear side (→).
217883 Figure 134

682 ‒ Engine
.541210. Refitting the camshaft on vehicle

20. Lubricate the seal (3) and fit it on the thrust plate (2).
21. Mount the shoulder plate (2) with the sheet metal gasket (1)
and tighten the screws (5) to the required torque and accord-
ing to the sequence shown in the relative chapter.
182146 Figure 135
22. Fit the rocker arm shaft as described in the relevant chapter Refitting the vehicle rocker arm shaft (F3B Engines) ( ➠ Page 76)
(operation 541230).
23. Fit the gears (1) and (3) onto the camshaft and perform timing
as in the relative chapter COMPLETE TIMING SYSTEM OVER-
HAUL .
24. Refit the HP pump gear as in the chapter High pressure fuel
pump refitting on the vehicle (F3B engines) ( ➠ Page 26) (oper-
ation 771010).
25. Complete the reconnection by performing the operations for
removal in the reverse order.
217884 Figure 136

682 ‒ Engine
MAIN REPAIRS ON ENGINE PARTS

.540840. Replace rod-piston on vehicle (F2C Engines)
Work material
Pliers for removing/refitting piston rings (105 -160 mm) 99360184
Clamp for fitting piston into cylinder liner (90 - 175 mm) 99360603
Tool for cylinder liner fastening 99360703
- 1/2" and 3/4"
Tightening torques
Screws fixing connecting rod cap 50 N⋅m
Main action
.540840. Removing rod-piston on vehicle (F2C Engines)
4. Remove the oil sump as described in the relevant chapter ( Removal of oil sump on vehicle ( ➠ Page 51)).
5. Unscrew the screws (1) and remove the suction strainer (2).
6. Fit the specific tool for rotation of the engine flywheel.
code
129709 Figure 137
7. Unscrew the fastening screws (1) of the rod caps (2) and re-
move them.
8. Remove the engine head as described in the relevant chapter (
540610Remove the cylinder head on the vehicle (F2C engines)
( ➠ Page 79)).
155859 Figure 138

682 ‒ Engine
9. Clean the upper part of the liner form carbon deposits as to

facilitate the piston way out.
10. Apply the cylinder liner fastening pins (2) with the specific tool.
code
11. From above, remove the connecting rod-piston assembly (1).

12. Repeat these operations for the other pistons.
13. Mark the rod bearing shells position when removing them as to
reassemble them in the same position, should you not have to
replace them. 155860 Figure 139
14. Remove the retaining piston rings (2) using round tipped pliers
(1).
49024 Figure 140
15. Disassemble the piston pin (1) as to release the rod from the
piston.
Note If removal is difficult use the appropriate drift.
49025 Figure 141

682 ‒ Engine
.540840. Refitting rod-piston on vehicle (F2C Engines)

16. The piston (1) has to be fitted on the connecting rod (2) so
that the graphic symbol (4), showing the assembly position in
the cylinder liner, and the punch marks (3) on the connecting
rod face each other as shown in the figure.
73536 Figure 142
17. Lubricate with engine oil the piston pin (2) and the relevant
seats. 1
18. Fit the pin (2) and fasten it on the piston (1) with the piston 2
rings (3).
3
74052 Figure 143
19. Use the specified calliper (3) to fit the piston rings (1) on the
piston (2).
code
20. The rings need to be mounted with the word "TOP" (4) facing
upwards, direct the ring openings so they are staggered 120°
apart.
22. Remove the cylinder liner fastening pins.
code
192193 Figure 144
23. Check the assembly clearance of crankpins as described in

the relevant chapter (540831 Checking assembly clearance of
crankpins ( ➠ Page 229)).
24. Fit the bearing shells on the connecting rod and on the cap after
lubricating them with engine oil.

682 ‒ Engine
Caution!
Retaining screws Minimum thread diameter
▶ Before using the connecting rod cap fixing screws, measure the thread diameter and make sure that it is at least
11.4 mm; otherwise, replace the screw.
25. Clean and oil the cylinder linings (3).

26. Using the specific strap (2), assemble the piston-rod assembly
(1) into the cylinder barrels making sure that the openings of
the circlips are offset by 120°.
code
27. Make sure that the pistons belong all to the same class.
28. In addition, check that the ideogram stamped on the piston
crown faces the engine flywheel; or the recess in the piston skirt
matches the position of oil nozzles.
155861 Figure 145
29. Connect the connecting rods to the relevant pins of the crank-
shaft, mount the connecting rod caps (2) together with half-
bearings; tighten the connecting rod caps fixing screws (1)
to the prescribed torque. Using the specific tool (3) further
tighten the screws with an angle of 90°.
Tightening torque
Screws fixing connecting rod cap 50 N⋅m

code
1/2" and 3/4"
30. Clean the surface of the lower crankcase.

31. Refit the oil sump as described in the relevant chapter (
155862 Figure 146
540430Refitting of oil sump on vehicle ( ➠ Page 52)).
32. Refit the engine head as described in the relevant chapter
(540610 Refitting the cylinder head on the vehicle (F2C
engines) ( ➠ Page 81)).

682 ‒ Engine
.540420. Replace cylinder liners on vehicle (F2C Engines)
Work material
Cylinder liner protrusion gauge (to be used with 99360334
99370415-99395603 and special plates)
Tool to extract cylinder liners (use with special rings) 99360706
Ring (115 mm) (to be used with 99360706) 99360724
Tightening torques
Cylinder liner fixing screws 170 N⋅m
Technical data
Cylinder liner protrusion 0.035 mm to0.065 mm
Main action
.540420. Removal of cylinder liners on vehicle (F2C Engines)
4. Remove the oil sump as described in the relevant chapter ( Removal of oil sump on vehicle ( ➠ Page 51)).
5. Remove the engine head as described in the relevant chapter ( 540610Remove the cylinder head on the vehicle (F2C en-
gines) ( ➠ Page 79)).
6. Remove the connecting rods and the pistons as described in the relevant chapter (operation 540840 Removing rod-piston on
vehicle (F2C Engines) ( ➠ Page 89)).
7. Position the specific tool (2) and the specific plate (4) as shown
in the figure, checking that the plate (4) rests on the cylinder
liner correctly.
code
8. Fasten the screw nut (1) and take off the cylinder liner (3)
from the crankcase.
47577 Figure 147

682 ‒ Engine
.540420. Refitting cylinder liners on vehicle (F2C Engines)

9. Always replace water sealing rings (3), (4) and (5) . Install
the adjustment ring (1) on the cylinder liner (2); lubricate the
lower part of the liner and install it in the cylinder unit using the
proper tool.
Note The adjusting ring (1) is equipped with a spare part
having the following thickness: 0.08 mm - 0.10 mm -
0.12 mm - 0.14 mm.
16798 Figure 148
10. Check cylinder liner protrusion using the specific tool (2) and
tightening the screw (1) to the specified torque.
Tightening torque
Cylinder liner fixing screws 170 N⋅m

code
Cylinder liner protrusion gauge (to be used with 99370415- 99360334
99395603 and special plates)
11. Using the dial gauge (3), make sure that the protrusion of the
cylinder liner in relation to the contact surface of the cylinder
heads observes the values in the table; Otherwise replace the
adjustment ring, supplied as a spare part in various thicknesses.
Technical data 60520 Figure 149
Cylinder liner protrusion 0.035 mm to0.065 mm

682 ‒ Engine
MAIN REPAIRS ON SERVICE PARTS
12. Refit the connecting rods and the pistons as described in the
relevant chapter (operation 540840 Refitting rod-piston on
13. Refit the engine head as described in the relevant chapter
(540610 Refitting the cylinder head on the vehicle (F2C
engines) ( ➠ Page 81)).
14. Refit the oil sump as described in the relevant chapter (
540430Refitting of oil sump on vehicle ( ➠ Page 52)).
114041 Figure 150

CYLINDER LINER PROTRUSION

.760810. Replacement of starter motor on the vehicle
Tightening torques
Starter motor fixing screws 40 N⋅m to48 N⋅m
Main action
1. Unscrew the nuts (2) and disconnect the electrical connections
(1).
2. Loosen nuts (4) and remove starter motor.
3. To refit, carry out the operations for removal in reverse order,
tightening the locking nuts to tightening torque.
Tightening torque
Starter motor fixing screws 40 N⋅m to48 N⋅m
173818 Figure 151

682 ‒ Engine
.501450. Replacing the power steering pump on the vehicle (F2C Engines)
Main action
.501450. Remove the power steering pump on the vehicle (F2C Engines)
1. Unscrew the cap (2) of the power steering oil tank (3) and
disconnect the oil supply and return pipes (1).
173600 Figure 152
2. To simplify removal of the power steering pump (4) disconnect

the air delivery pipe (7) from the compressor (2) acting on the
coupling (1).
3. Slacken the fastener (9) and from the power steering pump
(4) disconnect the oil supply hose (8) by releasing it from its
clips.
4. Disconnect the oil supply hydraulic pipe (6) from the power
steering pump (4) by acting on the coupling (3).
5. Remove the fixing screws (5) of the power steering pump (4)
and disconnect it from the vehicle.
173601 Figure 153
.501450. Refitting the power steering pump on the vehicle (F2C Engines)
7. Fill up the power steering circuit and carry out the bleeding procedure as described in the relevant chapter (operation
501462).

682 ‒ Engine
.501450. Replacing the power steering pump on the vehicle (F3B Engines)
Main action
.501450. Removing the power steering pump on the vehicle (F3B Engines)
1. Disconnect the supply pipe (2) and oil delivery pipe (3) from
the pump (1) and drain the power steering circuit oil into a
suitable container.
217696 Figure 154
2. Undo the fixing screws (5) and remove the power steering
pump (3) by disconnecting it from the air compressor (4).
3. Remove the coupling (2) between the air compressor (4) and
power steering pump (3).
217697 Figure 155

682 ‒ Engine
.501450. Refitting the power steering pump on the vehicle (F3B Engines)
4. Smear grease on the coupling (2) and mount it into its seat on
the air compressor (1).
5. Replace the O-ring seal on the pump and smear with a thin
layer of suitable grease to simplify mounting onto the com-
pressor.
6. Fit the pump (3) into its cradle on the compressor (4) by align-
ing the notch on the coupling (2) with the pump drive shaft and
tighten the fixing screw (5).
217697 Figure 156
7. Connect the supply pipe (2) and oil delivery pipe (3) to the
pump (1) and fill the power steering circuit with oil.
8. Bleed the air from the power steering circuit as in the chapter
Bleeding air from the power steering circuit ( ➠ Page 18) (op-
eration 501450).
217696 Figure 157
.790510. Replacing the vehicle air compressor (F2C Engines)
Main action
.790510. Removing the vehicle air compressor (F2C Engines)
1. Remove the power steering pump as described in the relevant chapter (501450 Remove the power steering pump on the
2. Drain the engine coolant circuit.

682 ‒ Engine
3. Remove the fuel filter (5) as described in the relevant chapter

(operation 542011).
4. To simplify removal of the air compressor (3) remove the
engine ignition pushbutton panel (7) by acting on the fixing
screws (6).
5. Disconnect the air pipe (2) and pipes (8) from the compressor
(3).
6. Disconnect the water pipe (1) from the compressor (3).
7. Release the air supply pipe from the mounting brackets on the
engine head.
8. Unscrew the fixing screws (4) and disconnect the air com-
pressor (3).
173599 Figure 158
.790510. Refitting the vehicle air compressor (F2C Engines)

543210).
.790510. Replacing the vehicle air compressor (F3B Engines)
Main action
.790510. Replace the vehicle air compressor (F3B Engines)
1. Tilt the cab.
2. Remove power by disconnecting the battery negative cable.
3. Open the cap under the radiator and drain the engine cooling circuit into a suitable container.
4. Undo the fixing screw (2) of the supply pipe (1).

5. Undo the coupling (3) on the air delivery pipe (1) from the
compressor.
216016 Figure 159

682 ‒ Engine
6. Undo the coupling (7) on the air delivery pipe and remove it.
7. Remove the power steering pump (3) as described in the
relevant chapter Removing the power steering pump on the
vehicle (F3B Engines) ( ➠ Page 97) (Operation 501450).
8. Undo the couplings (1) and remove the cooling pipe (2).
9. Disconnect the air intake hose (4) from the air compressor (6).
10. Remove the screw (5) and disconnect the cooling pipe from
the compressor (6).
217693 Figure 160
11. Undo the screws (2) and remove the services air compressor
(1) from the vehicle.
217694 Figure 161

682 ‒ Engine
.790510. Refitting the vehicle air compressor (F3B Engines)

12. Replace the O-Ring gasket (1) and spread a thin layer of grease
for gaskets to simplify installation of the compressor into its
seat.
217695 Figure 162
13. Install the air compressor (1) into its cradle and tighten the
retaining screws (2).
217694 Figure 163

682 ‒ Engine
14. Mount the compressor air delivery pipe and connect it to the
compressor by tightening the coupling (7).
15. Connect the coolant pipe to the compressor (6) by tightening
the screws (5).
16. Connect the air intake hose (4) to the compressor (6).
17. Mount the cooling pipe (2) by screwing in the coupling (1).
18. Refit the power steering pump (3) as described in the relating
chapter Refitting the power steering pump on the vehicle (F3B
Engines) ( ➠ Page 98) (Operation 501450).
19. Fill the engine cooling air circuit and bleed the air as in the rel-
ative chapter Cooling system air bleeding ( ➠ Page 64) (Opera-
tion 506010)
20. Fill and bleed the air from the power steering circuit as in
the chapter Bleeding air from the power steering circuit
217693 Figure 164

682 ‒ Engine
F2C ENGINE 103
Contents
Contents TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 141

TIGHTENING TORQUES . . . . . . . . . . . . . . . 143
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . 105
LEFT SIDE VIEW . . . . . . . . . . . . . . . . . . . . 105 EQUIPMENT F2C Euro III . . . . . . . . . . . . . . . . . 159
RIGHT SIDE VIEW . . . . . . . . . . . . . . . . . . . 106 EQUIPMENT F2C Euro 4 . . . . . . . . . . . . . . . . . 168

FRONT VIEW (no fan) . . . . . . . . . . . . . . . . . 107
ENGINE REMOVAL - REFITTING . . . . . . . . . . . . 176
REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . 108
TOP SIDE VIEW . . . . . . . . . . . . . . . . . . . . . 109 ENGINE DISASSEMBLING . . . . . . . . . . . . . . . . 184
TECHNICAL NAME . . . . . . . . . . . . . . . . . . . . 109 CYLINDER UNIT REPAIR OPERATIONS . . . . . . . 198
CHARACTERISTIC CURVES . . . . . . . . . . . . . . . 110 OVERHAULING THE CONNECTING

CHARACTERISTIC CURVES F2CE0681D . . . . . 110 ROD-PISTON ASSEMBLY . . . . . . . . . . . . . . . . . 219
CHARACTERISTIC CURVES F2CE0681C . . . . . 111 CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . 230
CHARACTERISTIC CURVES F2CE0681B . . . . . 112
COMPLETE TIMING SYSTEM OVERHAUL . . . . . . 237
POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . 112
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 243
Engine fuel supply scheme . . . . . . . . . . . . . . . 114
Mechanical supply pump . . . . . . . . . . . . . . . . 114
High pressure pump CP3 . . . . . . . . . . . . . . . . 115
Rail (pressure accumulator) . . . . . . . . . . . . . . 121
Electro-injector . . . . . . . . . . . . . . . . . . . . . 121
LUBRICATION SYSTEM LAYOUT . . . . . . . . . . . 122

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 123
Safety valve . . . . . . . . . . . . . . . . . . . . . . . . 124
Heat exchanger . . . . . . . . . . . . . . . . . . . . . 124
Engine oil filter . . . . . . . . . . . . . . . . . . . . . . 126
Filter by-pass valve . . . . . . . . . . . . . . . . . . . 127
Oil vapour recirculation (Blow-by) . . . . . . . . . . . . 127
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Water pump . . . . . . . . . . . . . . . . . . . . . . . 131
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 131
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . 132
turbocharger . . . . . . . . . . . . . . . . . . . . . . . 133
ENGINE BRAKE DEVICE CEB (Combined Engine

Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
CHARACTERISTICS AND DATA . . . . . . . . . . . . 134
DATA - INSTALLATION CLEARANCES . . . . . . . 136

682 ‒ Engine
104 F2C ENGINE

682 ‒ Engine
F2C ENGINE 105
ENGINE VIEWS
F2C ENGINE
540110 ENGINE VIEWS
LEFT SIDE VIEW
125695 Figure 165

682 ‒ Engine
106 F2C ENGINE
ENGINE VIEWS
RIGHT SIDE VIEW
125696 Figure 166

682 ‒ Engine
F2C ENGINE 107
ENGINE VIEWS
FRONT VIEW (no fan)
113049 Figure 167

682 ‒ Engine
108 F2C ENGINE
ENGINE VIEWS
REAR VIEW
125698 Figure 168

682 ‒ Engine
F2C ENGINE 109
TECHNICAL NAME
TOP SIDE VIEW
125699 Figure 169
TECHNICAL NAME
F2CE0681B*B052-XXXXXX
● F2 CE0681B*B052 ‒ Indication of the engine family

● F2 C E0681B*B052 ‒ Evolution of the family with the same or different displacement
● F2C E 0681B*B052 ‒ Engine
● F2CE 0 681B*B052 ‒ Number of strokes and cylinder position
0 4 times, vertical without post-treatment
3 4 times, vertical with post-treatment
● F2CE0 6 81B*B052 ‒ Number of cylinders

● F2CE06 8 1B*B052 ‒ Power supply + Injection (TCA, direct injection diesel)
● F2CE068 1 B*B052 ‒ Use (1 truck)
● F2CE0681 B *B052 ‒ Engine torque and power level
D 290 HP - E3
C 340 HP - E3
B 380 HP - E3
G 350 HP - E4
E 390 HP - E4
● F2CE0681B*B 052 ‒ Gaseous emissions level

682 ‒ Engine
110 F2C ENGINE
CHARACTERISTIC CURVES
B Euro III
P Euro 4
● F2CE0681B*B 052 ‒ Version no. within the bill of materials

● F2CE0681B*B052- XXXXXX ‒ Progressive production number
540110 CHARACTERISTIC CURVES F2CE0681D
300
250
200
150
100
50
0
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
1700
1500
1300
1100
900
700
500
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
171969 Figure 170
Technical data
Max POWER 213 kW (290 HP) at 2100 rpm
Technical data
TORQUE max. 1200 Nm (122 kgm) to 1000 to 1780 rpm

682 ‒ Engine
F2C ENGINE 111
540110 CHARACTERISTIC CURVES F2CE0681C

300
250
200
150
100
50
0
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
1700
1500
1300
1100
900
700
500
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
171970 Figure 171
Technical data
Technical data

682 ‒ Engine
112 F2C ENGINE
POWER SUPPLY
540110 CHARACTERISTIC CURVES F2CE0681B

300
250
200
150
100
50
0
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
1700
1500
1300
1100
900
700
500
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
171971 Figure 172
Technical data
Technical data
5420 POWER SUPPLY

The Common Rail supply system has a special pump that continuously keeps fuel at high pressure, independently from the stroke
and the cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the control unit.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place
in the related cylinder.

682 ‒ Engine
F2C ENGINE 113
POWER SUPPLY
200107 Figure 173

A Return circuit B Delivery circuit

682 ‒ Engine
114 F2C ENGINE
POWER SUPPLY
Engine fuel supply scheme
200108 Figure 174

1 High-pressure pump 7 E.C.U. (Electronic Control Unit)
2 Fuel filter 8 Electro-injectors
3 Tank 9 Overpressure sensor
4 Water/fuel separator 10 Common rail
5 Water indicator 11 Pressure sensor
6 Fuel pre-filter
A High pressure B Low pressure
773010 Mechanical supply pump

Gear pump, mounted on the rear part of the high pressure pump, has the function of supplying it.
It is controlled by the high pressure pump shaft.

682 ‒ Engine
F2C ENGINE 115
POWER SUPPLY
Normal operating condition
72592 Figure 175

A Fuel tank inlet 1 By-pass valve in closed
B Fuel delivery outlet to position
filter 2 By-pass valve in closed
position
Output overpressure condition

By-pass valve (1) opens in the presence of overpressure at the out-
let B. This pressure, overcoming the elastic resistance of the valve
spring (1), connects the output with the entrance through the duct
(2).
72593 Figure 176
Bleeding conditions
The by-pass valve (2) operates when the engine is shut off and the
supply system needs to be filled by means of the primer pump. In this
situation the by-pass valve (1) stays closed whereas by-pass valve (2)
opens due to inlet pressure, and fuel is drained out through B.
Note The mechanical supply pump cannot be replaced individually,

so it must not be removed from the high pressure pump.
72594 Figure 177
771010 High pressure pump CP3

Pump with 3 radial plungers, controlled by distribution gears, requires no timing. The mechanical supply pump controlled by the
high pressure pump shaft is mounted on the rear side of the high pressure pump.
The following operations are planned for the HP pump - supply pump assembly:
● replacement of the drive gear;

● flow regulator replacement.

682 ‒ Engine
116 F2C ENGINE
POWER SUPPLY
High pressure pump CP3
72595 Figure 178

1 Rail fuel outlet coupling 6 Fuel outlet filter mount coupling
2 High-pressure pump 7 Control unit heat exchanger fuel inlet coupling
3 Flow regulator 8 Fuel outlet coupling from mechanical pump to filter
4 Control gear 9 Mechanical supply pump
5 Fuel inlet coupling from filter

682 ‒ Engine
F2C ENGINE 117
POWER SUPPLY
High-pressure pump internal structure

Sez. B-B
Sez. C-C
70498 Figure 179

1 Cylinder 5 Piston
2 Three lobe element 6 Pump shaft
3 Plate intake valve 7 Low pressure fuel inlet
4 Spheric delivery valve 8 Fuel canals to power plungers
Each pump unit consists of:
● a piston (5) actuated by a three lobe element (2) floating on the pump shaft (6). The element (2), floating on an offset part
of the shaft (6), does not rotate with the shaft during the shaft's rotation, but is only moved in a circular movement on a
wider range, alternatively activating the three plungers;
● one plate intake valve(3);
● ball delivery valve (4).

682 ‒ Engine
118 F2C ENGINE
POWER SUPPLY
Operating principle
Sez. B - B
Sez. D - D
72597 Figure 180
1 Rail fuel outlet coupling 5 Plunger supply duct
2 Rail delivery valve 6 Flow regulator supply duct
3 Plunger 7 Flow regulator
4 Pump shaft
The pumping element (3) is oriented to the pump shaft cam (4). During the operation phase, the plunger is powered through the
power supply duct (5).

682 ‒ Engine
F2C ENGINE 119
POWER SUPPLY
The fuel amount to be sent to the plunger is set by the flow regulator (7). The load regulator, based on the PWM command from
the control unit, shuts the flow of fuel to the plunger. During the fuel pump compression phase, once a pressure is reached that will
open the delivery valve to the common rail (2), it powers it through the outlet (1).
C-C section
1 Plunger inlet 6 Plunger inlet
2 Pump lubrication ducts 7 Regulator discharge duct
3 Plunger inlet 8 5 bar pressure limiter valve
4 Main plunger supply duct 9 Fuel drain from regulator
5 Flow regulator inlet
Sez. C - C
72598 Figure 181
The figure shows the low pressure fuel paths within the pump; it also shows the main supply duct of the plungers (4), the supply
ducts of plungers (1),(3) and (6), the ducts used to lubricate the pump (2), the flow regulator (5), the 5 bar relief valve (8) and
the fuel discharger (7).
The supply and return lines (2).
The load regulator (5) sets the quantity of fuel with which the plungers must be supplied; The excess fuel lows out through the
duct (9).
The 5 bar relief valve, in addition to functioning as a collector for fuel discharge, has the function of keeping the pressure constant
at 5 bar at the entrance of the regulator.

682 ‒ Engine
120 F2C ENGINE
POWER SUPPLY
A-A section
1 Fuel outlet duct 3 Fuel outlet from pump
2 Fuel outlet duct with high pressure pipe
fitting for common rail
Sez. A - A
72601 Figure 182
The figure shows the high pressure fuel flow through the plunger outlet ducts.
Operation
The cylinder is filled through the plate intake valve only if the supply pressure can open the delivery valves on the plungers (approx.
2 bar).
The quantity of fuel that powers the high pressure pump is dosed by the load regulator on the low pressure system; the flow regu-
lator is controlled by the EDC 7 control unit via a PWM signal.
If the fuel is sent to the plunger, its piston is moving down (intake stroke).
When the piston stroke inverts, the intake valve closes and the fuel remaining in the plunger chamber, which cannot exit, is com-
pressed beyond the existing supply pressure in the rail.
The pressure generated this way causes the discharge valve to open and the compressed fuel reaches the high pressure circuit.
The pumping element compresses the fuel up to the top dead centre (discharge stroke). Then the pressure decreases so that the
discharge valve closes.
The plunger piston returns to the bottom dead centre and the residual fuel is decompressed.
When the pressure in the plunger chamber is lower than the supply pressure, the intake valve opens again and the cycle is re-
peated.
The delivery valves must always be free in their movement, with no impurities or oxidation.
The delivery pressure to the rail is modulated by the electronic control unit through the pressure regulator solenoid valve.
The pump is lubricated and cooled by the same fuel. The removal - refitting time of the radialjet pump on the engine is significantly
reduced compared to traditional injection pumps because no timing is necessary.
In the event of removal - refitting of the fuel filter pipe and high pressure pump, make sure hands and components are as clean as
possible.

682 ‒ Engine
F2C ENGINE 121
POWER SUPPLY
774510 Rail (pressure accumulator)

Rail
1 Rail 4 Fuel inlet from
2 Fuel return high-pressure pump
3 Pipes to injectors 5 Pressure sensor
6 Overpressure valve
114254 Figure 183
The rail volume is of reduced size to allow a quick pressurisation at start-up, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise pulsations caused by injectors openings and closings and by the high-pressure pump
operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.
A fuel pressure sensor (5) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back informa-
tion, depending on which the rail pressure value is checked and, if necessary, corrected.
775010 Electro-injector
Electro-injector
1 Fuel return hole 2 Fuel delivery
1,Fuel delivery
2,Fuel return hole
114255 Figure 184

682 ‒ Engine
122 F2C ENGINE
LUBRICATION SYSTEM LAYOUT
5430 LUBRICATION SYSTEM LAYOUT
192201 Figure 185

1 Oil dropping 2 Oil under pressure

682 ‒ Engine
F2C ENGINE 123
543010 Oil pump

The oil (1) pump cannot be overhauled. If you find any damage,
replace the entire oil pump.
To change the gearing (2) of the crankshaft, see the relevant
chapter.
114245 Figure 186
OIL PUMP CROSS-SECTION
112327 Figure 187

1 Safety valve - Start of opening pressure 10.1 ± 0.7 bar.

682 ‒ Engine
124 F2C ENGINE
543076 Safety valve

MAIN DATA TO CHECK THE SAFETY VALVE SPRING
190 + 6N
324 + 9N
43,65
33,5
25,5
22,95
117716 Figure 188
543110 Heat exchanger

Heat exchanger
114246 Figure 189

1 Exchanger gasket 2 Heat exchanger internal part

682 ‒ Engine
F2C ENGINE 125
3 cover 5 Oil filter gasket

4 oil filter
MAIN DATA TO CHECK THE OIL PRESSURE ADJUSTMENT

VALVE SPRING
168 ± 9
308 ± 15
63
51
36,4
88819 Figure 190

682 ‒ Engine
126 F2C ENGINE
543070 Engine oil filter
227431 Figure 191

1 Closing cap 3 By-pass valve (3.4 bar)
2 Support
Characteristics
Technical data
Maximum operating pressure 13 bar
Operating temperature −30 ℃ to120 ℃
Bypass valve opening pressure 3.4 ±0.3 bar

682 ‒ Engine
F2C ENGINE 127
Oil vapour recirculation (Blow-by)
543077 Filter by-pass valve
73545 Figure 192
The valve quickly opens at a specific pressure.
Technical data
Bypass valve opening pressure 3.4 ±0.3 bar
5404 Oil vapour recirculation (Blow-by)

Part of the gas produced by combustion leaks out of the piston gaskets into the sump and mixes with the oil vapour it contains.
This mixture is conveyed upwards and is partially separated from the oil by a device located at the top of the timing system cover
and sent into the air intake circuit.
The device is essentially composed of a rotary filter fitted to the camshaft and a front cover housing the normally closed valves that
manage the flow of the mixture.

682 ‒ Engine
128 F2C ENGINE
Oil vapour recirculation (Blow-by)
192202 Figure 193

1 Gas with oil content above 10 g/h 3 Condensed oil that returns to the oil sump
2 Gas with oil content of ~ 0.2 g/h

682 ‒ Engine
F2C ENGINE 129
COOLING
5432 COOLING
Description
Engine cooling system is closed circuit forced circulation.
It consists mainly of the following components:
● expansion tank plug;

● a heat exchanger to cool the lubricating oil;
● a centrifugal water pump incorporated in the crankcase;
● fan not supplied;
● a 2-way thermostat regulating the circulation of the coolant.
Operation
The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head into the cylin-
der head.
When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open and the fluid is
channelled from here to the radiator and cooled by the fan.
The pressure inside the system due to temperature variation is appropriately controlled via the expansion chamber.

682 ‒ Engine
130 F2C ENGINE
COOLING
192203 Figure 194

1 Water leaking from the thermostat 3 Pump inlet water
2 Water circulating in the engine

682 ‒ Engine
F2C ENGINE 131
COOLING
543210 Water pump

The water pump is composed of: rotor, shaft with bearings, T gasket
and drive pulley with dust guard.
Note Check that the pump casing shows no sign of cracking or

water leakage; replace the water pump assembly if it does.
114250 Figure 195
543250 Thermostat
Thermostat operation view
1 Water circulating in the

engine
192204 Figure 196
1 Water leaking from the

thermostat
1
192205 Figure 197

682 ‒ Engine
132 F2C ENGINE
TURBOCHARGING
Check that the thermostat works properly, replace it if there is any doubt.
Technical data
Start of stroke temperature 84 ±2 ℃
Minimum stroke (15 mm) 94 ±2 ℃
5424 TURBOCHARGING
The turbocharging system is composed of:
● an air filter;
● a turbocharger;
● an intercooler radiator.
192206 Figure 198

1 Exhaust gas 3 Intake air.
2 Hot compressed air 4 Compressed air in intake
Description
The turbocharger consists of the following main parts, a turbine, a valve for regulating the boost pressure, a central body and a
compressor.
During operation of the engine exhaust gases pass through the body of the turbine by rotating the impeller of the turbine itself.

682 ‒ Engine
F2C ENGINE 133
ENGINE BRAKE DEVICE CEB (Combined Engine Brake)
The impeller of the compressor, being connected through to the impeller shaft of the turbine wheel with the latter compressing
the air sucked through the air filter.
The compressor outlet air is sent directly to the pistons through the intake manifold.
The turbocharger is equipped with a pressure regulating valve fitted on the exhaust manifold upstream of the turbine and connec-
ted via tubing to the intake manifold.
Its purpose is to divide the output of the exhaust gas sending a part directly into the exhaust pipe when the boost pressure down-
stream of the compressor reaches the prescribed value in bar.
Cooling and lubrication of the turbocharger and the bearing brass is performed by means of the engine oil.
542410 turbocharger
Holset HX40W/HX52W
The turbocharger is fitted with pressure relief valve. Essentially it
consists of:
● a central body in which a shaft is housed, supported by bushings,

the ends of which are connected to: the turbine rotor and the
compressor rotor;
● a turbine casing and a compressor casing mounted on the end
of the central body;
● a pressure limiter valve fitted on the turbine casing. Its function
is to choke the exhaust gas outlet, conveying a portion of it
straight into the exhaust pipe when the turbocharging pressure
downstream from the compressor reaches the setting value.
166358 Figure 199
5437 ENGINE BRAKE DEVICE CEB (Combined Engine Brake)

In engines with fixed a geometry turbine and wastegate, to improve
the performance of the decompression exhaust brake Iveco Turbo
Brake (ITB), the CEB (Combined Engine Brake) has also been added.
For this reason, there is a butterfly valve operated by a pneumatic
cylinder in the engine exhaust manifold.
When the driver activates the engine brake, the throttle valve actu-
ates, blocking the exhaust gas outlet.
The exhaust gas thus returns to the cylinder where it provides resist-
ance to the up stroke of the piston.
This resistance extends throughout the entire kinematic chain, apply-
ing a braking effect on the driving wheels.
125814 Figure 200

682 ‒ Engine
134 F2C ENGINE
CHARACTERISTICS AND DATA
54 CHARACTERISTICS AND DATA

CHARACTERISTICS AND DATA (Euro III version)
F2CE0681D F2CE0681C F2CE0681B
type
290 HP 340 HP 380 HP
Cycle Diesel 4-stroke
Power Supply Turbocharged with intercooler
Injection Direct
Number of cylinders 6 in line
Bore mm 117
Stroke mm 135
Total displacement cm3 8710
Compression ratio 1 : 15.9 ± 0.8
kW 211 248 278

(HP) (290) (340) (380)
Maximum nominal power
rpm 2100 2100 2100
Nm 1145 1300 1500

Maximum nominal torque (kgm) (114) (130) (150)
rpm 1100 - 1600 1100 - 1600 1100 - 1600
Idle speed with no load rpm 600
Maximum engine idle speed rpm 2400
TURBOCHARGING Intercooler Direct injection
Turbocharger type HX52W HX52W HX52W
LUBRICATION
Oil pressure with engine warmed up Forced by gear pump, pressure relief valve, oil filter
at idle speed bar 2
at max speed bar 5
COOLING
Water pump drive: Belt driven
Thermostat: Fluid filled
initial opening °C 85°
REFILLING (Urania FE5W30 and Urania LD7)
litres 26
Total capacity of 1st filling
kg 23.4

682 ‒ Engine
F2C ENGINE 135
CHARACTERISTICS AND DATA (Euro 4 version)

F2CE3681G F2CE3681E
type
350 HP 390 HP
Cycle Diesel 4-stroke
Power Supply Turbocharged with intercooler
Injection Direct
Bore mm 117
Stroke mm 135
Compression ratio 1 : 15.9 ± 0.8
kW 255 285
(HP) (347) (388)
Max. power
rpm 2,100 2,100
Nm 1500 1590
Maximum torque (kgm) (150) (159)
rpm 1270 1270
Idle speed with no load rpm 600
Maximum engine idle speed rpm 2400
TURBOCHARGING
Turbocharger type HX40W HX52W
LUBRICATION
Oil pressure with engine warmed up Forced by gear pump, pressure relief valve, oil filter
at idle speed bar 2
at max speed bar 5
COOLING
Water pump control: Belt driven
Thermostat: Fluid filled
initial opening °C 85 °
REFILLING (Urania FE5W30 and Urania LD7)
Litres 26
kg 23.4

682 ‒ Engine
136 F2C ENGINE
DATA - INSTALLATION CLEARANCES
Distribution/power supply data
type F2C - Euro III F2C - Euro 4
DISTRIBUTION
A 17°
start before T.D.C.
B 31°
End after B.D.C.
DISTRIBUTION
D 48 °
start before B.D.C.
C 9°
End after T.D.C.
For timing check X

mm
mm
Of operation X
mm 0.35 - 0.45
mm 0.55 ÷ 0.65
High pressure fuel feed electronic system type BOSCH EDC 7
Composed of CP 3.3 high-pressure pump, injectors, hydraulic
Power Supply
accumulator (rail), EDC 7 control unit, pressure and
temperature sensors
Electro-injectors type CRIN3 CRIN2
Firing order 1-4-2-6-3-5
Injection pressure bar 1600
type F2C Euro III F2C Euro 4
CYLINDER ASSEMBLY AND CRANK GEARS mm
upper 130.500 to 30.525

Cylinder liner housing: ⌀ 1
lower 129.510 - 129.535
upper 130.461 - 130.486

Cylinder liners with 2 mm outer
lower 129.475 - 129.500
diameter:
length L 226.15
upper 0.014 – 0.064

Cylinder liners crankcase seats
lower 0.010 – 0.060
Outer diameter ⌀2

682 ‒ Engine
F2C ENGINE 137
Cylinder liners:
117.000 - 117.012
A*
117.010 - 117.022
Internal diameter ⌀3 B*
0.035 – 0.065
Protrusion (with 6,000 Kg load) X*
A* 0.094 - 0.118
Piston - cylinder liners
B* 0.094 - 0.118
Piston diameter ⌀1
Piston pin ⌀3 51.994 - 52.000
Piston pin - pin seat 0.010 – 0.022
X1 3.120 to 3.140 3.218 - 3.242

Circlip slots X2 2.550 - 2.570 2.550 - 2.570
X3 4.020 – 4.040 4.020 – 4.040
Circlips:
trapezoidal sealing S1 3.000
bevelled S2 2.470 - 2.500
Oilscraper S3 3.970 – 3.990
1
Circlips slots 2 0.050 – 0.100
3 0.030 – 0.070
Circlips
X1 0.30 – 0.40
Circlip end gap in cylinder liner: X2 0.60 – 0.75
X3 0.35 – 0.65
Connecting rod small end bush ⌀1 55.700 to 55.730

seat ⌀2 85.987 - 86.013
Connecting big-end bearings seat
⌀1 85.987 - 85.996
Selection classes ⌀2 85.997 - 86.005
⌀3 86.006 - 86.013
Connecting rod small end bush
diameter
55.780 - 55.820
external ⌀4
52.015 - 52.030
internal ⌀3
Big-end half-bearings S
1.994 - 2.002
Red colour
2.002 - 2.010
Green colour
2.010 - 2.018
Yellow **
Connecting rod small end bush - housing 0.05 - 0.08
Piston pin - bushing 0.015 – 0.036

682 ‒ Engine
138 F2C ENGINE
Big-end half-bearings 0.127 - 0.254 - 0.508
A g. 3450 to 3470 g. 3308 - 3338

Connecting rod weight
B g. 3471 to 3490 g. 3339 - 3368
Class
C g. 3491 to 3510 g. 3369 - 3398
Measuring point
X1 125
Maximum error in parallelism of
= 0.08
connecting rod axes
Main journals
- rated 92.970 - 93.000
- class 1 ⌀1 92.970 - 92.979
- class 2 92.980 – 92.989
- class 3 92.990 – 93.000
Crankpins
- rated 81.915 - 81.945
- class 1 ⌀2 81.915 - 81.924
- class 2 81.925 - 81.934
- class 3 81.935 ÷ 81.845
Main half-bearings
Red colour 2.968 - 2.978
S1
Green colour 2.978 - 2.988
yellow colour ** 2.988 - 2.998
Big-end half-bearings
Red colour 1.994 - 2.002
S2
Green colour 2.002 - 2.010
yellow colour ** 2.010 - 2.018
Main bearings
- rated 99.000 - 99.030
- class 1 ⌀3 99.000 – 99.009
- class 2 99.010 – 99.019
- class 3 99.020 – 99.030
Main journals - half-bearings 0.050 – 0.090
Half-bearings - crankpins 0.040 – 0.080
Main half-bearings 0.127* - 0.254 - 0.508
Big-end half-bearings 0.127* - 0.254 - 0.508
Shoulder main journal X1 39.96 – 40.04

X1
Shoulder main bearing X2 38.94 – 38.99

X2
Shoulder half rings X3 3.38 – 3.43
Crankshaft shoulder 0.10 – 0.30

682 ‒ Engine
F2C ENGINE 139
1 2
Alignment // 1-2
Centring 1-2 0.04
Taper 1-2
*Indicates the selection class

** Factory-assembled only, not provided as spare part.
CYLINDER HEAD - TIMING SYSTEM mm
Valve guide housing on cylinder head ⌀1 12.980 – 12.997
Valve guides
Inner diameter ⌀2 8.023 – 8.038
Outer diameter ⌀3 13.012 – 13.025
Valve guide outer diameter - seats on the head 0.015 – 0.045

Valve guide oversizing 0.2 - 0.4
⌀2 7.970 – 7.985
α 60° 30' – 7° 30''
Valves:
⌀2 7.970 – 7.985
α 45° +15'
-0°
Valve stem and related guide
⌀1 33.540 - 33.940
Housing on head for valve seat:
⌀1 33.110 - 33.510
⌀2 36.435 - 37.135
Outside diameter of valve seats;
α 59° - 61°
valve seats inclination on cylinder
⌀2 35.980 - 36.480
head:
α 44° - 46°
X
Recessing
X
Between valve seat and cylinder head
Valve spring height: H 71.34 70.77

under a load of:
N 460 ± 22 H1 51 (460 ± 22 N) 51 (460 ± 23 N)
N 731.4 ± 42 H2 39 (731.4 ± 42 N) 39 (740 ± 33 N)

682 ‒ Engine
140 F2C ENGINE
Camshaft bushing housings fitted in the cylinder

head: ⌀ 69.00 to 69.030
1→7
Camshaft journals:
⌀ 64.924 - 64.940
1→7
Camshaft bushing outer diameter: ⌀ 69.090 - 69.130
Bushing inner diameter ⌀ 65.080 - 65.116
Bushings and seats in cylinder head 0.060 - 0.130
Bushings and supporting pins 0.100 - 0.192
7.4034
Useful cam height:
8.2108
1
Rocker arm shaft ⌀ 31.964 - 31.980
32.025 - 32.041
Bushing housing in rocker arms:
32.025 - 32.041
0.045 - 0.077
Bushings and housings:
0.045 - 0.077
Engine brake control lever

32.03 - 32.04
Eccentric pin outer diameter ⌀2
43.98 - 44.00
Rocker shaft seat ⌀1
0.04 to 0.076
TURBOCHARGER
Axial clearance 0.025 – 0.127
Radial play 0.330 - 0.508 / 0.406 - 0.610 (HX40W/HX52W)

682 ‒ Engine
F2C ENGINE 141
TIGHTENING TORQUES
TIGHTENING TORQUES
TORQUE
DETAIL
Nm (Kgm)
Union for piston cooling nozzle M12x1.5 35 ± 2 (3.5 ± 0.2)
Heat exchanger fastening screws M12x1.75 63 ± 7 (6.3 ± 0.7)
Plug M42x1.5 125 ± 15 (12.5 ± 1.5)
Spacer and oil sump fastening screws M10x1.5 41.5 ± 3.5 (4.1 ± 0.3)
M10x1.25 41.5 ± 3.5 (4.1 ± 0.3)
Gear case to crankcase fastening screws: M12x1.75 63 ± 7 (6.3 ± 0.7)
M8x1.25 23.5 ± 1.5 (2.3 ± 1.5)
Screw fixing cylinder head ◆ 50 (5)
pre-tightening
First step 100 (10)
pre-tightening
Second step
Angle tightening 90 °
Third step
Fourth step
Rocker shaft tightening screw M12x1.75x130 104.5 ± 10.5 (10.4 ± 1)
Lock nut for rocker arm adjustment screw ◆ 39 ± 5 (3.5 ± 5)
Screws for electro-injector fixing brackets ◆ M10x45 41 ± 3 (4.1 ± 0.3)
Thrust plate fastening screws to head ◆ 23.5 ± 3.5 (2.3 ± 0.3)
Screws fastening engine support bracket to cylinder head 74 ± 8 (7.4 ± 0.8)
Screws fixing camshaft gear ● M10x1.5x45 25 (2.5)
First step pre-tightening
Second step Angle tightening 45°
M8
pre-tightening 10 (1.0)
Screws fixing phonic wheel to timing gear
tightening 28.5 ± 3.5 (2.8 ± 0.3)
pre-tightening 32.5 ± 7.5 (3.2 ± 0.7)

Exhaust manifold fixing screws ●
tightening 47.5 ± 2.5 (4.7 ± 0.2)
Screws fastening connecting rod cap ◆ M12x1.25x69 50 (5)
pre-tightening
First step
Second step
Engine flywheel fastening screws ◆ M18x1.5x72 120 ± 6 (12 ± 0.6)
pre-tightening
First step
Angle tightening 90° ± 4.5°
Second step
Screws fixing flywheel pulley to crankshaft ◆ 70 (7)
pre-tightening
First step
Second step
Cap retaining screws ◆ M16x2 140 (14)
pre-tightening
First step
Angle tightening 60° + 60°
Second step
Flywheel cover casing fastening screws M10x1.5 41.5 ± 3.5 (4.1 ± 0.3)
Flywheel cover casing fastening screws M12x1.75 63 ± 7 (6.3 ± 0.3)
Damper flywheel fastening screws ◆ 115 ± 15 (11.5 ± 1.5)
Screws fixing idler gear pins ◆ M12x1.75x90 30 (3)
pre-tightening
First step
Second step
Screw fixing link rod for idle gear ◆ 24.5 ± 2.5 (2.4 ± 0.2)
Screw fixing oil pump 24.5 ± 2.5 (2.4 ± 0.2)
Screw fixing oil pump suction strainer 24.5 ± 2.5 (2.4 ± 0.2)

682 ‒ Engine
142 F2C ENGINE
TIGHTENING TORQUES
TORQUE
DETAIL
Nm (Kgm)
Screw fastening front cover to crankcase 19 ± 3 (1.9 ± 0.3)
Control unit fastening screw 19 ± 3 (1.9 ± 0.3)
Screw fastening fuel filter support to cylinder head ◆ M8x1.25x60 24.5 ± 2.5 (2.4 ± 2.5)
Screw fixing engine support to the gear case ◆ 100 (10)
pre-tightening
First step
Angle tightening 60°
Second step
pre-tightening 35 ± 5 (3.5 ± 0.5)
Screws and nuts securing turbocharger ●
tightening 46 ± 2 (4.6 ± 0.2)
Screws fixing front and rear engine suspensions M16 268.5 ± 21.5 (26.85 ± 2.15)
Screw fixing water pump to crankcase 24.5 ± 2.5 (2.4 ± 0.2)
Screw fixing pulley to hub 55 ± 5 (5.5 ± 0.5)
Rocker arm cover fastening screws 8.5 ± 1.5 (0.8 ± 0.1)
Screws fixing thermostat box to cylinder head 24.5 ± 2.5 (2.4 ± 0.2)
Screws fixing automatic tensioner to crankcase 45 ± 5 (4.5 ± 0.5)
Screws fixing fixed tensioner to crankcase 105 ± 5 (10.5 ± 0.5)
Screws fixing fan support to crankcase 24.5 ± 2.5 (2.4 ± 0.2)
Starter motor fastening screws 44 ± 4 (4 ± 0.4)
Screws fixing heater box to cylinder head 50 ± 5 (5 ± 0.5)
Nut for fastening high pressure pump gear 105 ± 5 (10.5 ± 0.5)
Screw fixing air-conditioner compressor to support 24.5 ± 2.5 (2.4 ± 2.5)
Upper alternator mounting fastening screw 71.5 ±3.5 (7.1 ± 0.4)
Screw fixing alternator bracket to crankcase 24.5 ± 2.5 (2.4 ± 0.2)
Water pipe fittings 24.5 ± 2.5 (2.4 ± 0.2)
Water temperature sensor 32.5 ± 2.5 (3.2 ± 0.2)
Flywheel rev sensor fastening screw 8±4 (0.8 ± 0.4)
Camshaft rev sensor fastening screw 8±4 (0.8 ± 0.4)
Overboost pressure sensor fastening screw 8±2 (0.8 ± 0.2)
Absolute pressure sensor fastening screw 22.5 ± 2.5 (2.2 ± 0.2)
P.W.M. control valve fastening screw/nut. 8±2 (0.8 ± 0.2)
Fuel/coolant temperature sensor 35 ± 3.5 (3.5 ± 0.3)
Coolant temperature indicator 23.5 ±2.5 (2.3 ± 0.2)
Filter clogging sensor 10 ± 1 (1 ± 0.1)
Oil temperature switch 25 ± 1 (2.5 ± 0.1)
Oil pressure sensor 25 ± 1 (2.5 ± 0.1)
Electric wire fastening screw 8±2 (0.8 ± 0.2)
Engine suspensions fastening screws M12x1.75x70 50 (5)
pre-tightening
First step
Second step
Screw fastening oil filter body M8 24.5 ± 2.5 (2.5 ± 0.2)
Nut fixing positive alternator M8x1.25 12.5 ± 2.5 (1.3 ± 0.3)
Starter motor terminal nut 30 M10x1.5 21 ± 3.4 (2.1 ± 0.3)
Starter motor terminal nut 50 M5x0.8 3.6 ± 1 (0.4 ± 0.1)
Torque tightening screw M10x1.5x45 41.5 ± 3.5 (4.2 ± 0.4)

682 ‒ Engine
F2C ENGINE 143
TIGHTENING TORQUES
TORQUE
DETAIL
Nm (Kgm)
Engine suspension fastening screws (R8.8) M14x2x50 40 (4)
pre-tightening
First step
Angle tightening 30°
Second step
Engine suspension fixing screw (R 10.9) M14x2x50 167 ± 17 (16.7 ± 1.7)
Electro-injector bracket fixing screw M10x1.5x40 41 ± 2 (4.1 ± 0.2)
Upper alternator mounting fastening screw 71.5 ±3.5 (7.2 ± 0.4)
140 ± 6 Nm
Inner screws 60°
Crankcase reinforcement plate fastening screws
60°
Outer screws 50 Nm
Crankcase SUCTION STRAINER/REINFORCEMENT PLATE fastening screws M10x1.25x25 49.25 ± 2.75 (4.91 ± 0.3)
◆ Lubricate with MOLYKOTE oil before assembly
● Lubricate with graphitized oil before assembly
540110 TIGHTENING TORQUES

Tightening sequence order of lower crankcase plate fixing screws
Tightening inner screws(1)
● 1st step - 140 Nm
● 2nd step - 60°
● 3rd step - 60°
Tightening outer screws(2)

● 50 Nm
209247 Figure 201

682 ‒ Engine
144 F2C ENGINE
TIGHTENING TORQUES
Tightening sequence diagram for the engine front suspension fastening screws
200222 Figure 202
Tightening torque
Engine front suspensions fastening screws Tightening sequence: Screws 1 to 4
190.5 ±21.5 N⋅m
A - LEFT SIDE
B - RIGHT SIDE
Tightening sequence diagram for the engine rear suspension fastening screws
200223 Figure 203
Tightening torque
Screws securing engine rear suspensions Tightening sequence: Screws 1 to 4
295 ±30 N⋅m
A - LEFT SIDE
B - RIGHT SIDE

682 ‒ Engine
F2C ENGINE 145
TIGHTENING TORQUES
Cylinder head fastening screw tightening diagram
44900 Figure 204
Tightening torque
Cylinder head fastening screws 1. Phase 1
50 ±2.5 N⋅m
2. Phase 2
100 ±5 N⋅m
Cylinder head fastening screws (angle tightening) 1. Phase 3
90 ±4.5°
2. Phase 4
75 ±3.5°

682 ‒ Engine
146 F2C ENGINE
TIGHTENING TORQUES
Diagram of tightening sequence for screws securing rocker arm shaft
180270 Figure 205
Tightening torque
Screws securing rocker shaft Tightening sequence: 1 - 2 - 3 - 4 - 5 - 6 - 7
117.5 ±12.5 N⋅m
Diagram of tightening sequence for exhaust manifold fastening screws
200228 Figure 206
Tightening torque
Exhaust manifold fastening screws 1. Tightening sequence: 1 - 8
45 N⋅m
45 N⋅m
Note Lubricate with graphitized oil before assembly

682 ‒ Engine
F2C ENGINE 147
TIGHTENING TORQUES
Diagram of tightening sequence for turbocharger fastening screws and nuts
225763 Figure 207
Tightening torque
Screws and nuts securing the turbocharger 1. Pre-tightening
35 ±5 N⋅m
2. Tightening
46 ±2 N⋅m
Tightening torque
Oil drain pipe 1. Flange screws
21 N⋅m to27 N⋅m
2. Male connector
Tightening sequence: 3
105 N⋅m to115 N⋅m
3. Female connector
50 N⋅m to60 N⋅m
225756 Figure 208

682 ‒ Engine
148 F2C ENGINE
TIGHTENING TORQUES
225764 Figure 209
Tightening torque
Oil delivery pipe 1. Pipe fastening screw
21 N⋅m to25 N⋅m
2. Fittings
40 N⋅m to45 N⋅m

682 ‒ Engine
F2C ENGINE 149
TIGHTENING TORQUES
Diagram of tightening sequence for screws securing flywheel housing
225760 Figure 210
Tightening torque
Flywheel housing fastening screws 1. Screws M12
71 N⋅m to83 N⋅m
2. Screws M10
40 N⋅m to46 N⋅m
Screws fixing blow-by box Tightening sequence: 1 - 6
21 N⋅m to27 N⋅m
Screws securing high pressure pump flange 1. Tightening sequence: A - B - C - D - E
21 N⋅m to27 N⋅m
2. Tightening sequence: A - C - E - B - D
21 N⋅m to27 N⋅m

682 ‒ Engine
150 F2C ENGINE
TIGHTENING TORQUES
Tightening sequence diagram flywheel fastening screws
200225 Figure 211
Tightening torque
Screws fixing engine flywheel bolt Pre-tightening
120 ±6 N⋅m
Screws fixing engine flywheel bolt Angle tightening
90 ±4.5°
Note Lubricate the screws with Molykote before assembly

682 ‒ Engine
F2C ENGINE 151
TIGHTENING TORQUES
Tightening sequence diagram for damper flywheel fastening screws
Tightening torque
Screws fixing damper flywheel Tightening sequence: 1 - 6
80 N⋅m
225767 Figure 212
Diagram of tightening sequence for oil sump fastening screws
200227 Figure 213
Tightening torque
Engine control unit 1. Spacers
21 N⋅m to26 N⋅m
2. Screw
21 N⋅m to26 N⋅m
3. nut

682 ‒ Engine
152 F2C ENGINE
TIGHTENING TORQUES
200227 Figure 213
Tightening torque
Engine control unit 3. Tightening sequence: 4 - 5
21 N⋅m to26 N⋅m
4. Adapter
45 ±2 N⋅m
Diagram of tightening sequence for heat exchanger fastening screws
180264 Figure 214
Tightening torque
Heat exchanger fastening screws Tightening sequence: 1 - 18
21 N⋅m to26 N⋅m

682 ‒ Engine
F2C ENGINE 153
TIGHTENING TORQUES
Layout of tightening sequence for oil sump fastening screws
200226 Figure 215
Tightening torque
Oil sump fastening screws 1. Tightening sequence: 1 - 26
38 N⋅m to45 N⋅m
38 N⋅m to45 N⋅m
Diagram of tightening sequence for screws securing oil pump
Tightening torque
Screws fixing the oil pump Tightening sequence: 1 - 8
22 N⋅m to27 N⋅m
225754 Figure 216

682 ‒ Engine
154 F2C ENGINE
TIGHTENING TORQUES
Diagram of tightening sequence for oil filter fastening screws
Tightening torque
Oil filter fastening screws Tightening sequence: 1 - 4
22 N⋅m to27 N⋅m
225757 Figure 217
Diagram of tightening sequence for rocker arm cover fastening screws
200224 Figure 218

Position the cover and insert all the screws
Tighten until contact is made following the sequence: 1 - 20
Tightening torque
Tappet cover fastening screws 8.5 ±1.5 N⋅m

682 ‒ Engine
F2C ENGINE 155
TIGHTENING TORQUES
Diagram of tightening sequence for screws securing shoulder plate to cylinder head
151833 Figure 219
Tightening torque
Screws fixing shoulder plate to head Tightening sequence: 1 - 10
23.5 ±3.5 N⋅m
Diagram of tightening sequence for intake manifold fastening screws
200221 Figure 220
Tightening torque
Intake manifold fastening screws (M10) 1. Tightening sequence: 1 - 2 - 3 - 4 - 5 - 6
41 N⋅m to50 N⋅m
2. Tightening sequence: 1 - 5 - 3 - 4 - 6 - 2
41 N⋅m to50 N⋅m

682 ‒ Engine
156 F2C ENGINE
TIGHTENING TORQUES
Diagram of tightening sequence for thermostat fastening screws
151832 Figure 221
Tightening torque
Thermostat case fastening screws Tightening sequence: 1 - 10
21 N⋅m to27 N⋅m
Diagram of tightening sequence for water pump fastening screws
Tightening torque
Screws securing water pump Tightening sequence: 1 - 4
21 N⋅m to27 N⋅m
225768 Figure 222

682 ‒ Engine
F2C ENGINE 157
TIGHTENING TORQUES
Diagram of tightening sequence for screws securing the auxiliary device control assembly
225769 Figure 223
Tightening torque
Screws securing crankshaft pulley 50 N⋅m
Screws securing fixed tensioner to crankcase 40 N⋅m to50 N⋅m
Screws securing automatic tensioner to crankcase 95 N⋅m to105 N⋅m
Diagram of tightening sequence for air conditioning compressor fastening screws
136523 Figure 224
Tightening torque
Screws securing air conditioner compressor Tightening sequence: 1 - 5
21 N⋅m to27 N⋅m

682 ‒ Engine
158 F2C ENGINE
TIGHTENING TORQUES
Tightening torque
Screws securing air conditioner compressor support 44 N⋅m to48 N⋅m
Layout of tightening sequence for alternator fastening screws
Tightening torque
Alternator fastening screws 1. Screws M10
Tightening sequence: 1 - 2 - 3
40 N⋅m to46 N⋅m
2. Screws M8
21 N⋅m to27 N⋅m
3. M10 screw
40 N⋅m to46 N⋅m
4. M8 screw
Tightening sequence: 7 225755 Figure 225
21 N⋅m to27 N⋅m
Diagram of tightening sequence for P.T.O. fastening screws
136519 Figure 226
Tightening torque
PTO fastening screws Tightening sequence: 1 - 16
44 ±4 N⋅m

682 ‒ Engine
F2C ENGINE 159
EQUIPMENT F2C Euro III
Diagram of tightening sequence for phonic wheel fastening screws
169808 Figure 227
Tightening torque
Screws securing phonic wheel 1. Pre-tightening
10 N⋅m
2. Tightening
28.5 ±3.5 N⋅m

Rotary telescopic stand(range 2000 daN, torque 375 daNm) (99322230)

682 ‒ Engine
160 F2C ENGINE
Extraction tool for injectors (99342157)
Key to fit crankshaft rear gasket (99346260)
Key to fit crankshaft front gasket (99346265)
Pliers for removing/refitting piston rings (105 -160 mm) (99360184)
Guide for fitting rubber belt (99360192)

682 ‒ Engine
F2C ENGINE 161
Plate for take downfit engine valves (to be used with 99360257) (99360256)
Tool for engine valve removal and refitting (to be used with 99360256) (99360257)
Punch for valve guide removal (99360288)
Adjuster for gasket assembly on valve guide (99360292)
Tool for valve guide refitting(to be used with 99360288) (99360294)

682 ‒ Engine
162 F2C ENGINE
Cylinder liner protrusion gauge (to be used with 99370415-99395603 and special plates)
(99360334)
Cylinder liner compression cap (to be used with 99360334) (99360335)
Tool for rotating the flywheel (99360341)
Tool for retaining the flywheel (99360351)
Crankshaft lifting tool (99360500)

682 ‒ Engine
F2C ENGINE 163
Drift to take down and fit back camshaft bushes (99360505)
Bracket for removing and refitting engine flywheel (99360551)
Tool for rocker arm shaft assembly and fitting (99360558)
Arm for engine removal and refitting (99360585)
Clamp for fitting piston into cylinder liner (90 - 175 mm) (99360603)

682 ‒ Engine
164 F2C ENGINE
Tool for engine T.D.C. positioning (99360612)
Tool for timing of phonic wheel on timing gear (99360613)
Tool for cylinder liner fastening (99360703)
Tool to extract cylinder liners (use with special rings) (99360706)

682 ‒ Engine
F2C ENGINE 165
Ring (115 mm) (to be used with 99360706) (99360724)
Brackets for fastening engine to 99322230 rotary stand (99361046)
Set of 8 ignition keys 14X18 (13-17-18-19-21-22-24-27-30mm) (99368542)
Tool to check timing (use with 99395606) (99370400)
Dial gauge base to adjust lay shaft bearings (use with 99395603) (99370415)

682 ‒ Engine
166 F2C ENGINE
14X18 coupling torque wrench (20-120 Nm) (99389833)
Torque screwdriver (1-6 Nm) for adjusting the locking nut of the injector solenoid valve
connectors (99389834)
Sleeker for valve guide (99390310)
Set of gauges for angle tightening with square connection - 1/2" and 3/4" (99395216)

682 ‒ Engine
F2C ENGINE 167
Gauge to determine centre distance between camshaft and high pressure pump
(99395221)
Gauge for defining the distance between the centres of camshaft and timing gear
(99395222)
Gauge for camshaft timing (99395223)
Dial gauge (0-5 mm) (99395603)

682 ‒ Engine
168 F2C ENGINE
EQUIPMENT F2C Euro 4
Dial gauge (0-30 mm) (99395606)


682 ‒ Engine
F2C ENGINE 169
Plate for take downfit engine valves (to be used with 99360257) (99360256)
Tool for engine valve removal and refitting (to be used with 99360256) (99360257)

682 ‒ Engine
170 F2C ENGINE
Tool for valve guide refitting(to be used with 99360288) (99360294)
(99360334)
Cylinder liner compression cap (to be used with 99360334) (99360335)

682 ‒ Engine
F2C ENGINE 171

682 ‒ Engine
172 F2C ENGINE

682 ‒ Engine
F2C ENGINE 173
Tool for timing of phonic wheel on timing gear (99360613)

682 ‒ Engine
174 F2C ENGINE
Set of 8 ignition keys 14X18 (13-17-18-19-21-22-24-27-30mm) (99368542)

682 ‒ Engine
F2C ENGINE 175
(99395221)
(99395222)

682 ‒ Engine
176 F2C ENGINE
ENGINE REMOVAL - REFITTING
Gauge for camshaft timing (99395223)
Dial gauge (0-5 mm) (99395603)
Dial gauge (0-30 mm) (99395606)
.540110. ENGINE REMOVAL - REFITTING
Work material
Equipment for recovering and refilling R134A refrigerant 99305146
in air-conditioners
Arm for engine removal and refitting 99360585
Tightening torques
Engine support screws tightening torques 167 ±17 N⋅m

682 ‒ Engine
F2C ENGINE 177
Main action
.540110. Removing the bottom portion of the engine
10
3 4
7 5
6 2
171961 Figure 228

1. Drain the coolant in a proper container, by removing the plug (8) from under the radiator.
2. Bleed the coolant gas R134 A from the climate control system using the specific tool connected to the coupling (9) on the
evaporator pipes (10).
Equipment for recovering and refilling R134A refrigerant in air-conditioners 99305146
3. Remove the piping (2) between the radiator and the water pump acting on the metal fasteners (1).
4. Drain power steering oil in a proper container, by disconnecting delivery and oil return pipes (7). opening the power steering
oil reservoir plug and removing it from inside the oil filter casing.
5. Remove the fasteners from the cable bundle that route from the chassis to the starter motor (6) and disconnect the elec-
trical connection (3) of the starter motor (6).
6. Disconnect the ground cable (5) and release the collar (4) that clamps the electric cables to the crankcase in order to free
the cable bundle.

682 ‒ Engine
178 F2C ENGINE
.540110. Removing the top portion of the engine
4
6
7
5
171962 Figure 229

7. Disconnect the metal fastener (5) of the exhaust side exhaust piping (4).
8. Disconnect the metal fastener (5) of the turbine side exhaust piping (4).
9. Disconnect the air supply pipe (1) to the engine brake.
10. Undo the two fixing screws (3) that secure the complete engine brake assembly to the bracket (2) on the chassis end re-
move the pneumatic piping of the engine brake by acting on the retainer (1).
11. Disconnect the compressor air supply pipe (7) by acting on the retainer (6).

682 ‒ Engine
F2C ENGINE 179
6
7
171963 Figure 230

12. Disconnect the pipe (7) exiting the water pump (6).
13. Disconnect the air supply intercooler sleeve (3) by acting on the metal retainers.
14. Disconnect the R134 A coolant gas supply and return pipes (1) to the A/C by acting on the retainers (2).
15. Disconnect the air pipe (4) from the intercooler inlet (5).

682 ‒ Engine
180 F2C ENGINE
12
11
10 9 8 7 6
171964 Figure 231

16. Disconnect the radiator breather pipe (1) from the engine side.
17. Disconnect the water delivery sleeve (2) from the thermostat body to the radiator, acting on the metal clips.
18. Remove the oil dipstick retainer bracket (4) to the radiator acting on the retainer (5).
19. Remove the fasteners and disconnect the positive cable (10) of the alternator (8) and its connector (9).
20. Disconnect the electric connection (7) of the A/C compressor (6).
21. Disconnect the electric connection (12) of the power steering oil level.

682 ‒ Engine
F2C ENGINE 181
11 1
2
10
12
8
3
7
6 5
171965 Figure 232

22. Disconnect the ignition connectors (4) on the engine..
23. Disconnect the fuel pipe (5) that runs from the coupling on the crankcase of the HP pump.
24. Disconnect the fuel pipe (12) that runs to the engine control unit (2).
25. Disconnect the air intake pipe (8) that runs from the air filter to the engine by acting on the fasteners (3-6).
26. Disconnect the connection (1) that runs from the chassis to the engine control unit (2).

682 ‒ Engine
182 F2C ENGINE
11 1
2
10
12
8
3
7
6 5
171965 Figure 232

27. Release the bracket (11) that fastens the cab tipping pipes from the central cab support bracket (9).
28. Undo the screws (10-7) from the cab support central bracket (9) and remove it.

682 ‒ Engine
F2C ENGINE 183
10
6 2
5
171966 Figure 233

29. Undo the eight fixing screws (1-3-6) of the engine supports to chassis from the support brackets (4-2-5).
30. Hook the specific tool (10) to the specific eyelets on the engine and lift the engine from the vehicle.
Arm for engine removal and refitting 99360585
.540110. Refitting the top portion of the engine

31. Lower the engine into the chassis.
32. Screw in the eight engine support fixing screws to the chassis at the specified tightening torque.
Tightening torque
Engine support screws tightening torques 167 ±17 N⋅m
33. Refit the cab support central bracket and screw in the fixing screws.
34. Use the bracket to refit and secure the cab tipping pipe to the central cab support bracket.
35. Reconnect the fuel supply pipe to the engine control unit.
36. Reconnect the cable/connection that runs from the chassis to the control unit/engine.
37. Reconnect the air intake pipe that runs from the air filter to the engine by acting on the fasteners.
38. Reconnect the fuel pipe that runs from the coupling on the crankcase of the HP pump.
39. Reconnect the ignition connectors on the engine.

682 ‒ Engine
184 F2C ENGINE
ENGINE DISASSEMBLING
40. Reconnect the electric connection of the power steering oil level.
41. Reconnect the electric connection of the A/C compressor.
42. Reconnect and fit the fasteners to the positive cable of the alternator and its connector.
43. Reconnect the air pipe from the intercooler inlet.
44. Reconnect the oil dipstick to the radiator by acting on the fastener.
45. Reconnect the water delivery sleeve from the thermostat body to the radiator by tightening the metal clips.
46. Reconnect the radiator breather pipe from the engine side.
47. Reconnect the R134 A gas supply and return pipes to the A/C by acting on the retainers.
48. Reconnect the intercooler air delivery sleeve.
49. Reconnect the pipe exiting the water pump.
50. Refit the air delivery pipe to the compressor by acting on the retainers.
51. Screw in the two fixing screws of the engine brake complete assembly to the chassis mounted bracket.
52. Reconnect the air supply pipe to the engine brake.
53. Reconnect the metal fastener of the turbine side exhaust piping.
54. Reconnect the metal fastener of the exhaust side exhaust piping.
.540110. Refitting the bottom portion of the engine

55. Fit fasteners to the cable bundle that runs from the chassis to the starter motor.
56. Reconnect the electric connection and the ground cable to the starter motor.
57. Fasten the electric cable retainer collar to the crankcase.
58. Reconnect the power steering oil delivery and return pipes.
59. Reconnect the piping between the radiator and the water pump acting on the metal fasteners.
60. Fit the radiator plug.
61. Fit the plug of the power steering oil reservoir with its filter inside.
62. Fit the plugs to the climate control system evaporator pipes.
63. Top-up power steering oil level, coolant and R134 gas for the climate control system.
.540110. ENGINE DISASSEMBLING
Work material
Rotary telescopic stand(range 2000 daN, torque 375 99322230
daNm)
Extraction tool for injectors 99342101
Crankshaft lifting tool 99360500
Brackets for fastening engine to 99322230 rotary stand 99361046
Note Before mounting the engine on the specified rotating stand, remove the following parts that may interfere with mounting
the dedicated brackets.
Main action
1. Refit the heat exchanger and oil pipe as follows.
Rotary telescopic stand(range 2000 daN, torque 375 daNm) 99322230

682 ‒ Engine
F2C ENGINE 185
.543110. Heat exchanger removal

2. Place a container to collect coolant under the heat exchanger
(2).
3. Unscrew the fixing screws and remove the heat exchanger
assembly (2).
4. Remove the oil outlet pipe (1).
5. Mount the engine on the specific rotary stand.
code
daNm)
6. Discharge the oil from the sump into a container.
125700 Figure 234

682 ‒ Engine
186 F2C ENGINE
.540110. Removal of electrical components
172610 Figure 235

Installation of electrical components
A Fuel temperature sensor H Temperature/air pressure sensor
B Camshaft timing sensor I A/C compressor
C EDC control unit 7 L Water temperature sensor
D Fuel regulation valve on high-pressure pump M Connector on the engine head for connection with
E Starting motor electro-injectors
F Oil pressure/temperature transmitter N Engine speed sensor on flywheel
G Alternator
7. Disconnect the electric parts.

682 ‒ Engine
F2C ENGINE 187
.760810. Replacement of starter motor

8. Before placing the engine on the rotating stand, remove the
starter motor (1).
code
daNm)
172609 Figure 236
9. Unscrew the screws(2) and remove the head cover (1) to

access the rail and injector wiring.
114016 Figure 237
.543910. Removal of air conditioner compressor drive belt

10. Remove the fan.
11. Cut the air conditioner compressor belt (1), as it must not be
used again.
12. Using a suitable tool (4) work in the direction of the arrow, and
remove the belt (5) driving the water pump and alternator.
13. Unscrew the screws and remove the pulley (2) with the
damper flywheel (3).
125701 Figure 238

682 ‒ Engine
188 F2C ENGINE
.760310. Alternator removal

14. Remove the water pump (2) and the pulley (3), working with
the screws (1).
125702 Figure 239
15. Remove the alternator (6).

16. Remove the belt tensioner (5).
17. Remove the air-conditioner compressor (1).
18. Remove flanged pipe (3).
19. Remove the fixed belt tensioner (4).
20. Remove thermostat assembly (2).
125703 Figure 240
21. Apply a suitable puller (2) and remove the sealing gasket (1).
22. Unscrew the screws and remove the front cover(3).
114551 Figure 241
.543210. Water pump removal

23. To remove the water pump, see the operation 760310 Replacement of alternator on the vehicle ( ➠ Page 67).

682 ‒ Engine
F2C ENGINE 189
.543251. Thermostat case removal

24. To remove the thermostat casing, see the operation 760310 Alternator removal ( ➠ Page 188).
.543070. Oil filter removal

25. Remove the oil filter (1).
26. Remove the oil inlet pipe (5).
27. Remove the oil outlet pipe (2).
28. Remove the turbocharger (4) from the exhaust manifold (3).
29. Remove the starter motor from the other side of the engine.
3
5 1
171976 Figure 242
.542410. Turbocharger removal

30. To remove the turbocharger, see the operation 543070 Oil filter removal ( ➠ Page 189).
.540720. Exhaust manifold removal

31. To remove the exhaust manifold, see the operation 543070 Oil filter removal ( ➠ Page 189).
.540710. Intake manifold removal

32. Remove the fuel filter (1).
33. Remove the oil level dipstick(2).
34. Remove the intake manifold (3).
125704 Figure 243
.542011. Fuel filter removal

35. To remove the fuel filter, see the operation 540710 Intake manifold removal ( ➠ Page 189).

682 ‒ Engine
190 F2C ENGINE
.766161. ECU removal

36. Disconnect the piping (2) from the support to the HP pump
and remove the control unit (1) along with the support below.
125705 Figure 244
.540452. Blow-by case removal

37. Unscrew the screws (1) and remove the blow-by box (2).
114015 Figure 245
.540486. Blow-by filter removal

39. Remove the centrifugal filter (3) below, IF ANY.
114018 Figure 246

682 ‒ Engine
F2C ENGINE 191
40. Use the appropriate wrench to loosen the screws (2) and re-
move the gear (3) with the pulser ring.
41. Unscrew the nut (4) remove the control gear (5) of the high
pressure pump.
42. Remove the rpm sensor (1).
Note If it is difficult to remove the gear (5), loosen the
screws of the high pressure pump, and using a drift on
the control shaft, remove the gear (5).
114019 Figure 247
.771010. High-pressure pump removal

43. Disconnect the fuel pipe (2), unscrew the retaining screws and
remove the high pressure pump (1).
44. Remove the fuel filter support (3) and pipes.
114014 Figure 248
45. Unscrew the screws (1) and remove the thrust plate (2).
46. Use the appropriate wrench to loosen the screws (4) and re-
move the idle gear (5).
47. Remove the HP pump connection flange (3).
114020 Figure 249

682 ‒ Engine
192 F2C ENGINE
.540850. Engine flywheel removal

48. Block rotation of the engine flywheel (2) using the specific tool,
unscrew the retaining screws (1) and remove the engine fly-
wheel.
114009 Figure 250
49. Apply a suitable puller (2) and remove the sealing gasket (1).
45257 Figure 251
.540460. Oil sump removal

125706 Figure 252

682 ‒ Engine
F2C ENGINE 193
.543060. Suction strainer removal

51. Slacken the screws (1) and remove the suction strainer (2).
129709 Figure 253
.540463. Flywheel case removal

52. Unscrew the screws (1) and remove the flywheel case (2).
114022 Figure 254
.543010. Disassembling the oil pump

53. Remove the screws (2) and disassemble the double gear (3).
54. Unscrew the retaining screw (5) and remove the articulated
rod (4).
55. Remove the oil pump (1).
114023 Figure 255

682 ‒ Engine
194 F2C ENGINE
.541230. Rocker arm shaft removal

56. Disconnect fuel delivery pipes (3).
58. Loosen the fixing screws (1) of rocker arm shaft.
114024 Figure 256
59. Apply the specific tool (1) to the rocker arm shaft and remove
the shaft, remove the cross-pieces (3), from the cylinder head.
114025 Figure 257
.774510. Rail removal

60. Take out the fastening brackets(3).
172927 Figure 258
Conditions
● In the case of Euro III engines

682 ‒ Engine
F2C ENGINE 195
▶ Position the specific tool (1) and hooks on the injector.

code
169826 Figure 259
Conditions
● In the case of Euro 4 engines
▶ Position the specific tool (1) and hooks on the injector.

code
221507 Figure 260
.775011. Injector removal

62. To remove the injectors follow the operation 774510 Rail removal ( ➠ Page 194).
.541210. Camshaft of distribution removal

63. Remove the camshaft and the fixing screws on cylinder heads.
64. By means of wire ropes, lift the cylinder head (1) and remove
the seal gasket (2).
45266 Figure 261

682 ‒ Engine
196 F2C ENGINE
.540610. Cylinder head removal

65. To remove the cylinder head follow operation 541210 Camshaft of distribution removal ( ➠ Page 195).
.540840. Piston connecting rod dismantling

66. Turn the crankcase (1) into vertical position.
115881 Figure 262
67. Unscrew the screws (2) fixing the connecting rod cap (3) and
remove it.
68. From above, remove the connecting rod-piston assembly (1).
115882 Figure 263
Caution!
▶ Keep the big end bearing shells in their respective housings and/or note down their assembly position since, if re-
using them, they will need to be fitted in the position found upon removal.

682 ‒ Engine
F2C ENGINE 197
70. Using the appropriate wrench and socket threaded wrench,

unscrew the screws (1-3) and remove the stiffening plate (2)
and the main bearing caps (4).
Note Note down the assembly position of the top and bot-
tom main bearing shells since, if reusing them, they will
need to be fitted in the position found upon removal.
114615 Figure 264
.540810. Crankshaft removal

71. Using the specified tool (1), remove the crankshaft (2).
code
114035 Figure 265
.540416. Main bearings removal

Caution!
▶ Once the engine disassembly is complete, clean accurately the removed parts and check their integrity.
▶ Instructions for main checks and measurements in order to determine whether the parts can be reused can be
found in the following pages.
72. Remove the main half-bearings (1), loosen the screws and re-
move the oil nozzles (2).
73. Remove the cylinder sleeves as described in the related para-
graph.
47571 Figure 266

682 ‒ Engine
198 F2C ENGINE
CYLINDER UNIT REPAIR OPERATIONS
.540414. Oil sprayer removal

74. To remove the oil nozzles follow operation 540416 Main bearings removal ( ➠ Page 197).
.5406. CYLINDER UNIT REPAIR OPERATIONS
Work material
Dial gauge base to adjust lay shaft bearings (use with 99370415
99395603)
Dial gauge (0-5 mm) 99395603
Micrometer
Tightening torques
Selection class 1. A 117.000 mm to117.012 mm
2. B 117.010 mm to117.022 mm
Cylinder liners protrusion 170 N⋅m
Main action
.540410. CRANKCASE CHECKS
1. In order to check the inner diameter of cylinder liners and
identify the degree of ovalisation, taper and wear, use gauge
(2) fitted with a centesimal dial gauge (1), previously reset on
the 117 mm ring gauge (3).
Note If the 117 mm ring gauge is not available, use a micro-
meter.
34994 Figure 267

682 ‒ Engine
F2C ENGINE 199
2. Measurements should be carried out for every single cylinder

liner at three different heights and on two (A-B) perpendicular
plane levels as illustrated in Figure.
192194 Figure 268

1 1 measurement
st
3 3rd measurement
2 2nd measurement
3. When wear is over 0.150 mm or maximum ovalisation is 0.100

mm compared to the values shown in the figure, replace the
cylinder barrel since it is not possible to grind, lap or dress it.
Note Cylinder liners are equipped with spare parts belonging
to selection class A.
225036 Figure 269

A Selection class Ø 117 X Selection class marking
to 117.012 mm area
B Selection class Ø
117.010 to 117.022
mm

682 ‒ Engine
200 F2C ENGINE
4. The illustrated diagram refers to the cylinder liner outer diamet-

ers and their housing inner diameters.
114037 Figure 270

A Ø 130.500 to 130.525 D Ø 130.461 to 130.486
mm mm
B Ø 129.510 to 129.535 D Ø 129.475 to 129.500
mm mm
114038 Figure 271

5. Cylinder liners can be removed and fitted several times into different housings, if needed.

682 ‒ Engine
F2C ENGINE 201
114039 Figure 272

6. Make sure that the main data of the cylinder liners are the same as those in the figure.
Tightening torque
Selection class 1. A
117.000 mm to117.012 mm
2. B
117.010 mm to117.022 mm

682 ‒ Engine
202 F2C ENGINE
7. Check the selection class marking area.
114040 Figure 273

A Selection class marking
area
.540420. Cylinder liners Removal

8. Position the specified parts (1 - 2) and the specific plate (4)
as shown in the figure, checking that the plate (4) rests on the
cylinder liner correctly.
code
from the crankcase.
47577 Figure 274

682 ‒ Engine
F2C ENGINE 203
.540420. Cylinder liner fitting and protrusion check

10. Always replace water sealing rings (3-4-5).
11. Install the adjustment ring (1) on the cylinder liner (2); lubricate
the lower part of the liner and install it in the cylinder unit using
the proper tool.
0.12 mm - 0.14 mm.
16798 Figure 275
12. Check cylinder liner protrusion using the specific tool (1-2-3-4)
and tightening the screw (1) to the specified torque.
Tightening torque
Cylinder liners protrusion 170 N⋅m

code
13. With specific dial gauge (5) on specific base (6).

Dial gauge (0-5 mm) 99395603
99395603)
14. Measure the cylinder liner protrusion from the cylinder head
supporting surface, which must be 0.035 to 0.065 mm; Oth-
erwise replace the adjustment ring, supplied as a spare part in
various thicknesses.
114041 Figure 277

682 ‒ Engine
204 F2C ENGINE
15. On completing assembly, lock the cylinder liners (1) on the )

crankcase (2) with the specified stud bolts (3).
code
35012 Figure 278
.540810. Crankshaft measurements
221518 Figure 279

16. Check the condition of the crankshaft main journals; there must no be signs of scoring, ovalisation or excessive wear.
Note The values shown refer to pin regular diameter.

682 ‒ Engine
F2C ENGINE 205
.540811. Measuring main journals

17. Before grinding the crank pins using a micrometer (1), measure
the main journals and the crank pins (2) and decide, on the
basis of the undersizing of the bearings, the final diameter to
which the pins are to be ground.
Tool / Material
Micrometer
Note It is advisable to enter readings in a table.
47535 Figure 280
18. During the grinding operation, pay attention to the values of the
main journal couplings shown in the details X.
Note All the main journals and crankpins must also be ground
to the same undersizing class, in order to avoid any
alteration to shaft balance.
114043 Figure 281

X Journal fillet detail
.540812. Measuring crankpins

Tool / Material
Micrometer
47536 Figure 282

682 ‒ Engine
206 F2C ENGINE
crankpins shown in Y.
114044 Figure 283

Y Crankpin fillet detail
36061 Figure 284

21. Write down the measurements of the main journals and crankpins of the crankshaft in the table.

682 ‒ Engine
F2C ENGINE 207
.540816. Defining the diameter class of the seats for half bearings on the crankcase
114046 Figure 285

22. To identify the diameter class of the seats for the main half-bearings, look at the main bearing caps in the position shown in
the figure.
DEFINING THE DIAMETER CLASS OF THE SEATS FOR HALF BEARINGS ON THE CRANKCASE
CLASS RATED DIAMETER OF MAIN BEARINGS
1 99.000 - 99.009
2 99.010 - 99.019
3 99.020 - 99.030
23. Read off the 2 sets of figures.

Note The first set of digits (four) is the coupling number of the crankcase with the respective caps.
The following seven digits, considered individually, indicate the diameter class of each related main journal seat.
Each of these digits may be 1, 2 or 3.

682 ‒ Engine
208 F2C ENGINE
.540816. Definition of the diameter class of the main journals (nominal diameter)
190216 Figure 286

24. Before selecting the journal bearings, define the diameter class of each main journal.
Definition of the diameter class of the main journals (nominal diameter)
CLASS RATED DIAMETER OF MAIN JOURNAL
1 92.970 - 92.979
2 92.980 – 92.989
3 92.990 – 93.000
25. In order to identify the diameter class of the main journals, identify the three sets of figures marked on the front of the crank-
shaft.
Note The first number, of five digits, is the part number of the shaft.
The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows
the status of the pins (1 = STD, 2 = - 0.127), the other seven digits, taken singly, give the diameter class of each of the
main journals they refer to.

682 ‒ Engine
F2C ENGINE 209
.540816. Selecting the main bearing shells
190220 Figure 287

26. Identify the most suitable half-bearings for each of the journals (the half-bearings, if necessary, can have different classes from
one journal to another).
Thickness of the main bearing shells
STD +0.127
Red 2.968 - 2.978 –

Red/Black – 3.031 to 3.041
Green 2.978 - 2.988 –
Green/Black – 3.041 - 3.051
Yellow* 2.988 - 2.998 –
Yellow/Black* – 3.051 - 3.061
* Fitted in production only and not supplied as spares
Note Depending on the thickness, the half-bearings are selected in classes of tolerance marked by a coloured sign (Red,
Green, Yellow...).
The table contains the characteristics of the main bearings available as spare parts in standard measurement (STD)
and greater (+0.127).
.540816. Main half-bearings selection (nominal diameter pins)

27. After reading off the main data, for each of the main journals, on the crankcase and crankshaft, choose the type of
half-bearings to use according to the following table.

682 ‒ Engine
210 F2C ENGINE
Main half-bearings selection (nominal diameter)
STD CLASS 1 2 3
Green Green Yellow
Green Yellow Yellow
Red Green Green
Green Green Yellow
Red Red Green
Red Green Green
.540816. Main half-bearings selection (rectified)

Conditions
● Ground main journals
▶ If the journals have been rectified, the procedure described cannot be applied. In this case, ascertain that the new dia-
meter of the journals is as shown in the table and fit the only type of half-bearings suitable for the undersizing.

682 ‒ Engine
F2C ENGINE 211
Selecting the main half-bearings (-0.127)
red/black = 3.031 ÷ 3.041 mm

green/black = 3.041 ÷ 3.051 mm
yellow/black = 3.051 ÷ 3.061 mm
- 0.127 CLASS 1 2 3
Green/Black Green/Black Yellow/Black

92.843
1
92.853
Green/Black Yellow/Black Yellow/Black
Red/Black Green/Black Green/Black

92.853
2
92.863
Red/Black Red/Black Green/Black

92.863
3
92.872

682 ‒ Engine
212 F2C ENGINE

682 ‒ Engine
F2C ENGINE 213
.540831. Definition of the connecting rod diameter class
187914 Figure 288

1. Per Euro III Coloured mark to identify weight
A (yellow) = 3331 g - 3361 g
B (green) = 3362 g - 3391 g
C (blue) = 3392 g - 3421 g
1. Per Euro 4 Coloured mark to identify weight
A (Yellow) = 3450 g - 3470 g
B (Green) = 3471 g - 3490 g
C (Blue) = 3491 g - 3510 g
2 Positioning socket visible from the front end of the engine
3 Coloured mark to identify diameter class
Yellow = 85.987 - 85.996 mm
Green = 85.997 - 86.005 mm
Blue = 86.006 - 86.013 mm
4 Progressive number for connecting rod identification
28. Select the connecting-rod half bearings by referring to the coloured markings on the connecting-rod body, in the indicated
position.

682 ‒ Engine
214 F2C ENGINE
187914 Figure 288
Note The colour indicating the diameter class of the seat for half bearings can be: Yellow, Green or Blue.

682 ‒ Engine
F2C ENGINE 215
.540831. Definition of the diameter class of the crankpins (nominal diameter)
190211 Figure 289

29. The diameter class of each connecting rod bearing must be selected before identifying the diameter of each crankpin.
Definition of the diameter class of the crankpins (nominal diameter)
CLASS CRANKPIN NOMINAL DIAMETER
1 81.915 - 81.924
2 81.925 - 81.934
3 81.935 - 81.945
30. In order to identify the diameter class of the crankpins, identify the three sets of figures marked on the front of the crankshaft.
Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the
status of the journals (1 = STD, 2 = - 0.127), the other six digits, taken individually, give the diameter class of each of
the crankpins they refer to (at top).

682 ‒ Engine
216 F2C ENGINE
.540831. Selecting the big end half bearings
190219 Figure 290

31. Identify the most suitable half-bearings for each of the journals (the half-bearings, if necessary, can have different classes from
Big end half-bearing thickness
STD +0.127
Red 1.994 - 2.002 –

Red/Black – 2.057 - 2.065
Green 2.002 - 2.010 –
Green/Black – 2.065 - 2.073
Yellow* 2.010 - 2.018 –
Yellow/Black* – 2.073 - 2.081
* Fitted in production only and not supplied as spares
Note Depending on thickness, the half-bearings are selected in tolerance classes marked by a coloured sign (red/black -
green/black - yellow/black).
The table gives the specifications of the connecting-rod bearings available as spare parts in the standard sizes (STD)
and in the permissible oversizes (+0.127, +0.254, +0.508).
.540831. Main half-bearings selection (nominal diameter crankpins)

32. Determine the type of connecting rod half-bearing to fit on each pin by following the indications in the table.

682 ‒ Engine
F2C ENGINE 217
Main half-bearings selection (nominal diameter crankpins)
1 2 3
STD CLASS
Yellow Green Blue
Green Green Yellow
Green Yellow Yellow
Red Green Green
Green Green Yellow
Red Red Green
Red Green Green
.540831. Connecting rod half-bearings selection (rectified crankpins)

Conditions
● Reground crankpins
▶ Make sure that the new journal diameter is the one indicated in the table and identify the matching half-bearings.

682 ‒ Engine
218 F2C ENGINE
Selecting the connecting rod half-bearings (-0.127)
red/black = 2.057 to 2.065 mm

green/black = 2.065 to 2.073
mm
yellow/black = 2.073 to 2.081
mm
- 0.127 CLASS 1 2 3

81.789
1
81.799
Green/Black Yellow/Black Yellow/Black

81.799
2
81.809

81.809
3
81.819
.540815. Replacing the timing and oil pump gear control

33. Check that the teeth of the gears are not damaged or worn,
otherwise remove them using the appropriate extractor.
Note Before mounting the gear, spread a 5 mm layer of
Loctite 603 onto the crankshaft, 30 mm from the seal.
34. When mounting the gear (1) on the crankshaft (2), heat it to a
temperature that does not exceed 180° C.
35. Let it cool down after pressing.
36. If changing the pin , after fitting it on, check it protrudes from
the crankshaft as shown in the figure.
115883 Figure 291
.540817. Checking crankshaft thrust clearance

37. Thrust clearance is checked by placing a magnetic stand dial
gauge (1) on the crankshaft (2), as shown in the figure; If a
higher clearance than required is found, replace the rear main
half-bearings carrying the thrust bearings and repeat the clear-
ance check.
47588 Figure 292

682 ‒ Engine
F2C ENGINE 219
OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY
.5408. OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY
Work material
- 1/2" and 3/4"
Tightening torques
Connecting rod cap screw tightening torque 50 ±2.5 N⋅m
Main action
47580 Figure 293

1 Connecting rod body 6 Slotted oil scraper ring with spiral spring
2 Half-bearings 7 Claw seal ring
3 Connecting rod cap 8 Trapezoidal seal ring
4 Cap retaining screws 9 Pin piston
5 Circlip 10 Piston
1. Make sure the pistons do not show any trace of seizing, scoring, cracking or excessive wear; Otherwise, replace them.

682 ‒ Engine
220 F2C ENGINE
.540842. Piston rings removal

2. Remove the piston rings from the piston (2) using specific pliers
(1).
code
Note Pistons are equipped with three piston rings: a sealing

ring, with trapezoidal section; a sealing ring with cham-
fer cut; a scraper ring.
Pistons are grouped into classes A and B for diameter.
126311 Figure 294
.540840. Measuring the piston diameter

3. Remove the retaining piston rings (2) using round tipped pliers
(1).
126312 Figure 295
4. Remove the piston pin (1). If removal is difficult use the appro-
priate drift.
49026 Figure 296

682 ‒ Engine
F2C ENGINE 221
.540841. Measuring the piston pin diameter

5. Pin diameter (1) measuring with a micrometer (2).
32618 Figure 297
6. For correct pin-piston coupling lubricate the pin (1) and the
relevant housing on the piston hubs with engine oil; Pin must be
inserted in the piston with a light finger pressure and it should
not come out by gravity.
49026 Figure 298
Conditions
114053 Figure 299

X 0.6 ± 0.15 (The dimension is measured on ⌀ of 113
mm)
▶ Make sure that the main data of the piston, circlips and pin in the figure correspond.

682 ‒ Engine
222 F2C ENGINE
Conditions
221519 Figure 300

X 0.6 ± 0.15 (The dimension is measured on ⌀ of 113
mm)
▶ Make sure that the main data of the piston, circlips and pin in the figure correspond.
.540842. Measuring seal rings

7. Check the thickness of the piston ring (2) using a micrometer
(1).
192195 Figure 301

682 ‒ Engine
F2C ENGINE 223
8. Check the clearance between the sealing rings (2) and the re-
lated housings on the piston (1) using a feeler gauge (3).
16552 Figure 302
9. The sealing ring (2) of the 1st seat is trapezoidal. Clearance "
X" between the sealing ring and its seat is measured by placing
the piston (1) with its ring in the cylinder liner (3), so that the
sealing ring comes half way out of the cylinder liner.
3513 Figure 303
10. Using a feeler gauge (2), check the end gap of the sealing rings
(1) entered in the cylinder liner (3).
11. If the distance between ends is lower or higher than the value
required, replace split rings.
36134 Figure 304

682 ‒ Engine
224 F2C ENGINE
.540830. Connecting rod checks

Caution!
▶ When installing connecting rods, make sure they all belong to the same weight class and supplier.
▶ The connecting rod/cap is "torn"; before assembly, check that the connecting rod is not ruined
▶ Each connecting rod may only be mounted with its cap.
▶ If the cap is mounted backwards, the connecting rod must be discarded.
221520 Figure 305

12. Make sure that a missing area less than 5 mm2 is allowed along the external fracture line.
13. Make sure that there are no cracks in the threaded area.

682 ‒ Engine
F2C ENGINE 225
200115 Figure 306

1 Coloured mark to identify weight 3 Progressive number for connecting rod identification
2 Coloured mark to identify diameter class
14. Make sure that the connecting rods weight the same.
Conditions
▶ Make sure that the connecting rods weight the same.

Weights of Euro III connecting rods
WEIGHT DIAMETER
⌀ 85.987-85.996 Yellow
CLASS A Yellow 3450 g - 3470 g ⌀ 85.997-86.005 Green
⌀ 86.006-86.013 Blue
⌀ 85.987-85.996 Yellow
CLASS B Green 3471 g - 3490 g
⌀ 85.997-86.005 Green

682 ‒ Engine
226 F2C ENGINE
WEIGHT DIAMETER
CLASS B Green 3471 g - 3490 g ⌀ 86.006-86.013 Blue
⌀ 85.987-85.996 Yellow
CLASS C Blue 3491 g - 3510 g ⌀ 85.997-86.005 Green
⌀ 86.006-86.013 Blue
Conditions
▶ Make sure that the connecting rods weight the same.

Weights of Euro 4 connecting rods
WEIGHT DIAMETER
⌀ 85.987-85.996 Yellow
CLASS A Yellow 3308 g - 3338 g ⌀ 85.997-86.005 Green
⌀ 86.006-86.013 Blue
⌀ 85.987-85.996 Yellow
CLASS B Green 3339 g - 3368 g ⌀ 85.997-86.005 Green
⌀ 86.006-86.013 Blue
⌀ 85.987-85.996 Yellow
CLASS C Blue 3369 g - 3398 g ⌀ 85.997-86.005 Green
⌀ 86.006-86.013 Blue
15. Check the parallelism of the connecting rod axes (1)

using a device (5) proceeding as follows: Fit the connecting rod
(1) on the spindle of the tool (5) and lock it with the screw (4);
Set the spindle (3) on the "V" prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 307

682 ‒ Engine
F2C ENGINE 227
16. Check the bend of the connecting rod (5) by comparing

two points (A - B) and of the pin (3) on the horizontal plane
of the connecting rod axis.
17. Position the mount (1) of the dial gauge (2) so that this pre-
loads by approx. 0.5 mm on the pin (3) at point A and set the
dial gauge to zero (2).
18. Shift the spindle (4) with the connecting rod (5) and compare
any deviation on the opposite side B of the pin (3): the differ-
ence between A and B must not exceed 0.08 mm.
61694 Figure 308
19. Check the bend of the connecting rod (5) by comparing

two points C and D of the pin (3) on the vertical plane of the
connecting rod axis.
20. Position the vertical support (1) of the dial gauge (2) so that
this rests on the pin (3) at point C.
21. Swing the connecting rod to and fro, establishing the highest
position of the pin and reset the dial gauge (2) in this condition.
22. Move spindle (4) with connecting rod (5) and repeat the
highest point check on opposite side D of pin (3). The
difference between points C and D must not exceed 0.08 mm.
61695 Figure 309
.540840. Piston-connecting rod assembly installation

23. To remove, perform the operations in the reverse order.
Note The connecting rod screws can be used again until the
thread diameter (d) measured in zone (L) is at least
11.4 mm.
117694 Figure 310

682 ‒ Engine
228 F2C ENGINE
.540842. Fitting piston rings

24. Use the specified calliper (3) to fit the piston rings (1) on the
piston (2).
code
25. The rings must be mounted with the writing “TOP” (4) facing
upwards; orient the ring openings so that they are each offset
120°.
126313 Figure 311
.540840. Fitting the connecting rod-piston assembly into the cylinder liners
Caution!
▶ If the cap (1) is mounted backwards, the connecting rod must be discarded.
26. Mount the half bearings (1), both on the connector rod as well
as on the cap.
Note The pistons are supplied as spare parts in class A and
can also be fitted in class B cylinder liners.
115885 Figure 312
27. Using the specific strap (1), assemble the piston-rod assembly
(2) into the cylinder barrels making sure that the openings of
the circlips are offset by 120° and that pistons are all of the
same class A or B.
47593 Figure 313

682 ‒ Engine
F2C ENGINE 229
61831 Figure 314

1 Connecting rod-piston assembly 2 Marking area on the piston crown of ideogram specify-
ing the assembly position and the selection class
3 Area of connecting rod punch marking
28. Make sure that the ideogram stamped on the piston crown shall be facing the engine flywheel or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle position.
.540831. Checking assembly clearance of crankpins

29. To measure clearance, connect the connecting rods to the relative crankpins, place a length of calibrated wire on the latter.
30. Mount the connecting rod caps (1) together with half-bearings;
tighten the connecting rod caps fixing screws (2) to the pre-
scribed torque.
Tightening torque
Connecting rod cap screw tighten- 50 ±2.5 N⋅m
ing torque
31. Using the specific tool (3) further tighten the screws with an
angle of 90°.
code
1/2" and 3/4"
115886 Figure 315
32. Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the
envelope containing the wire.

682 ‒ Engine
230 F2C ENGINE
CYLINDER HEAD OVERHAUL
.540610. CYLINDER HEAD OVERHAUL
Consumables
LOCTITE 270
Work material
Plate for take downfit engine valves (to be used with 99360256
99360257)
Tool for engine valve removal and refitting (to be used 99360257
with 99360256)
Punch for valve guide removal 99360288
Tool for valve guide refitting(to be used with 99360288) 99360294
99395603)
Sleeker for valve guide 99390310
Micrometer
Grinder
Metal brush
Tightening torques
Protrusion of the valve guide from the cylinder head 16.3 mm to16.7 mm
Intake valves recessing −0.5 mm to−0.8 mm
Exhaust valves recessing −1.6 mm to−1.9 mm
Main action
1. Before removing cylinder head, check hydraulic tightness using specific tool; in case of leaks not caused by cup plugs or
threaded plugs, replace cylinder head.
Tool / Material
LOCTITE 270
Note In case of plugs removal/replacement, when assembling apply specified sealant on the plugs.
.540662. Valve removal

Note Before removing cylinder head valves, number them in view of their remounting in the same position should they not have
to be overhauled or replaced.
Intake valves are different from exhaust valves in that they have a notch placed at valve head centre.

682 ‒ Engine
F2C ENGINE 231
2. Fit the specific tool (2) and fix it with the bracket (4).
3. Screw the lever (1) until you can disassemble the cotters (3);
4. take out the tool (2) and extract the top plate (5), spring (6)
and bottom plate (7).
code
99360257)
with 99360256)
5. Repeat this operation for all the valves.

6. Turn the cylinder head upside down and remove the valves (8).
47583 Figure 316
.540610. Checking the planarity of the head on the cylinder block

7. Check the supporting surface (1) of the head on the cylinder
block with a rule (2) and a feeler gauge (3).
8. If you find any deformation, level the head on a surface grinder;
maximum amount of stock removal is 0.2 mm.
Note After levelling, make sure that valve sinking and injector
protrusion are as described in the relative paragraph.
36159 Figure 317
.540662. Valve descale and check

9. Remove all carbon deposits from the valves using a wire brush.
Tool / Material
Metal brush
10. Check that the valves show no signs of seizure or cracking; also
check, using a micrometer, that the diameter of the valve stem
is within the specified values, otherwise replace the valves.
48625 Figure 318

682 ‒ Engine
232 F2C ENGINE
11. Check, by means of a micrometer, that valve stem diameters

are as specified.
Tool / Material
Micrometer
12. Regrind the valve seats, if required, using a grinding machine and
removing as less material as possible.
Tool / Material
Grinder
221525 Figure 319

* Measurement to be A Intake valve
made after driving in B Exhaust valve
the valve guides

682 ‒ Engine
F2C ENGINE 233
.540667. Replacing the valve guides
221524 Figure 320

A Intake valve seat B Exhaust valve seat
13. Use a bore gauge to check that the guide valve diameter is the indicated value. Remove the valve guides by means of the spe-
cific drift. They are fitted with the drift equipped with the adequate part. This last determines the exact valve guide fitting po-
sition in the cylinder head; as these are not available, position the valve guides in the cylinder head so they protrude from the
cylinder head by an amount equal to the value specified.

682 ‒ Engine
234 F2C ENGINE
221524 Figure 320
Tightening torque
Protrusion of the valve guide from the cylinder head 16.3 mm to16.7 mm

Tool for valve guide refitting(to be used with 99360288) 99360294
14. After installing the valve guides, regrind their bores with a suitable smoother.

682 ‒ Engine
F2C ENGINE 235

.540661. Replacing - regrinding the valve seats

Note To replace the valve seats, remove them using the appropriate tool.
15. Use a suitable too(1) to grind the valve seats (2) on the cylin-
der head.
Note Valve seats must be reamed whenever valves or valve
guides are replaced or ground.
16. After reaming the valve seats, use the specific tool, to check the
valve position, with respect to the cylinder head surface is the
same as the specified value.
Tightening torque

99395603)
.540665. Valve spring check

17. Before assembly, check the valve spring flexibility using a suitable
tool.
70000 Figure 322
Conditions

682 ‒ Engine
236 F2C ENGINE
▶ Compare the load and elastic deformation data with those

of the new springs given in the following figure.
221521 Figure 323

A Free spring C Valve opened
B Valve closed
Conditions
▶ Compare the load and elastic deformation data with those

of the new springs given in the following figure.
221522 Figure 324

A Free spring C Valve opened
B Valve closed

682 ‒ Engine
F2C ENGINE 237
COMPLETE TIMING SYSTEM OVERHAUL
.540662. Valve assembly

18. Lubricate the valve stem and insert the valves in the respect-
ive valve guides; fit the lower plates (1). Use the suitable keying
device to fit the oil seal (2) on the valve guides (3) of the ex-
haust valves. then fit the valves as follows.
Note If the valves have not been overhauled or replaced,
reassemble them according to the number sequence
adopted during disassembly.
Intake valves are different form exhaust valves in that
they have a notch placed at valve head centre.
87051 Figure 325
19. Fit the springs (6) and the upper plate (5).
20. Fit the specific tool (2) and fix it with the bracket (4); using the
valve assembly/disassembly tool (1), screw until the cotters (3)
can be disassembled; remove the tool (2).
code
99360257)
with 99360256)
86290 Figure 326
.5412. COMPLETE TIMING SYSTEM OVERHAUL
Work material
Drift to take down and fit back camshaft bushes 99360505
Technical data
Rated assembly play between idler gear bushings and pins. 0.040 mm to0.080 mm
Diameter of bush grinding 65.010 ±0.10 mm

682 ‒ Engine
238 F2C ENGINE
Main action
.5412. Checking the distribution main mechanical drive parts
1. Check the following distribution mechanical drive parts.
114210 Figure 327

1 Camshaft 6 Idler gear
2 Bush 7 Twin idler gear
3 Pin 8 Crankshaft driving
4 Rod gear
5 Camshaft control gear
2. Check the measurements in the figure: the rated assembly play

between idler gear bushings and pins must be as follows.
Technical data
Rated assembly play between idler gear 0.040 mm to0.080 mm
bushings and pins.
221526 Figure 328

682 ‒ Engine
F2C ENGINE 239
.541252. Checking the idler gear

3. Check the idler gear with measurements (2).
4. Check wear condition of the bush (1) and replace if worn.
221523 Figure 329
.541252. Checking the twin idler gear

5. Check the twin idler gear with measurements (2).
6. Check wear condition of the bush (1) and replace if worn.
114212 Figure 330
.541254. Bushing replacement

7. Bushings (1) can be replaced when they are worn. Put up the bushing, then grind it so as to bring it to the specified dimension.
Technical data
Diameter of bush grinding 65.010 ±0.10 mm
Note The bush fitting in the gears (2) shall be carried out following the direction of the arrows and with the value shown in
the figures.

682 ‒ Engine
240 F2C ENGINE
.541211. Camshaft bushes check
114214 Figure 331

MAIN DATA OF CAMSHAFT BUSHES AND RELATIVE SEATS ON THE CYLINDER HEAD
* Bushing inside diameter after driving in
8. The surface of the bushings must show no sign of seizing or scoring; replace them if they do.
9. Measure the bushes inner diameters with a bore meter and replace them, if the value measured exceeds the tolerance value.
10. To remove and refit the bushes, use the specific drift.

682 ‒ Engine
F2C ENGINE 241
.541213. Camshaft bushes check
114214 Figure 332

MAIN DATA OF CAMSHAFT BUSHES AND RELATIVE SEATS ON THE CYLINDER HEAD
11. The surface of the bushings must show no sign of seizing or scoring; replace them if they do.
12. Measure the bushes inner diameters with a bore meter and replace them, if the value measured exceeds the tolerance value.
13. To remove and refit the bushes, use the specific drift.
.541213. Camshaft bushes replacement

.541213. Camshaft bushes removal
14. Extract the bushings (2) using a suitable tool (3) as shown in
the figure.
code
15. Position the drift accurately during the phase of removal.
114280 Figure 333
.541213. Camshaft bushes fitting

16. For fitting, perform the removal operations in reverse order, taking care that the lubrication hole (1) on the bushing coincides
with that on the seat.

682 ‒ Engine
242 F2C ENGINE
.541233. Rocker shaft check
126315 Figure 334

17. The camshaft cams control the 12 valve rockers directly. The intake valve control rocker arms are keyed on rocker arms shaft
directly. Exhaust valves control rocker arms are keyed on rocker arms shaft putting in between the levers with engine brake
control eccentric pin. Rockers slide directly on the cam profiles via rollers. The other end acts on a crosspiece that rests on
the stem of the two valves.
18. A pad is placed between the rocker adjusting screw and the bar. Two lubrication holes are obtained inside the rockers. The
rocker arm shaft covers practically all of the cylinder head; it has to be detached completely to reach all parts beneath.
114217 Figure 335

19. Rocker arm shaft: Check the shaft surface shows any trace of scoring or seizure. otherwise, replace it.
.541233. Intake valve rocker arms check

20. Check the condition of the pump injector rocker arms as in the
figure.
114219 Figure 336

21. Check the condition of the input valve rocker arms as in the
figure.
114218 Figure 337

682 ‒ Engine
F2C ENGINE 243
ENGINE ASSEMBLY
.541231. Exhaust valve rocker arm check
181656 Figure 338

22. The bush surfaces must not show any trace of scoring of excessive wear; otherwise, replace bushes or the whole rocker.
.543751. Lever with engine brake control eccentric pin check

23. The bush surfaces must not show any trace of scoring of ex-
cessive wear; otherwise, replace bushes or the whole rocker.
126316 Figure 339
.540110. ENGINE ASSEMBLY
Consumables
LOCTITE
LOCTITE 275
LOCTITE 5970
Work material
Key to fit crankshaft rear gasket 99346260

682 ‒ Engine
244 F2C ENGINE
ENGINE ASSEMBLY

- 1/2" and 3/4"
Gauge to determine centre distance between camshaft 99395221
and high pressure pump
Gauge for defining the distance between the centres of 99395222
camshaft and timing gear
Box wrench
Tightening torques
Pre-tightening the cylinder head using a torque 1. 1st step 50 ±2.5 N⋅m
wrench 2. 2nd step 100 ±5 N⋅m
Angle tightening with specific tool. 1. 3rd step 90 ±4.5°
2. 4 step
th
75 ±3.5°
Tightening the oil pump - duplex gear - connecting rod screws 24.5 ±2.5 N⋅m
Pre-tightening the flywheel on camshaft using a 1st step 120 ±6 N⋅m
torque wrench
Angle tightening with specific tool. 2nd step 90 ±4.5°
Water pipe fittings 35 ±5 N⋅m
Female oil pipe union 55 ±5 N⋅m
Male oil pipe union 110 ±5 N⋅m
Technical data
Idle gear bushing dimensions 58.010 ±0.10 mm
Main action
1. Clean the surface to be coupled to remove impurities and oil
residue. Apply suitable silicone (1) to the cover (2) as in the
figure.
Tool / Material
LOCTITE 5970
2. The sealant bead diameter should be about 1.5 mm.
117690 Figure 340
Caution!
Front cover Assembly warnings
▶ Mount the front cover within 10 minutes of applying the sealant.

682 ‒ Engine
F2C ENGINE 245
ENGINE ASSEMBLY
3. Mount the front cover (1) and tighten the screws to torque.
114257 Figure 341
4. Fit precisely the gasket (1), fit the device (2), drive in the gasket
(1) by screwing the nut (3).
code
114258 Figure 342
.540610. Cylinder head assembly

5. Check that the pistons 1 -6 are exactly at the T.D.C. Put the
gasket (2) on the crankcase.
Caution!
Screws Replacement
▶ Do not re-use screws removed
▶ Use new screws.
6. Fit the cylinder head (1) and close the screws as indicated in the
following diagram.
42566 Figure 343

682 ‒ Engine
246 F2C ENGINE
ENGINE ASSEMBLY
7. Diagram showing the cylinder head fixing screws tightening

order.
44900 Figure 344
8. Pre-tightening with the torque wrench (1).

Tightening torque
Pre-tightening the cylinder 1. 1st step
head using a torque wrench 50 ±2.5 N⋅m
2. 2nd step
100 ±5 N⋅m
45267 Figure 345
9. Angle tightening with specific tool (1).

Tightening torque
Angle tightening with specific 1. 3rd step
tool. 90 ±4.5°
2. 4th step
75 ±3.5°

code
1/2" and 3/4"
45268 Figure 346
10. Mount the oil pump (1), twin gear (3) complete with connect-
ing rod (4) and lock the screws (2) to prescribed torque.
Tightening torque
Tightening the oil pump - duplex 24.5 ±2.5 N⋅m
gear - connecting rod screws
114023 Figure 347

682 ‒ Engine
F2C ENGINE 247
ENGINE ASSEMBLY

residue. Apply the prescribed silicone on the gear housing (1)
Tool / Material
LOCTITE 5970

Note Fit the gear housing within 10 minutes after sealant
application.
114261 Figure 348
13. Use a torque wrench to tighten the screws (1) to the correct
torque.
114262 Figure 349

residue. Apply the suitable silicon on the flange (1) of the high
pressure pump as shown in the figure.
Tool / Material
LOCTITE 5970

Note Fit the flange within 10 minutes after sealant application.
114263 Figure 350

682 ‒ Engine
248 F2C ENGINE
ENGINE ASSEMBLY
16. Use the specific gauge (1) to check and register the position of
the flange (2) attaching the high pressure water pump.
code
Gauge to determine centre distance between camshaft and 99395221
high pressure pump
17. Tighten the screws of the flange (2) to the specified torque.
114264 Figure 351
.771010. High pressure pump assembly

18. Fit the high pressure pump (1) onto the flange (2).
114272 Figure 352
.540850. Engine flywheel assembly

19. Fit precisely the gasket (1), fit the specific keying device (2),
drive in the gasket by screwing the nut (3).
code
Note If the teeth of the ring gear mounted on the engine

flywheel used for starting the engine are very damaged,
replace the ring gear. Fitting
It must be fitted after heating the ring gear to a temper-
ature of ~200 °C.
Note The crankshaft has a centring pin that has to couple 45258 Figure 353
with the relevant seat on the flywheel.

682 ‒ Engine
F2C ENGINE 249
ENGINE ASSEMBLY
114265 Figure 354

DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS
A Hole on flywheel with reference mark, corresponding C Hole on flywheel with reference mark, corresponding
to the TDC of pistons 3-4 to the TDC of pistons 2-5
B Hole on flywheel with reference mark, corresponding D Hole on flywheel with 2 reference marks, position
to the TDC of pistons 1-6 corresponding to 545.
20. Position the flywheel (1) on the crankshaft, lubricate the thread of the screws (2) with engine oil and screw them down.
21. Block the engine flywheel rotation using a suitable tool .

22. Tighten the screws (2) in two steps.
Tightening torque
Pre-tightening the flywheel on cam- 1st step
shaft using a torque wrench 120 ±6 N⋅m
49037 Figure 355

682 ‒ Engine
250 F2C ENGINE
ENGINE ASSEMBLY
23. Perform angle tightening with specific tool.

Tightening torque
Angle tightening with specific tool. 2nd step
90 ±4.5°

code
1/2" and 3/4"
49036 Figure 356
.541210. Fitting camshaft

24. Position the crankshaft with the pistons 1 and 6 at the top dead
centre (T.D.C.).
25. This condition is fulfilled when the hole with one reference
mark (5) of the engine flywheel (4) can be seen through the
inspection window.
26. This also takes place when the specific tool (1), through the
seat (2) of the engine speed sensor, enters the hole (3) in the
engine flywheel (4).
code
ately. Remove the specific tool (1).
code
29. Clean the surface of the plate (1) to be coupled to remove
impurities and oil residue.
30. Apply the suitable silicone (6) on the gear housing (1) as shown
in the figure.
Tool / Material
LOCTITE 5970
Note Take care NOT to put the sealant in the inner groove
(5).
32. Within 10 minutes of applying sealant, fit the plate (1) with
the gasket (1) 2 and tighten the screws (1) 4 to the specified
torque. 114267 Figure 358

682 ‒ Engine
F2C ENGINE 251
ENGINE ASSEMBLY
33. Apply the suitable gauge (1), check and adjust the position of
the rod (1) for the idle gear, tighten the screw (2) to the pre-
scribed torque.
code
114269 Figure 359
34. Refit the idler gear (2) and tighten screws (1) to the specified
torque using a suitable socket threaded wrench.
Note The idle gear bush (1) may be replaced when worn.
35. Put up the bushing, then grind it so as to bring it to the specified
dimension.
Technical data
Idle gear bushing dimensions 58.010 ±0.10 mm
114270 Figure 360
.541210. Camshaft and phonic wheel timing

36. Rotate the crankshaft with the specified tool so the hole iden-
tified with two marks (5) is visible from the inspection window
below the flywheel cover case.
code
37. In this condition, insert the specific tool (1), through the seat
(2) of the engine speed sensor, enters the hole (3) in the fly-
wheel (4).
code
115061 Figure 361

682 ‒ Engine
252 F2C ENGINE
ENGINE ASSEMBLY
38. Apply the specified tool on the front of the camshaft (1).
code
116052 Figure 362
39. Turn the specified tool (1) to insert the pin (3) in the whole
(2) on the head.
40. Fix the specified tool (1) with two screws (2) M8x 1.25 mm.
code
116053
116053 Figure 363
41. Mount the camshaft control gear (1) so that it coincides with
the fixing holes on the shaft, using the slots (2) on the control
gear.
42. Position the gear (1) taking care to arrange the spokes (4) as in
the figure.
43. This is necessary in order to properly set the phonic wheel
which has only one mounting position in relation to the gear.
44. Tighten the retaining screws (3).
117691 Figure 364

682 ‒ Engine
F2C ENGINE 253
ENGINE ASSEMBLY
45. Fit the cross pieces (1) onto the valve stem.
Note Before refitting the rocker-arm shaft assembly, make
sure that all the adjustment screws have been fully
unscrewed.
116055 Figure 365
.541230. Rocker arm shaft installation

code
47. Tighten the fixing screws to the prescribed torque.

48. Fit the engine brake lever retainer springs .
114025 Figure 366

682 ‒ Engine
254 F2C ENGINE
ENGINE ASSEMBLY
.775010. Injector assembly
125708 Figure 367

A M18 x 1.5
B M14 x 1.5
C M16 x 1.5
Caution!
Pipes. Replacement
▶ The previously removed pipes can no longer be refitted; they must be replaced.
49. Fit the oil delivery pipe to the engine brake on the cylinder head and the engine brake cylinder, manually tightening the screws.
50. Tighten the fixing screws to the prescribed torque.
51. Lubricate the injector O-rings with lubricants PDE SILIKONFETT 22, NLG 12, PDE LUBRICOMET GR 220 NLG12.
52. Fit the rail on the cylinder head, manually tightening the screws.
53. Fit the injectors in the correct position and tighten them to the prescribed torque.

682 ‒ Engine
F2C ENGINE 255
ENGINE ASSEMBLY
Caution!
Injectors: equidistance
▶ Make sure that the injectors (2) are at the same distance from the springs (1). The distance “X“ that separates
them must be equal.
54. Fit the pipes on the rail, manually tightening the couplings.
55. Tighten the screws fixing the rail to the cylinder head to the specified torque.
56. Fit the pipes on the injectors and the head, manually tightening the couplings.
Caution!
Possible damage to the vehicle! Check engine oil level.
▶ After fitting the high pressure pipes, check the engine oil level frequently for the next 20 hours of work.
▶ (IT MUST NOT INCREASE)
57. Tighten the couplings on the rail A, C to the specified torque.

58. Tighten the couplings on the injectors and the head B, C to the specified torque.
Rail couplings - injector couplings
TYPE DESCRIPTION TIGHTENING TORQUE
A M18 x 1.5 40 ± 2 Nm
B M14 x 1.5 35 ± 2 Nm
C M16 x 1.5 40 ± 2 Nm
.774510. Rail installation

59. Fit the rail by following the operation 775010 Injector assembly ( ➠ Page 254).

682 ‒ Engine
256 F2C ENGINE
ENGINE ASSEMBLY
.541215. Pulser ring timing

60. Fit the high pressure pump gear (7) and tighten the nut (8) to
61. In conjunction with the nut (8) use the specified flat washer
(PN 17095914) in replacement of that provided with the
Bosch CP3 pump.
62. Turn the crankshaft bringing cylinder no. 1 when firing; rotate
the flywheel until the two notches can be seen from the bot-
tom inspection window.
63. Fit the phonic wheel (4) so that the tooth marked with the
arrow (→) corresponds with the seat of the sensor (6). To
check for correct positioning, insert the specified tool in the
timing sensor seat (6).
64. Then tighten the screws (5).
65. Remove the specified tools.
code
114284 Figure 368
66. Fit the fuel delivery piping (1) from the high pressure pump to
the rail.
Note The previously removed pipes can no longer be refit-
ted; they must be replaced.
Caution!
Possible damage to the vehicle! Check engine oil
level.
▶ After fitting the high pressure pipes, check the engine
oil level frequently for the next 20 hours of work.
▶ (IT MUST NOT INCREASE) 114275 Figure 369
67. Tighten the nuts to the prescribed torque.

682 ‒ Engine
F2C ENGINE 257
ENGINE ASSEMBLY
.540486. Blow-by filter fitting

68. IF PRESENT fit the centrifugal filter (1) on the phonic wheel
and tighten the screws (2) to the specified torque.
114285 Figure 370
69. Fit the distribution cover (1) and tighten the screws (2) to the
specified torque.
114286 Figure 371
.541230. Intake and exhaust rocker arm clearance adjustment

Note The adjustment of clearance between the rocker arms and bridges controlling the intake and exhaust valves must be done
very carefully.

682 ‒ Engine
258 F2C ENGINE
ENGINE ASSEMBLY
187916 Figure 372

A Hole on flywheel with reference mark, corresponding D Flywheel hole with two notches corresponding to
to the TDC of pistons 1-6 position 54° before TDC of pistons 1-6 (camshaft
B Hole on flywheel with reference mark, corresponding timing reference);
to the TDC of pistons 2-5 E Flywheel hole with three notches corresponding to
C Hole on flywheel with reference mark, corresponding position 30° before TDC of pistons 1-6 (reference to
to the TDC of pistons 3-4 HP fuel pump and timing system phonic wheel timing).
70. In order to perform adjustments correctly, during each rotation phase check the positioning accuracy using the specific pin,
inserting it into the hole marked with a notch on the flywheel corresponding to piston position.

682 ‒ Engine
F2C ENGINE 259
ENGINE ASSEMBLY
71. Take the cylinder whose clearance has to be adjusted into the
combustion phase; the valves of this cylinder are closed while
they balance the symmetric cylinder valves.
Note The correspondence of the symmetrical cylinders is 1 -
6, 2 - 5 and 3 - 4.
72. In order to properly operate, follow these instructions and data
specified on the table.
73. Using a box wrench, remove the adjustment screw fastening
nut (1).
Tool / Material
Box wrench
114287 Figure 373
74. Insert the feeler gauge blade (3) corresponding to the operat-
ing clearance shown in the table "Characteristics and data"
of the ENGINE section.
75. Screw or unscrew the adjustment screw of the rocker arm (2)
with the appropriate wrench.
76. Check that the feeler gauge blade (3) can slide with slight fric-
tion.
77. Lock the nut (1) by stopping the adjustment screw.
78. To carry out the adjustments stated above, the sequence shown in the table is mandatory.
FIRING ORDER 1-4-2-6-3-5
Start and rotation in the engine Adjust valve clearance for cylinder
Balancing cylinder valves no.
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle degree [°]
120
5 2
Angle degree [°]
120
1 6
Angle degree [°]
120
4 3
Angle degree [°]
120
2 5
Angle degree [°]
Note Check during each rotation phase, the accuracy of the position by using the specific pin and inserting it into the hole
marked with a notch on the flywheel corresponding to piston position.

682 ‒ Engine
260 F2C ENGINE
ENGINE ASSEMBLY
.540452. Blow-by case fitting

79. Fit the blow-by case (1) with its gasket and then tighten the
screws (2) to the prescribed torque.
Caution!
Blow-by body Correct assembly standards
▶ The blow-by case must be perfectly fitted on axis
with the camshaft so as not to damage the gasket.
80. Fit the cover (3) and tighten the screws (4) to the specified
torque.
114288 Figure 374
81. Fit the electric cable in the head (injectors+pressure sensor)

passing it through the hole (5) and fastening it using straps as
shown in the figure (↓).
115880 Figure 375
.540630. Tappet cover assembly

82. Mount the cover (1) of the cylinder head and tighten the
screws (2) to the torque specified following the correct
sequence.
114016 Figure 376

682 ‒ Engine
F2C ENGINE 261
ENGINE ASSEMBLY
83. Follow the order in the diagram when tightening. 17 14 13 1 4 5 8

18 9
19 10
20 11
16 15 12 2 3 6 7
192197 Figure 377
117695 Figure 378

84. Before fitting the suction strainer, it is very important to apply silicone to the contact area (1) between the crankcase, flywheel
housing and front cover, following these specifications. Clean the surface to be coupled to remove impurities and oil residue.
Apply the adequate silicone (1) as shown in the figure. The sealant bead diameter has to be 1.5 ±0.5/0.2 mm.
Tool / Material
LOCTITE
LOCTITE 275

682 ‒ Engine
262 F2C ENGINE
ENGINE ASSEMBLY
.543060. Suction strainer installation

85. Fit the suction strainer (2), tightening the screws (1) on the
crankcase to the specified torque.
125709 Figure 379
.540430. Oil sump assembly

86. Rotate the engine.
87. Arrange the gasket on oil sump (1), position the spacer (3)
and fit the sump on crankcase screwing up the screws (2) at
prescribed torque.
125706 Figure 380
.543210. Water pump assembly

88. Refit the alternator (6), belt tensioner (5), A/C compressor
(1), flanged pipe (3), fixed belt tensioner (4) the thermostat
assembly (2).
125703 Figure 381

682 ‒ Engine
F2C ENGINE 263
ENGINE ASSEMBLY
89. Refit the water pump (2) and the pulley (3) and tighten the
screws (1).
125702 Figure 382
.543411. Water pump drive belt installation

90. Remount the pulley (2) with the damper flywheel (3).
91. Using a suitable tool (4) work in the direction of the arrow, and
refit the belt (5) driving the water pump and alternator.
92. Fit the spring belt (1) onto the pulley.
93. Position the belt onto the tang of the air conditioner pulley.
94. Using a suitable tool, rotate the crankshaft so as to fit the belt
onto the air conditioner pulley.
Note During the operation, guide the belt appropriately so as
to avoid torsion/tension that could damage it.
Place a piece of rubber between the pulley and the belt
if needed.
Note The flexible belt must be replaced with a new one

every time it is removed from the vehicle.
125701 Figure 383
.543910. Air-conditioning compressor drive belt installation

95. To fit the A/C compressor drive belt see the operation 543411 Water pump drive belt installation ( ➠ Page 263).

682 ‒ Engine
264 F2C ENGINE
ENGINE ASSEMBLY
.766161. ECU installation

96. Connect the piping (2) from the support to the HP pump and
install the control unit (1) along with the support below.
125705 Figure 384
.540710. Inlet manifold assembly

97. Install the fuel filter (1), the oil dipstick (2) and intake manifold
(3).
125704 Figure 385
.542011. Fuel filter assembly

98. Fit the fuel filter by following the operation 540710 Inlet manifold assembly ( ➠ Page 264).

682 ‒ Engine
F2C ENGINE 265
ENGINE ASSEMBLY
.543070. Oil filter assembly

99. Install the oil filter (1), the oil intake pipe (5), the oil outlet pipe
(2), the turbocharger (4) and exhaust manifold (3).
100. Fit the starter motor from the other side of the engine.
101. The couplings of the pipes, cooling water and lubricating oil of
the turbocharger must be locked to the prescribed torque.
3
Tightening torque
Water pipe fittings 35 ±5 N⋅m
4
Female oil pipe union 55 ±5 N⋅m
Male oil pipe union 110 ±5 N⋅m 2
5 1
171976 Figure 386
.542410. Turbocharger assembly

102. Fit the turbocharger by following the operation 543070 Oil filter assembly ( ➠ Page 265).
.540720. Exhaust manifold assembly

103. Fit the exhaust manifold by following the operation 543070 Oil filter assembly ( ➠ Page 265).
.760310. Alternator assembly

104. Refit the alternator (6), belt tensioner (5), A/C compressor
(1), flanged pipe (3), fixed belt tensioner (4) the thermostat
assembly (2).
125703 Figure 387
.543251. Thermostat assembly

105. Fit the thermostat by following the operation 760310 Alternator assembly ( ➠ Page 265).

682 ‒ Engine
266 F2C ENGINE
ENGINE ASSEMBLY
.540110. Assembly of electrical components
172610 Figure 388

Installation of electrical components
A Fuel temperature sensor H Temperature/air pressure sensor
B Camshaft timing sensor I A/C compressor
C EDC control unit 7 L Water temperature sensor
D Fuel regulation valve on high-pressure pump M Connector on the engine head for connection with
E Starting motor electro-injectors
F Oil pressure/temperature transmitter N Engine speed sensor on flywheel
G Alternator
106. Connect the electrical components.

682 ‒ Engine
F3B ENGINE 267
Contents
Contents Viscostatic fan . . . . . . . . . . . . . . . . . . . . . . . . 293
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . 269 Water pump . . . . . . . . . . . . . . . . . . . . . . . . . 294
Left side view . . . . . . . . . . . . . . . . . . . . . . . 269 Section on water pump . . . . . . . . . . . . . . . . . 294
Right side view . . . . . . . . . . . . . . . . . . . . . . 270 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 294

Front view . . . . . . . . . . . . . . . . . . . . . . . . . 271 Water circulating in the engine . . . . . . . . . . . . 294
Rear view . . . . . . . . . . . . . . . . . . . . . . . . . 272 Water leaking from the thermostat . . . . . . . . . 294
Top view . . . . . . . . . . . . . . . . . . . . . . . . . 273
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . 295
TECHNICAL NAME . . . . . . . . . . . . . . . . . . . . 273 Turbocharging diagram . . . . . . . . . . . . . . . . . 295
POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . 274 HOLSET HE 551 W turbocharger . . . . . . . . . . 296
Fuel supply diagram . . . . . . . . . . . . . . . . . . . 275 ENGINE BRAKE DEVICE CEB (Combined Engine
Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
High pressure pump CP 2.2 . . . . . . . . . . . . . . . . 275
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 297
Rail (pressure accumulator) . . . . . . . . . . . . . . . . 277
DATA - INSTALLATION CLEARANCES . . . . . . . 299
Pressure limiter valve . . . . . . . . . . . . . . . . . . . . 278
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 305
Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . 278
Injector section . . . . . . . . . . . . . . . . . . . . . 279 Diagrams of tightening sequence of main engine
components . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 280
Diagram of tightening sequence of screws
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 securing lower crankcase to crankcase . . . . . . . 308
Cylinder head fastening screw tightening
Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . 281 diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 309
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 282 Diagram of tightening sequence for exhaust
manifold fastening screws . . . . . . . . . . . . . . . 310
Lubrication circuit . . . . . . . . . . . . . . . . . . . . 282
Diagram of tightening sequence for heat
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 exchanger fixing screws . . . . . . . . . . . . . . . . 310
Oil pump cross-section . . . . . . . . . . . . . . . . . 283 Diagram of tightening sequence for rocker arm
cover fixing screws . . . . . . . . . . . . . . . . . . . 310
Overpressure valve . . . . . . . . . . . . . . . . . . . 284
Scheme of the tightening order of rocker arms
Oil pressure regulator valve . . . . . . . . . . . . . . . . 284 shafts fastening screws . . . . . . . . . . . . . . . . . 311
Diagram of tightening sequence for thermostat
Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 286 cover fastening screws . . . . . . . . . . . . . . . . . 312
Filter by-pass valve . . . . . . . . . . . . . . . . . . . . . . 287 Diagram of tightening sequence for intake

manifold fastening screws . . . . . . . . . . . . . . . 313
Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . 288
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Valve integrated in piston cooling nozzle . . . . . . . . 289
ENGINE DISASSEMBLING . . . . . . . . . . . . . . . . 323
Oil vapour breather (Blow-by) . . . . . . . . . . . . . . 289
CRANKCASE CHECKS . . . . . . . . . . . . . . . . . . 345
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Cylinder liners Removal . . . . . . . . . . . . . . . . 349
Description . . . . . . . . . . . . . . . . . . . . . . . . 291 Cylinder liner refitting and protrusion check . . . . 350
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 292 Crankshaft measurements . . . . . . . . . . . . . . . 352

682 ‒ Engine
268 F3B ENGINE
Contents
Measuring main journals . . . . . . . . . . . . . . . . 354

Preliminary measurement for main half-bearings
selection . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Selecting the main half-bearings . . . . . . . . . . . . 357
Crankpins . . . . . . . . . . . . . . . . . . . . . . . . . 361
Selecting the big-end half-bearings . . . . . . . . . . 361
Checking the timing and oil pump gear
control . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Main journal fitting clearance check . . . . . . . . . 368
Checking crankshaft shoulder clearance . . . . . . 371
Crankpin fitting clearance check . . . . . . . . . . . 371
PISTON - CONNECTING ROD ASSEMBLY

OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . 372
CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . 381
COMPLETE TIMING SYSTEM OVERHAUL . . . . . . 391

Timing system drive . . . . . . . . . . . . . . . . . . . 391
Idler gear pin . . . . . . . . . . . . . . . . . . . . . . . 391
Twin intermediate gear pin . . . . . . . . . . . . . . 392
Bushing replacement . . . . . . . . . . . . . . . . . . 392
Checking cam lift and journals alignment . . . . . . 393
Camshaft bushings check . . . . . . . . . . . . . . . . 396
Replacing camshaft bushings using beater . . . . . . 397
Rocker shaft check . . . . . . . . . . . . . . . . . . . 400
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 401

682 ‒ Engine
F3B ENGINE 269
ENGINE VIEWS
F3B ENGINE
5401 ENGINE VIEWS
Left side view
204932 Figure 389

682 ‒ Engine
270 F3B ENGINE
ENGINE VIEWS
Right side view
204933 Figure 390

682 ‒ Engine
F3B ENGINE 271
ENGINE VIEWS
Front view
204934 Figure 391

682 ‒ Engine
272 F3B ENGINE
ENGINE VIEWS
Rear view
204935 Figure 392

682 ‒ Engine
F3B ENGINE 273
TECHNICAL NAME
Top view
204936 Figure 393
TECHNICAL NAME
F3BEE681A*Z001-XXXXXX
● F3BEE681A*Z001 ‒ Indication of the engine family

● F3BEE681A*Z001 ‒ Evolution of the family with the same or different displacement
● F3BEE681A*Z001 ‒ Engine
● F3BEE 681A*Z001 ‒ Number of times and cylinder position
E 4-stroke, vertical
● F3BEE6 81A*Z001 ‒ Number of cylinders

● F3BEE68 1A*Z001 ‒ Fuel supply + Injection (TCA, direct diesel injection)
● F3BEE681 A*Z001 ‒ Use (truck)
● F3BEE681A *Z001 ‒ Power and engine torque level
A 480 HP/2200 Nm
B 430 HP/2100 Nm
● F3BEE681A*Z 001 ‒ Gas emission level

● F3BEE681A*Z 001 ‒ Version no. within the bill of materials

682 ‒ Engine
274 F3B ENGINE
POWER SUPPLY
● F3BEE681A*Z001- XXXXXX ‒ Progressive production number
5420 POWER SUPPLY

The Common Rail supply system has a special pump that continuously keeps fuel at high pressure, independently from the stroke
and the cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the control unit.
When the injector solenoid valve is energised by the electronic control unit, the injection of fuel taken directly from the rail occurs
in the relative cylinder.
204937 Figure 394

A Fuel supply system B Tank return circuit

682 ‒ Engine
F3B ENGINE 275
High pressure pump CP 2.2
Fuel supply diagram
204943 Figure 395

A High pressure B Low pressure
1 High-pressure pump 6 Engine control unit

2 Fuel filter 7 Electric injectors
3 Tank 8 Rail pressure accumulator
4 Water separator filter 9 Pressure sensor
5 Fuel pre-filter 10 Overpressure valve
771010 High pressure pump CP 2.2

It is a pump, equipped with two plungers, that takes drive from the distribution gear. The gear supply pump is installed on the same
control shaft.

682 ‒ Engine
276 F3B ENGINE
High pressure pump CP 2.2
9 1
8
2
2 10
3
5
7 6 5 4
221382 Figure 396
1 Fuel delivery to rail 6 Fuel delivery to filter
2 Flow regulator 7 Fuel supply from tank
3 Pump lubrication oil coupling 8 Fuel supply from filter
4 Fuel pump 9 Fuel return to tank
5 Phonic wheel position sensor 10 Pressure regulator valve

682 ‒ Engine
F3B ENGINE 277
Rail (pressure accumulator)
774510 Rail (pressure accumulator)
180254 Figure 397

1 Pressure sensor 4 Fuel return
2 Rail 5 Overpressure valve
3 Pipes to injectors 6 Intake from the high-pressure fuel pump
The rail volume is of reduced size to allow a quick pressurisation at start-up, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise pulsations caused by injectors openings and closings and by the high-pressure pump
operation.
This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.
Some calibrated holes have been made in the fittings of the high pressure pipes, with the function of damping the oscillations in
pressure generated by the opening of the injectors and the plungers of the high pressure pump.
A fuel pressure sensor (1) is screwed to the rail.
The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is
checked and, if necessary, corrected.
Characteristics
Technical data
Nominal pressure 2,200 bar

682 ‒ Engine
278 F3B ENGINE
Pressure limiter valve
774513 Pressure limiter valve
158450 Figure 398

It is a safety valve mounted on the hydraulic rail which prevents the pressure of the fuel in the rail from exceeding the threshold
2400 bar.
It consists of a shutter and a spring, calibrated so that when the pressure in the rail reaches too high a value, the valve regulates it by
releasing part of the fuel to the tank.
Furthermore, in case of failure of the injection pressure control system, it allows the engine to function with limited performance.
775010 Electro-injectors
The electro-injectors are mounted on the cylinder head and oper-
ated by the engine control unit. They are powered by a high pressure
fuel line and are connected to an atmospheric pressure return line,
necessary for the pilot valve to function.
114255 Figure 399

1 Electro-injector 2 Fuel coupling

682 ‒ Engine
F3B ENGINE 279
Electro-injectors
Injector section
186530 Figure 400

1 Coil 6 Nozzle
2 High-pressure fuel inlet fitting 7 Pressure chamber
3 Filter 8 Control volume
4 Pressure rod 9 Pilot valve shutter
5 Needle

682 ‒ Engine
280 F3B ENGINE
Fuel filter
Operation
The electro-injector essentially consists of two parts:
- actuator spray nozzle consisting of a pressure rod (4), needle (5) and jet(6).
- control solenoid valve made up of coil (1) and pilot valve.
Electro-injector operation can be divided into three phases:
● 1st Phase - Rest position The coil (1) is cut off and the shutter (9) of the pilot valve is in the closed position.
In this condition the opening force is balanced by the closing force, because the pressure of the fuel in the control volume (8)
is the same in the pressure chamber (7).
● 2nd Phase - Start of injection The coil (1) is energized and causes the shutter (9) to rise.
The control volume fuel (8) flows back towards the return manifold, causing a drop in pressure
At the same time, in the pressure chamber (7) the pressure line exerts an opening force that causes the needle (5) to rise,
with the consequent introduction of fuel into the cylinders.
● 3rd Phase - End of injection The coil (1) is cut off and causes the shutter (9) to return to the closed position, recreating
a balance of forces, bringing the needle (5) back to the closed position and consequently ending injection.
Fuel filter
205074 Figure 401

1 Fuel filter 4 Fitting for bleeding
2 Fuel temperature sensor 5 Drain valve
3 Clogged filter sensor * Alternative

682 ‒ Engine
F3B ENGINE 281
Fuel pre-filter
Fuel pre-filter
205073 Figure 402

1 Fuel inlet 4 Filter
2 Fuel outlet 5 Transparent water accumulation chamber
3 Bleed pump

682 ‒ Engine
282 F3B ENGINE
LUBRICATION
5430 LUBRICATION
The engine is lubricated by a gear pump driven via gears by the crankshaft.
A heat exchanger governs the temperature of the lubricating oil.
It houses the oil filter, indicator sensors and safety valves.
Lubrication circuit
218357 Figure 403

A Engine brake solenoid valve detail D Oil dropping
B Oil to brake cylinders E Oil under pressure
C To engine brake cylinder 6 F High-pressure pump lubrication pipe

682 ‒ Engine
F3B ENGINE 283
Oil pump
543010 Oil pump

The oil (1) pump cannot be overhauled.
If you find any damage, replace the entire oil pump.
To change the gearing (2) of the crankshaft, see the relevant
chapter.
060560a Figure 404
Oil pump cross-section
108846 Figure 405
Technical data
Initial opening pressure - Overpressure safety valve 10 ±1 bar

682 ‒ Engine
284 F3B ENGINE
Oil pressure regulator valve
543076 Overpressure valve

Main data to check the safety valve spring
073540 Figure 406
543075 Oil pressure regulator valve

The oil pressure relief valve is located on the left-hand side of the
crankcase.
Start of opening pressure 5 bar.
161256 Figure 407

682 ‒ Engine
F3B ENGINE 285
Oil pressure regulator valve
Main data to check the oil pressure adjustment valve spring
161269 Figure 408

A Start opening B Opening end

682 ‒ Engine
286 F3B ENGINE
Heat exchanger
543110 Heat exchanger
180296 Figure 409

1 By-pass valve 3 Oil filter support seat
2 Heat exchanger
Technical data
By-pass valve opening pressure 2.5 ±0.3 bar

682 ‒ Engine
F3B ENGINE 287
Filter by-pass valve
543077 Filter by-pass valve

The valve quickly opens at a pressure of: 3.4 ± 0.3 bar.
73545 Figure 410

682 ‒ Engine
288 F3B ENGINE
Engine oil filter
543070 Engine oil filter
180257 Figure 411

1 Oil filter support 4 Cartridge
2 Cap O-ring 5 Closing cap
3 Cartridge O-ring 6 Drainage plug
Technical data
By-pass valve opening pressure 3.4 ±0.3 bar
Tightening torque
Oil filter retainer at the support base 60 ±5 N⋅m
Drain plug on the engine oil filter 6.5 ±1.5 N⋅m

682 ‒ Engine
F3B ENGINE 289
Valve integrated in piston cooling nozzle
540414 Valve integrated in piston cooling nozzle

The valve allows oil to enter and thus lubrication of pistons only
above the pressure value shown below.
Technical data
Valve opening pressure 1.7 ±0.2 bar
This permits filling of the circuit and therefore the lubrication of the
most stressed parts, even when working at lower pressures.
109080 Figure 412
540480 Oil vapour breather (Blow-by)

Part of the gas produced by combustion leaks out of the piston gaskets into the sump and mixes with the oil vapour it contains.
This mixture is conveyed upwards and is partially separated from the oil by a device located at the top of the timing system cover
and released into the air.
The device is essentially composed of a rotary filter (3) keyed to the camshaft and a rear cover (2) housing the normally closed
valves (1) that manage the flow of the mixture.

682 ‒ Engine
290 F3B ENGINE
Oil vapour breather (Blow-by)
Oil vapour breather diagram (Blow-by)
204940 Figure 413

Oil vapour flow
1 Vapour breather valve 3 Blow-by filter

2 Blow-by box

682 ‒ Engine
F3B ENGINE 291
COOLING
5432 COOLING
Description
204941 Figure 414

A Water leaking from the thermostat C Pump inlet water
B Water circulating in the engine
The engine cooling system is of closed circuit forced circulation type and can be connected to an additional heater, if the vehicle
provides for such, and to the heat exchanger of the hydraulic retarder.
It consists mainly of the following components:
● An expansion tank and plug (1) with two built-in valves: an outlet and an inlet, which regulate the pressure of the system.
● A coolant level sensor placed at the bottom of the expansion tank with two coupling points.
Left-hand drive vehicles:

Technical data
coupling point for S1 probe 5.5 ℓ
Coupling point for S2 probe 4ℓ
● An engine cooling unit to dissipate the heat taken by the coolant from the engine through the intercooler.

682 ‒ Engine
292 F3B ENGINE
COOLING
204941 Figure 414

● A heat exchanger to cool the lubricating oil.
● A centrifugal water pump incorporated in the crankcase.
● A viscostatic fan on which the impeller is mounted.
● A 3-way thermostat regulating the circulation of the coolant.
Operation
The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head into the cylin-
der head.
When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open and the fluid is
channelled from here to the radiator and cooled by the fan.
The pressure inside the system depending on the temperature variation is controlled by the discharge and charge valves incorpor-
ated in the expansion reservoir filling plug (1).
The discharge valve has a double function:
● keep the system under light pressure in order to raise the coolant boiling point;
● discharge into the atmosphere the pressure surplus produced in case of high coolant temperatures.

682 ‒ Engine
F3B ENGINE 293
Viscostatic fan
The function of the inlet valve is to permit the transfer of coolant from the expansion tank to the radiator when a low pressure is
generated inside the system due to coolant volume reduction as a result of lowering of temperature.
Discharge valve opening:

Technical data
1st breather 0.9+0.2
−0.1 bar
2nd breather 1.2+0.2

−0.1 bar
Exhaust valve opening −0.03+0

−0.02 bar
Plug tightening torque(1) 8 ±1 N⋅m
543422 Viscostatic fan

The viscostatic coupling, on which the cooling fan is mounted, allows
the transmission of motion from the pulley to the fan by making use
of the viscosity of the oil inside it. Air passing through the cooling
radiator heats up when the engine is running and the coupling is
activated when the air comes into contact with the front of it.
Characteristics:
Technical data
Maximum control speed 2,470 rpm
Max. fan speed 2,346 ±50 rpm
Operating temperature
Conditions: With fan speed: 1,976 rpm 63 ±3 ℃
70487 Figure 415

682 ‒ Engine
294 F3B ENGINE
Water pump
543210 Water pump

Section on water pump
The water pump is composed of: rotor, bearing, gasket and drive
pulley.
Note Check that the pump casing shows no sign of cracking or

water leakage; replace the water pump assembly if it does.
60631 Figure 416
543250 Thermostat
Water circulating in the engine
60747 Figure 417
Water leaking from the thermostat
60748 Figure 418

682 ‒ Engine
F3B ENGINE 295
TURBOCHARGING
Check that the thermostat works properly, replace it if there is any doubt.
Thermostat technical data

Technical data
Start of stroke temperature 84 ±2 ℃
Minimum stroke temperature (15 mm) 94 ±2 ℃
5424 TURBOCHARGING
The turbocharging system is composed of:
● an air filter;
● a WG turbocharger;
● an "intercooler" radiator.
Turbocharging diagram
204942 Figure 419

A Engine exhaust gas C Compressed air (hot)
B Intake air D Compressed air cooled

682 ‒ Engine
296 F3B ENGINE
TURBOCHARGING
542410 HOLSET HE 551 W turbocharger
205031a Figure 420

The turbocharger is fitted with pressure relief valve.
Essentially it consists of:
● a central body in which a shaft is housed, supported by bushings, the ends of which are connected to: the turbine rotor and
the compressor rotor;
● a turbine casing and a compressor casing mounted on the end of the central body;
● a pressure limiter valve fitted on the turbine casing. This valve has to choke the exhaust gas outlet, by conveying part of the gas
directly into the exhaust pipe, when the boosting pressure downstream the compressor reaches the calibration value.

682 ‒ Engine
F3B ENGINE 297
ENGINE BRAKE DEVICE CEB (Combined Engine Brake)
5437 ENGINE BRAKE DEVICE CEB (Combined Engine Brake)

In engines with fixed a geometry turbine and wastegate, to improve
the performance of the decompression exhaust brake Iveco Turbo
Brake (ITB), the CEB (Combined Engine Brake) has also been added.
For this reason, there is a butterfly valve operated by a pneumatic
cylinder in the engine exhaust manifold.
When the driver activates the engine brake, the throttle valve actu-
ates, blocking the exhaust gas outlet.
The exhaust gas thus returns to the cylinder where it provides resist-
ance to the up stroke of the piston.
This resistance extends throughout the entire kinematic chain, apply-
ing a braking effect on the driving wheels.
125814 Figure 421
GENERAL CHARACTERISTICS
F3B
type
F3BEE681A F3BEE681B
Diesel 4-stroke
Cycle
Power Supply Turbocharged with aftercooler
Injection
Direct
Bore mm 135
Stroke mm 150
Compression ratio 16.5 : 1
kW 353 316
(HP) (480) (430)
Max. power
rpm 1900 1900
Nm 2100 2200
(kgm) (214) (224)
Maximum torque
rpm 1100 1100

682 ‒ Engine
298 F3B ENGINE
GENERAL CHARACTERISTICS
F3B
type
F3BEE681A F3BEE681B
Idle speed with no load rpm 550 ± 50
Maximum engine idle speed rpm 2320 ± 50
TIMING
start before T.D.C. −
end after B.D.C. −
start before B.D.C. −
End after T.D.C. −
For timing check
mm −
X
mm −
Of operation
mm 0.40 ± 0.05
X
mm 0.60 ± 0.05
High pressure fuel supply system managed by
BOSCH. It consists of a CPN 2.2 high-pressure
POWER SUPPLY pump, electro-injectors, hydraulic accumulator
(rail), EDC17 ECU, temperature and pressure
sensors.
Injection
–
Bosch
Electro-injectors type CRIN 2
Firing order 1-4-2-6-3-5
Varying injection pressure bar bar 1800
TURBOCHARGING
Turbocharger type: HE 551 W with fixed geometry and Wastegate
Forced by gear pump, pressure relief valve, oil

LUBRICATION
filter

682 ‒ Engine
F3B ENGINE 299
F3B
type
F3BEE681A F3BEE681B
Oil pressure with hot engine (100 °C ± 5 °C):

at idle speed bar 1.5
at max speed bar 4.5 - 5
COOLING By means of centrifugal pump, thermostat for
adjustment, fan with viscostatic coupling, radiator,
heat exchanger.
Water pump control: Belt driven
Thermostat: No. 1
opening start: 84°C ± 2°C
maximum opening: 94°C ± 2°C
FILLINGS:
Litres –
kg –
Capacity: Litres –
engine sump min level kg –
Litres –
engine sump max level
kg –
quantity in circulation that does not flow back to the en- Litres –
gine sump kg –
quantity contained in the cartridge filter (to be added to Litres 2.5
the cartridge filter spare part) kg 2.3
F3B
Type
mm
CYLINDER ASSEMBLY AND CRANK GEARS
Cylinder liner housing:
upper –
Ø1
lower –
Cylinder liners:
outer diameter:
upper 153.461 - 153.486
Ø2
lower 151.890 - 151.915
length L 252.2
Cylinder liners - crankcase seat
upper –
lower –
outer diameter Ø2 −

682 ‒ Engine
300 F3B ENGINE
F3B
Type
mm
Cylinder liners:
inner diameter Ø3 135.000 - 135.020
Protrusion X** 0.045 – 0.075
** With a load of 8,000 kg

Pistons:
measuring point X 52
Ø1A* 134.859 ÷ 134.873
outer diameter Ø 1
Ø1B* 134.872 ÷ 134.884
pin housing Ø2 54.010 ÷ 54.018
A* 0.027 ÷ 0.165
Piston - cylinder liners
B* 0.016 ÷ 0.052
* Selection class
Piston diameter Ø1 −
Piston protrusion X –
Piston pin Ø3 53.994 ÷ 54.000
Piston pin - pin seat 0.010 ÷ 0.024
X1* 2.478 ÷ 2.502

Piston ring slots X2 2.560 ÷ 2.580
X3 4.020 ÷ 4.040
* measured on Ø of 130 mm
Piston rings:
trapezoidal sealing S1* 2.296 – 2.340
bevelled S2 2.470 - 2.500
milled scraper ring with slots and internal spring S3 3.970 - 3.990
* measured at 2.5 mm from Ø at the outside
1 0.138 ÷ 0.206
Piston rings - slots 2 0.060 - 0.110
3 0.030 - 0.070
Piston rings −
Piston ring end gap in cylinder liner:
X1 0.40 ÷ 0.50
X2 0.65 – 0.80

682 ‒ Engine
F3B ENGINE 301
F3B
Type
mm
X3 0.40 – 0.75
Small end bushing seat Ø1 59.000 ÷ 59.030

Connecting rod bearing seat Ø2 94.000 ÷ 94.030
1 94.000 ÷ 94.010
Classes 2 94.011 ÷ 94.020
3 94.021 ÷ 94.030
Bushing diameter at connecting rod small end
external Ø4 59.085 ÷ 59.110
internal Ø3 54.019 ÷ 54.035
Connecting rod half-bearings (S) thickness
Red colour 1.965 ÷ 1.975
Green colour 1.976 ÷ 1.985
Yellow colour* 1.986 ÷ 1.995
* Fitted in production only and not supplied as spares.
Bush at connecting rod small end - housing 0.055 ÷ 0.110
Piston pin - bushing 0.019 ÷ 0.041
Connecting rod half-bearings –
Connecting rod weight

A g 4741 ÷ 4780
Class B g 4781 ÷ 4820
C g 4821 ÷ 4860
Measuring point X 125
Maximum error in parallelism of connecting rod

⁄⁄ 0.08
axes
Main journals Ø1 nominal value 99.970 – 100.000

1 99.970 – 99.979
Selection class 2 99.980 – 99.989
3 99.990 – 100.000
Crankpins Ø2 nominal value 89.970 ÷ 89.000
1 89.970 ÷ 89.979
Selection class 2 89.980 ÷ 89.989
3 89.990 ÷ 90.000
Main half-bearings S1
Red colour 3.110 – 3.120
Green colour 3.121 – 3.130

682 ‒ Engine
302 F3B ENGINE
F3B
Type
mm
Yellow colour* 3.131 – 3.140
Connecting rod half-bearings S2
Red colour 1.965 ÷ 1.975
Green colour 1.976 ÷ 1.985
Yellow colour* 1.986 ÷ 1.995
* The yellow half bearing is mounted only during production
Main bearings Ø3 106.300 - 106.330
Main journals - half-bearings 0.060 - 0.108

Crankpins half-bearing 0.060 - 0.108
Main half-bearings –
Connecting rod half-bearings –
Thrust main journal X1 47.95 - 48.00
Thrust main bearing X2 40.94 - 40.99
Half thrust washers (thickness) X3 3.38 - 3.43
Crankshaft thrust 0.10 - 0.30
Alignment 1-2 –
Centring 1-2 –
CYLINDER HEAD - TIMING SYSTEM
Valve guide housing on cylinder head Ø1 15.980 - 15.997

682 ‒ Engine
F3B ENGINE 303
F3B
Type
mm
Ø2 10.015 - 10.030
Valve guides
Ø3 16.012 - 16.025
Valve guides and seats on the head 0.015 - 0.045
Valve guides –
Valves:
Ø4 9.960 - 9.975
α 60° 30' ± 7' 30''
Ø4 9.960 - 9.975
α 60° +30' ± 7' 30''
Valve stem and related guide 0.040 – 0.070
Housing on head for valve seat:
Ø1 49.185 - 49.220
Ø1 46.985 - 47.020
Outside diameter of valve seats: valve housing inclination on cylinder head:
Ø2 49.260 - 49.275
Ø2 47.060 - 47.075
Valve seats 0.2
X 0.54- 0.86
Recessing
X 1.65- 1.95
Between valve seat and cylinder head 0.040 – 0.090
Valve spring height:

free spring H 76
under a load of:
660 ± 33 N H1 59
1140 ± 57 N H2 46

682 ‒ Engine
304 F3B ENGINE
F3B
Type
mm
Camshaft bush housing fitted in the cylinder head:

Ø 88.000- 88.030
1⇒7
Camshaft journals: 1 ⇒ 7 Ø 82.950 – 82.968
Camshaft bushing outer diameter: Ø 88.153 – 88.183
Bushing inner diameter Ø 83.018 – 83.085
Bushings and seats in cylinder head 0.123 - 0.183
Bushings and supporting pins 0.050 – 0.135
Useful cam height:

9.231
9.5607
Rocker-arm shaft Ø1 41.984 – 42.000
mm
Internal rocker arm diameter:
42.045 – 42.061
59.000 – 59.019
Rocker arm bush outer diameter:
–
59.070 – 59.110
Rocker arm bush inner diameter:
–
56.045 – 56.064
Bushes and housings:
–
0.051 – 0.110
Rocker arm bushes and shaft:

0.045 - 0.077

682 ‒ Engine
F3B ENGINE 305
TIGHTENING TORQUES
F3B
Type
mm
Engine brake control lever

Eccentric pin outer diameter Ø2 55.981 – 56.000
Rocker shaft seat Ø1 42.025 – 42.041
Rocker arms and engine brake control lever pin 0.045 – 0.083
Rocker arm shaft and seat on engine brake con-

0.025 – 0.057
trol lever
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
First step: pre-tightening 160 16
M18 fixing screws to secure the
Second step: Angle tightening M18 90 °
lower crankcase to the crankcase.
Third step: Angle tightening 60°
M12 fixing screws to secure the lower crankcase First step: pre-tightening 30 3
to the crankcase. Second step: Angle tightening 60°
Piston cooling nozzle fixing screw 45 ÷ 55 4.5 ÷ 5.5
Oil exchanger fastening screws 22 ÷ 27 2.2 ÷ 2.7
Oil tank bracket fixing screws 40 ÷ 49 4 ÷ 4.9
Rocker arm adjusting nut 34 - 44 3.4 ÷ 4.4
Rocker arm cover fastening screws 9 ÷ 11 0.9 ÷ 1.1
First step: pre-tightening 75 7.5
Second step: pre-tightening 150 15
Cylinder head fixing screws
Third step: Angle tightening 90 °
Fourth step: Angle tightening 90 °
First step: pre-tightening 16 ÷ 20 1.6 ÷ 2
Flywheel housing cover fastening screws
Second step: tightening 56 - 70 5.6 - 7
Securing the engine hook 90 ÷ 110 9 ÷ 11
Fixing screw for adjusting rod of idle transfer gear play 18 ÷ 22 1.8 ÷ 2.2
Screws fixing the oil pump 22 ÷ 27 2.2 ÷ 2.7
Suction strainer retaining screws 22 ÷ 27 2.2 ÷ 2.7
Screws fastening oil pressure regulating valve 21 ÷ 26 2.1 ÷ 2.6
Oil filter mount fixing screws 21 ÷ 26 2.1 ÷ 2.6
Rocker arms to cylinder head fixing screws
Second step: Angle tightening 90 °
Engine mount fastening screws
Second step: Angle tightening 45°
Screws fixing camshaft
Crankshaft front cover fixing screws 22 ÷ 27 2.2 ÷ 2.7
Exhaust manifold fixing screws First step: pre-tightening 35 ÷ 45 3.5 ÷ 4.5

682 ‒ Engine
306 F3B ENGINE
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
Exhaust manifold fixing screws Second step: tightening 65 ÷ 75 6.5 - 7.5
Water cooling pipe coupling on compressor 40 ÷ 46 4 ÷ 4.6
Compressor cooling water coupling 40 ÷ 46 4 ÷ 4.6
High-pressure fuel pipe couplings from pump to cylinder heads 40 ÷ 44 4 ÷ 4.4
Connecting rod cap retaining screws
Flywheel retaining screws
Securing the first middle gear
Securing the second middle gear
Control unit bracket to crankcase fixing screws 21 ÷ 27 2.1 - 2.7
Control unit to bracket fixing screws 9 ÷ 11 0.9 ÷ 1.1
Screws securing water pump 22 ÷ 27 2.2 ÷ 2.7
Thermostat body fixing screws 22 ÷ 27 2.2 ÷ 2.7
Fastening the water intake pipe 21 ÷ 27 2.1 - 2.7
Securing the steady tensioner 100 - 110 10 ÷ 11
Fan mount fastening screws 95 ÷ 105 9.5 ÷ 10.5
Screws securing starter motor 66 - 82 6.6 - 8.2
AC compressor to bracket fixing screws 22 ÷ 27 2.2 ÷ 2.7
High-pressure fuel pump retaining screws 35 - 40 3.5 - 4
Nut for fastening high pressure fuel pump gear 235 - 265 23.5 - 26.5
Alternator fixing screws 40 ÷ 48 4 ÷ 4.8
Alternator top and bottom brackets fixing screws 22 ÷ 27 2.2 ÷ 2.7
Fixing screws for compressor outlet pipe connector for cylinder heads 32 - 37 3.2 - 3.7
Compressor supply pipe retaining screws 50 ÷ 60 5÷6
Power take-off fixing screws 66 - 82 6.6 - 8.2
70 ± 5 7 - 0.5
Screws fixing crankshaft pulley
50 °
70 ± 5 7 - 0.5
Screws fixing damper to drive shaft
50 °
Screw fixing the automatic belt tensioner 45 ÷ 55 4.5 ÷ 5.5
Fuel filter fastener 22 ÷ 27 2.2 ÷ 2.7
Turbine oil delivery pipe to crankcase vent 40 ÷ 46 4 ÷ 4.6
Oil supply to turbine pipe coupling 21 ÷ 27 2.1 - 2.7
Screws fixing the oil delivery pipe to the turbine 40 ÷ 46 4 ÷ 4.6
Oil return pipe from turbine couplings. 21 ÷ 27 2.1 - 2.7
Compressor fixing nuts 74 - 80 7.4 - 8
Fastening the fuel supply pipe terminal 9 ÷ 11 0.9 ÷ 1.1
Filter to pump fuel pipe coupling 40 ÷ 46 4 ÷ 4.6
High-pressure fuel pump on crankcase lubrication pipe coupling 45 4.5

682 ‒ Engine
F3B ENGINE 307
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
High-pressure fuel pump on crankcase to pump lubrication pipe coupling 25 2.5
Fuel coupling between fuel filter and fuel pump. 34 ÷ 40 3.4 ÷ 4
M8 22 ÷ 27 2.2 ÷ 2.7
Screws fastening fuel pump support to cylinder head M10 42 - 48 4.2 - 4.8
M12 60 - 66 6 - 6.6
Fuel return pipe coupling from the high-pressure pump to the cylinder head return connector. 34 ÷ 40 3.4 ÷ 4
Screw for fuel return pipe fastener terminal 21 ÷ 27 2.1 - 2.7
Air to compressor intake/delivery couplings 85 ÷ 95 8.5 ÷ 9.5
High-pressure fuel pipe couplings between filter and HP pump 21 ÷ 27 2.1 - 2.7
Camshaft on cylinder head shoulder plate 21 ÷ 27 2.1 - 2.7
Relay to cylinder mounting bracket fixing screws 21 ÷ 27 2.1 - 2.7
Fastening fuel temperature sensor 27 ÷ 33 2.7 ÷ 3.3
Air to cylinder head intake manifold fixing screws 45 ÷ 55 4.5 ÷ 5.5
Intake air temperature pressure sensor fixing screws 7 – 10 0.7 ÷ 1
Securing the oil dipstick pipe 45 ÷ 55 4.5 ÷ 5.5
Retaining screws for ignition button bracket 21 ÷ 27 2.1 - 2.7
Screws fastening the intercooler air intake pipe 21 ÷ 27 2.1 - 2.7
Electrical connection on heater fixing screws 21 ÷ 27 2.1 - 2.7
Electric connection on starter motor nut 9 ÷ 11 0.9 ÷ 1.1
Securing the oil pressure sensor 8 ÷ 10 0.8 ÷ 1
Flywheel cover plate retaining screws 17 ÷ 25 1.7 ÷ 2.5
Fixing screws for fuel inlet ducts into cylinder head 20 ÷ 25 2 ÷ 2.5
Rail fuel supply pipe support fixing screw 9 ÷ 11 0.9 ÷ 1.1
Cylinder head side rail fuel supply pipes couplings 40 ÷ 44 4 ÷ 4.4
Head camshaft front cover fixing screws 35 ÷ 50 3.5 ÷ 5
Engine breather valve fixing screws 6÷8 0.6 ÷ 0.8
Steering oil tank fastening screws 18 ÷ 22 1.8 ÷ 2.2
Engine breather pipe fixing screws 21 ÷ 27 2.1 - 2.7
Screws fastening collars on exhaust manifold 11 ÷ 12 1.1 ÷ 1.2
Exhaust manifold to cylinder head fixing screws 55 ÷ 65 5.5 ÷ 6.5
Turbocharger captive fixing screws 55 ÷ 65 5.5 ÷ 6.5
Common rail to cylinder head fixing screws 21 ÷ 27 2.1 - 2.7
Screws fastening HP fuel pipe support to cylinder head inlet 18 ÷ 24 1.8 ÷ 2.4
Injector to cylinder head bracket fixing screws 18 ÷ 24 1.8 ÷ 2.4
Engine brake cylinders to cylinder head fixing screws 22 ÷ 27 2.2 ÷ 2.7
Fixing screws for HP pump to gearbox support flange 22 ÷ 27 2.2 ÷ 2.7
Fixing screws of camshaft rear cover for cylinder head 18 ÷ 22 1.8 ÷ 2.2
Rail supply high pressure fuel pipes couplings 40 ÷ 46 4 ÷ 4.6
Fuel return coupling from the rail to cylinder head. 33 ÷ 37 3.3 ÷ 3.7
High-pressure fuel pipe couplings (injector side) 33 ÷ 37 3.3 ÷ 3.7
High-pressure fuel pipe couplings (rail side) 38 ÷ 42 3.8 ÷ 4.2
Coupling for oil pipe to engine brake cylinder no. 6 40 ÷ 46 4 ÷ 4.6

682 ‒ Engine
308 F3B ENGINE
Diagrams of tightening sequence of main engine components
TORQUE
DETAIL
Nm ° kgm
Oil pipe to engine brake cylinder pipe coupling 29 ÷ 35 2.9 ÷ 3.5
Engine brake solenoid valve 29 ÷ 35 2.9 ÷ 3.5
Engine wiring to cylinder head fixing screws 7 – 10 0.7 ÷ 1
Blow-by filter fixing screws 7 – 10 0.7 ÷ 1
Fixing screws for injector wiring connection to cylinder heads 7 – 10 0.7 ÷ 1
Securing the flywheel speed sensor 6 ÷ 10 0.6 ÷ 1
Cooling circuit breather pipe on cylinder head 18 ÷ 22 1.8 ÷ 2.2
Gear casing cover fixing screws 9 ÷ 11 0.9 ÷ 1.1
Screws fixing additional power steering pump to the compressor 42 - 51 4.2 - 5.1
Auxiliary pump plate fastening screws 40 - 48 4 - 4.8
540110 Diagrams of tightening sequence of main engine components

Diagram of tightening sequence of screws securing lower crankcase to crankcase
60593 Figure 422

First step:
Tightening torque
inner screws pre-tightening 160 N⋅m
Second step:
Technical data
Inner screws angle tightening 90°
Third step:
Technical data
Inner screws angle tightening 60°

682 ‒ Engine
F3B ENGINE 309
60592 Figure 423

Fourth step:
Tightening torque
Outer screws preliminary tightening 30 N⋅m
60594 Figure 424

Fifth step:
Technical data
outer screws angle tightening 60°
Cylinder head fastening screw tightening diagram
60580 Figure 425

682 ‒ Engine
310 F3B ENGINE
Diagram of tightening sequence for exhaust manifold fastening screws
218302 Figure 426
Pre-tightening: 35 - 45 Nm
Tightening: 65 - 75 Nm
Diagram of tightening sequence for heat exchanger fixing screws
218301 Figure 427
Tightening: 22 ÷ 27 Nm
Diagram of tightening sequence for rocker arm cover fixing screws
117545 Figure 428

Step 1: screw until contact in sequence and then according to the diagram.

682 ‒ Engine
F3B ENGINE 311
Tightening torque
Rocker arm cover fastening screws Tightening sequence: 1 - 10 - 20 - 21 - 9
9 N⋅m to11 N⋅m
Scheme of the tightening order of rocker arms shafts fastening screws
218305 Figure 429
Tightening torque
Rocker arm shaft fastening screws 1. Step 1
80 N⋅m
2. Step 2
90°

682 ‒ Engine
312 F3B ENGINE
Diagram of tightening sequence for thermostat cover fastening screws
218304 Figure 430
Tightening torque
Thermostat fastening screws 1. Step 1
Tightening sequence: 1 - 2 - 3 - 4 -5 - 6 - 7
22 N⋅m to27 N⋅m
2. Step 2
Tightening sequence: 8 - 9 - 10 - 11- 12 - 13 - 14
22 N⋅m to27 N⋅m

682 ‒ Engine
F3B ENGINE 313
TOOLS
Diagram of tightening sequence for intake manifold fastening screws
218303 Figure 431
Tightening torque
Screws fixing intake manifold 1. Step 1
Tightening sequence: 1 - 2 - 3 - 4 - 5 - 6
45 N⋅m to55 N⋅m
2. Step 2
Tightening sequence: 1 - 5 - 3 - 4 - 6 - 2
45 N⋅m to55 N⋅m
TOOLS

682 ‒ Engine
314 F3B ENGINE
TOOLS
Dual-actuated bridge (99341001)
Bracket torque (99341009)

682 ‒ Engine
F3B ENGINE 315
TOOLS
Socket wrench for idle gear support fastening screws (99350072)
Tool to remove oil filter (engine) (99360091)

682 ‒ Engine
316 F3B ENGINE
TOOLS
Tool to remove and refit engine valves (to be used with special plates) (99360259)
Tool for engine valves removal and refitting (use with 99360259) (99360263)
Tool for valve guide refitting (use with 99360143) (99360296)
Spacer (to be used with 99360321) (99360325)

682 ‒ Engine
F3B ENGINE 317
TOOLS
(99360334)
Spacer (to be used with 99360334) (99360336)
Tool for cylinder liners compression (use with 99360334 -99360336) (99360338)

682 ‒ Engine
318 F3B ENGINE
TOOLS

682 ‒ Engine
F3B ENGINE 319
TOOLS

682 ‒ Engine
320 F3B ENGINE
TOOLS
Torque wrench (20-120 Nm) with 1/2" square head (99389813)
Coupling torque wrench 9X12 (5-60 Nm) (99389829)

682 ‒ Engine
F3B ENGINE 321
TOOLS

682 ‒ Engine
322 F3B ENGINE
TOOLS
(99395225)
(99395229)
Dial gauge (0-5 mm) (99395603)
Dial gauge (0-30 mm) (99395606)
Centring ring of crankshaft front gasket cover (99396035)

682 ‒ Engine
F3B ENGINE 323
.540110. ENGINE DISASSEMBLING
Work material
daNm)
Dual-actuated bridge 99341001
Bracket torque 99341009
Tool for retaining the flywheel 99360351
Socket threaded wrench
Metal ropes
Main action
1. Before fitting the engine on the specific rotating stand, remove the parts which could hinder installation of the brackets.
2. Disconnect the engine cable from the electrical components and remove it from the engine.
3. Fasten the engine to the specified rotating stand by means of dedicated brackets (1).
.543910. Air conditioning compressor belt removal

4. Cut the belt (1) and remove it from the drive pulley.
221477 Figure 432

682 ‒ Engine
324 F3B ENGINE
.553239. Air conditioning compressor removal

5. Remove the air-conditioner (1) together with the engine
mounting.
221478 Figure 433
.543075. Oil pressure adjustment valve removal

6. Remove the oil pressure adjustment valve (1).
60486 Figure 434
.543420. Disassembly of the fan

7. Remove the fan (1) from the electromagnetic connector.
221475 Figure 435

682 ‒ Engine
F3B ENGINE 325
.540860. Damper flywheel removal

8. Lock the flywheel using the specified tool (1).
code
71702 Figure 436
9. Remove the damper flywheel (2) turning the screws (1).
221481 Figure 437

682 ‒ Engine
326 F3B ENGINE
.543411. Coolant pump alternator drive belt disassembly

10. Using a suitable tool work on the automatic belt tensioner (1)
and remove the auxiliary device drive belt(2).
221479 Figure 438
.760310. Alternator removal

11. Remove the screws (1) and remove the alternator (2).
221480 Figure 439

682 ‒ Engine
F3B ENGINE 327
.543210. Water pump removal

12. Remove the automatic belt tensioner (1), unscrew the screws
(2) and remove the pulley (3), remove the water pump (4),
unscrew the screws (5) and remove the pulley(6).
221482 Figure 440
.543251. Thermostat case removal

13. Unscrew the screws (1) and remove the thermostat assembly
(2).
221513 Figure 441
.540442. Crankshaft front gasket removal

14. Apply a suitable puller (2) and remove the crankshaft sealing
gasket (1); remove the flange (3).
60490 Figure 442

682 ‒ Engine
328 F3B ENGINE
.542410. Turbocharger removal

15. Remove the oil delivery pipe (1) and the oil return pipe (2)
from the turbocharger.
16. Remove the air pipe (3) from turbocharger to intercooler.
221471 Figure 443
17. Unscrew the fastening screws (1) and remove the turbochar-
ger (2) together with the exhaust manifold (3).
221472 Figure 444
.540720. Exhaust manifold removal

18. Unscrew the screws and the fixing nuts . Separate the exhaust
manifold (3) from the turbocharger (2).
221472 Figure 445

682 ‒ Engine
F3B ENGINE 329
.543070. Oil filter removal

19. Unscrew and remove the oil filter (2).
20. Remove the oil filter support (1).
221473 Figure 446
.543110. Heat exchanger removal

21. Unscrew the screws (1) and remove the heat exchanger (2).
221474 Figure 447

682 ‒ Engine
330 F3B ENGINE
.760810. Starter motor disassembly

22. Remove the starter motor (1) by unscrewing the relative
screws.
221489 Figure 448
.540710. Intake manifold removal

23. Unscrew the screws (1) and remove the intake manifold (2),
together with the resistor for engine preheating, remove the
mount of the engine start and stop pushbuttons (3).
221487 Figure 449
.766161. Engine control unit removal

24. Unscrew the screws (1) and remove the engine control unit
(2).
221488 Figure 450

682 ‒ Engine
F3B ENGINE 331
.540480. Blow-by case removal

25. Unscrew the screws (1) and remove the blow-by case (2).
221483 Figure 451
.540486. Blow-by filter removal

26. Unscrew the screws (1) and remove the blow-by filter (2).
221484 Figure 452
.540452. Timing gear cover disassembly

27. Unscrew the screws (1) and remove the timing cover (2).
221485 Figure 453

682 ‒ Engine
332 F3B ENGINE
.540630. Removing the head cover

28. Unscrew the fastening screws (2) and remove the head cover
(1).
221486 Figure 454
.542011. Fuel filter removal

29. Disconnect the electrical connections (3).
30. Disconnect the pipes (1) from the high-pressure pump.
31. Remove the fuel filter (4) together with the mount (2).
221476 Figure 455
.773010. High pressure pump removal

32. Unscrew the nut (1).
221490 Figure 456

682 ‒ Engine
F3B ENGINE 333
33. Using the specified tool (1), remove the high pressure pump
control gear (2).
code
Dual-actuated bridge 99341001
221491 Figure 457
34. Disconnect pipes (1, 2).

35. Unscrew the screws (3) and remove the high pressure pump
(4).
221492 Figure 458
36. Unscrew the fastening screws (1) and remove the flange (2)
supporting the high pressure pump.
160624 Figure 459

682 ‒ Engine
334 F3B ENGINE
37. Unscrew the screws (2) and remove the gear (1) together
with the phonic wheel.
221493 Figure 460
38. Unscrew the screws (2) and remove the shoulder plate (1) and
the sheet gasket.
221494 Figure 461
39. Unscrew the screws (2) and remove the idle gear (1).
221495 Figure 462

682 ‒ Engine
F3B ENGINE 335
.540850. Engine flywheel removal

40. Using the specified tool to lock the mounted flywheel (1), un-
screw the fastening screws (2); then remove the tool (1) and
remove the flywheel (3).
code
221496 Figure 463
.540462. Crankshaft rear gasket removal

41. Take off the gasket (1).
221497 Figure 464

682 ‒ Engine
336 F3B ENGINE
.540463. Flywheel case removal

42. Unscrew the screws (1) and remove the flywheel case (2).
221498 Figure 465
.543010. Disassembling the oil pump

43. Remove the screws (1) and disassemble the double gear (2).
221499 Figure 466

682 ‒ Engine
F3B ENGINE 337
44. Unscrew the fastening screw (1) and remove the link rod (2).
221500 Figure 467
45. Unscrew the fastening screws (1) and remove the oil pump
(2).
221501 Figure 468
.541230. Rocker arm shaft removal

47. Unscrew the screw(1) fixing the rocker arm shaft.
221502 Figure 469

682 ‒ Engine
338 F3B ENGINE
48. Use the specified tool (1) on the rocker arm shaft (2) and
remove the shaft (2) from the cylinder head. Remove the guide
braces (3) from the cylinder head.
code
221503 Figure 470
.774510. Rail removal
221504 Figure 471

49. Unscrew the fittings and remove the high pressure fuel supply pipes (8).
50. Unscrew the fittings from the rail and the injectors and detach the high pressure fuel pipes (1, 2, 3, 4, 5 ) and (6) the fuel
return pipe (7) from the head.
Note The high pressure fuel pipes must be replaced at each disassembly.
51. Disconnect the electrical connection from the pressure sensor (11).
52. Unscrew the fastening screws (9) and remove the rail (10).

682 ‒ Engine
F3B ENGINE 339
.775010. Injector removal

53. Disconnect the electrical connections (1) from the electro-
injectors.
221505 Figure 472
221506 Figure 473

54. Disconnect the oil pipe (1) from the engine brake cylinders and the solenoid valve by unscrewing the fittings (2) and (3).

682 ‒ Engine
340 F3B ENGINE
55. Remove the screws (1) from the injector securing (2) brackets.
169827 Figure 474
56. Position the specified tool (1) extract the injectors from the
head.
code
221507 Figure 475
57. Install the appropriate plugs in the place of the injectors (1).
221510 Figure 476

682 ‒ Engine
F3B ENGINE 341
58. Unscrew the screws (1) and remove the engine brake cylinders
(2).
221508 Figure 477
59. Unscrew the screws (1) and remove the engine brake solenoid
valve (2).
221509 Figure 478
.541210. Camshaft removal

60. Extract the camshaft (1).
221511 Figure 479

682 ‒ Engine
342 F3B ENGINE
.540610. Cylinder head removal

61. Unscrew the cylinder head fastening screws (1).
Note The cylinder head fastening screws are to be replaced
each time you remove them.
221512 Figure 480
62. Using metal ropes, lift the cylinder head (1).

Tool / Material
Metal ropes
63. Take off the gasket (2).
60515 Figure 481
.540430. Oil sump removal

60516 Figure 482

682 ‒ Engine
F3B ENGINE 343
.543060. Suction strainer removal

65. Slacken the screws and remove the suction strainer (1).
60517 Figure 483
.540830. Connecting rod removal

66. Turn the crankcase (1) into vertical position.
47574 Figure 484
67. Unscrew the screws (2) fixing the connecting rod cap (3) and
remove it.
Note Keep the big-end half-bearings in their respective hous-
ings and/or note down their assembly position since, if
reusing them, they will need to be fitted in the position
found upon removal.
60518 Figure 485

682 ‒ Engine
344 F3B ENGINE
.540830. Axis alignment check

68. Check the parallelism of the connecting rod axis (1) using a
suitable device (5) proceed as follows.
69. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
70. Set the spindle on the «V» prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 486
.540416. Lower crankcase removal

71. Using an appropriate wrench and the socket threaded wrench
unscrew the screws (1) and (2) and take off the lower crank-
case .
Tool / Material
Socket threaded wrench
Note Note down the assembly position of the top and bot-
tom main half-bearings since, if reusing them, they will
need to be fitted in the position found upon removal.
60519 Figure 487

682 ‒ Engine
F3B ENGINE 345
CRANKCASE CHECKS
.540810. Crankshaft removal

72. Using the specified tool (1), remove the crankshaft (2).
code
47570 Figure 488
.540816. Main bearings removal

73. Disassemble the main half-bearings(1).
47571 Figure 489
.540414. Oil sprayer removal

74. Unscrew the screws and remove the oil sprayers (2).
75. Remove the cylinder liners as described in the related paragraph.
Note Once the engine disassembly is complete, clean accurately the removed parts and check their integrity.
The following pages give instructions for checks and main measurements to do as to determine whether the parts can
be reused.
.540410. CRANKCASE CHECKS
Consumables
LOCTITE 270
Work material
Bore gauge

682 ‒ Engine
346 F3B ENGINE
CRANKCASE CHECKS
Ring gauge
Centesimal dial gauge
Main action
1. After disassembling the engine, thoroughly clean the cylinder-
crankcase assembly.
2. Check thoroughly that no cracks are to be noticed on the
crankcase.
3. Check the condition of casting hole plugs.
Note If the caps are rusted, or if there is any doubt about the
efficiency of the seal, replace them.
4. When assembling plugs, apply the recommended sealant on
them.
Tool / Material
LOCTITE 270
5. In order to check the inner diameter of cylinder liners and 34994 Figure 490
identify the degree of ovalisation, taper and wear, use bore
meter (2) fitted with a centesimal dial gauge (1) previously re-
set (3) on the 135 mm ring gauge.
Tool / Material
Bore gauge
Ring gauge
Note If the 135 mm ring gauge is not available, use a micro-

meter.
6. Measurements should be carried out on each cylinder liner at

three different heights and on two perpendicular plane levels
(A-B) as illustrated in figure.
60596 Figure 491

1 1st measurement 3 3rd measurement
2 2nd measurement

682 ‒ Engine
F3B ENGINE 347
CRANKCASE CHECKS
7. When wear is over 0.150 mm or maximum ovalisation is 0.100

mm compared to the values shown in the figure, replace the
cylinder liner since it is not possible to adjust, lap or dress it.
Note Cylinder liners are equipped with spare parts belonging
to selection class «A».
60595 Figure 492

A Selection class Ø B Selection class Ø
135.000 ÷ 135.013 135.011 ÷ 135.024
mm mm
Y Selection class marking
area
8. The illustrated diagram refers to the cylinder liner outer diamet-

ers and their housing inner diameters.
9. Cylinder liners can be removed and fitted several times into
different seats, if needed.
60597 Figure 493

A Ø 153.500 ÷ 153.525 C Ø 153.461 ÷ 153.486
mm mm
B Ø 152.000 ÷ 152.025 D Ø 151.890 ÷ 151.915
mm mm

682 ‒ Engine
348 F3B ENGINE
CRANKCASE CHECKS
60598 Figure 494

10. CRANKCASE ASSEMBLY WITH CYLINDER LINERS.
108832 Figure 495

Cylinder liner main data
* Selection class A 135.000 ÷ 135.013 mm * Selection class B 135.011 ÷ 135.024 mm
11. CYLINDER LINER MAIN DATA.

682 ‒ Engine
F3B ENGINE 349
CRANKCASE CHECKS
108833 Figure 496

Y Selection class marking area
12. DETAIL "X".
.540420. Cylinder liners Removal
Work material
Main action
1. Position the parts (2) and the plate (4) as shown in the figure,
checking that the plate (4) rests on the cylinder liner correctly.
code
from the crankcase.
47577 Figure 497

682 ‒ Engine
350 F3B ENGINE
CRANKCASE CHECKS
.540420. Cylinder liner refitting and protrusion check
Work material
99395603)
Dial gauge (0-5 mm) 99395603
Tightening torques
Protrusion checking tool screw 225 N⋅m
Technical data
Cylinder liner protrusion compared to the cylinder head supporting surface 0.045 mm to0.075 mm
Main action
1. Always replace water sealing rings (3, 4, 5).
2. Install the adjustment ring (1) on the cylinder liner (2); lubricate
the lower part of the liner and install it in the cylinder unit using
the proper tool.
0.12 mm - 0.14 mm.
16798 Figure 498

682 ‒ Engine
F3B ENGINE 351
CRANKCASE CHECKS
3. Check the protrusion of the cylinder liners using the specified

tool (2) with spacers and tighten the screw (1) to the specified
torque.
Tightening torque
Protrusion checking tool screw 225 N⋅m

code
60520A Figure 499
4. Using the dial gauge provided with dial gauge stand (3), meas- 0,045 ÷ 0,075
ure the cylinder liner protrusion compared to the cylinder head
supporting surface, which must be the value indicated in the fig-
ure. Otherwise, replace the adjusting ring (1), supplied as spare
part in different thicknesses.
Technical data
Cylinder liner protrusion compared to the 0.045 mm to0.075 mm
cylinder head supporting surface

code
Dial gauge (0-5 mm) 99395603
99395603)
60520B Figure 500
5. Once assembly is complete, block the cylinder liners (1) on the

crankcase (2) with stud bolts (3).
code
60521 Figure 501

682 ‒ Engine
352 F3B ENGINE
CRANKCASE CHECKS
.540810. Crankshaft measurements
0
0
129684 Figure 502

682 ‒ Engine
F3B ENGINE 353
CRANKCASE CHECKS
Main action
1. Check the condition of the crankshaft main journals; there
must no be signs of scoring, ovalisation or excessive wear. The
values shown refer to pin regular diameter.
108834 Figure 503

X Main journal union
detail
2. Check the condition of the crankshaft crankpins; there must no

be signs of scoring, ovalisation or excessive wear. The values
shown refer to pin regular diameter.
108835 Figure 504

Y Crankpin union detail

682 ‒ Engine
354 F3B ENGINE
CRANKCASE CHECKS
.540811. Measuring main journals
Work material
Micrometer
Main action
Tool / Material
Micrometer
47535 Figure 505

main journals and crankpins union shown in X and Y Crank-
shaft measurements ( ➠ Page 352).
47536 Figure 506

682 ‒ Engine
F3B ENGINE 355
CRANKCASE CHECKS
36061 Figure 507

3. Table for noting down the measurements of the main journals and crankpins of the crankshaft.
.540816. Preliminary measurement for main half-bearings selection

Main action
1. For each of the journals of the crankshaft, it is necessary to carry out the following operations:
.540816. Main journals

2. Determine the diameter class of the seat in the crankcase.
3. Determine the class of diameter of the main journal.
4. Select the class of the half-bearings to mount.

682 ‒ Engine
356 F3B ENGINE
CRANKCASE CHECKS
.540816. Defining the diameter class of the seats for half bearings on the crankcase
190208 Figure 508

5. To identify the diameter class of the seats for the main half-bearings, look at the lower part of the crankcase in the position
shown in the figure.

682 ‒ Engine
F3B ENGINE 357
CRANKCASE CHECKS
DEFINING THE DIAMETER CLASS OF THE SEATS FOR HALF BEARINGS ON THE CRANKCASE
CLASS RATED DIAMETER OF MAIN BEARINGS
1 106.300 – 106.309
2 106.310 – 106.319
3 106.320 – 106.330
6. Read off the 2 sets of figures on the lower part of the crankcase.
Note The first set of digits (four) is the coupling number of the upper and lower crankcase.
The following seven digits, considered individually, indicate the diameter class of each related main journal seat.
Each of these digits may be 1, 2 or 3.
.540816. Selecting the main half-bearings

Main action
190220 Figure 509

▶ Identify the most suitable half-bearings for each of the journals (the half-bearings, if necessary, can have different classes from
Main half-bearing thickness
Main half-bearings
STD +0.127 +0.254 +0.508
Red 3.110 – 3.120 – 3.237 - 3.247 3.364 - 3.374

Red/Black – 3.173 ÷ 3.183 – –
Green 3.121 – 3.130 – – –
Green/Black – 3.184 - 3.193 – –
Note Depending on the thickness, the half-bearings are selected in tolerance classes marked by a coloured sign (red/black -
The tables give the specifications of the main bearings available as spare parts in the standard sizes (STD) and in the
permissible oversizes (+0.127, +0.254, +0.508).

682 ‒ Engine
358 F3B ENGINE
CRANKCASE CHECKS
.540816. Definition of the diameter class of the main journals (nominal diameter)
Main action
190216 Figure 510

1. Before selecting the main bearings, define the diameter class of each main journal.
Definition of the diameter class of the main journals (nominal diameter)
CLASS RATED DIAMETER OF MAIN JOURNALS
1 99.970 – 99.979
2 99.980 – 99.989
3 99.990 – 100.000
2. In order to identify the diameter class of the main journals, identify the three sets of figures marked on the bottom of the
crankshaft (see detail in figure).
The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows
the status of the pins (1 = STD, 2 = - 0.127), the other seven digits, taken singly, give the diameter class of each of the
main journals they refer to.

682 ‒ Engine
F3B ENGINE 359
CRANKCASE CHECKS
.540816. Main half-bearings selection (nominal diameter pins)

Main action
▶ After measuring the data, for each of the main journals on the crankcase and crankshaft, you choose the type of half-bearings
to use according to the table.
Main half-bearings selection (nominal diameter)
STD CLASS 1 2 3
Green Green Green

1
Green Green Green
Red Green Green

2
Red Green Green
Red Red Green

3
Red Red Green
.540816. Main half-bearings selection (rectified)

Main action
Conditions
● Ground main journals

682 ‒ Engine
360 F3B ENGINE
CRANKCASE CHECKS
red/black = 3.173 - 3.183 mm

green/black = 3.184 - 3.193 mm
- 0.127 CLASS 1 2 3
Green/Black Green/Black Green/Black

99.843
1
99.852

99.853
2
99.862

99.863
3
99.873
red = 3.237 - 3.247 mm
- 0.254 CLASS 1 2 3
Red Red Red
99.726
99.746
Red Red Red

682 ‒ Engine
F3B ENGINE 361
CRANKCASE CHECKS
red = 3.364 - 3.374 mm
- 0.508 CLASS 1 2 3
Red Red Red
99.472
99.492
Red Red Red
.540816. Crankpins
Main action
1. Determine the diameter class of the seat in the connecting rod.
2. Determine the class of diameter of the crankpin.
3. Select the class of the half-bearings to mount.
.540831. Selecting the big-end half-bearings

Main action
190219 Figure 511

▶ Identify the most suitable half-bearings for each of the journals (the half-bearings, if necessary, can have different classes from

682 ‒ Engine
362 F3B ENGINE
CRANKCASE CHECKS
190219 Figure 511

Big end half-bearing thickness
Big-end half-bearings
STD +0.127 +0.254 +0.508
Red 1.965 – 1.975 – 2.092 ÷ 2.102 2.219 ÷ 2.229

Red/Black – 2.028 ÷ 2.038 – –
Green 1.976 – 1.985 – 2.103 ÷ 2.112 2.230 ÷ 2.239
Green/Black – 2.039 ÷ 2.048 – –
Note Depending on the thickness, the half-bearings are selected in tolerance classes marked by a coloured sign (red/black -
The table gives the specifications of the big-end bearings available as spare parts in the standard sizes (STD) and in the
permissible oversizes (+0.127, +0.254, +0.508).

682 ‒ Engine
F3B ENGINE 363
CRANKCASE CHECKS
.540831. Definition of the diameter class of the crankpins (nominal diameter)

Main action
190211 Figure 512

1. The diameter class of each big-end bearing must be selected before identifying the diameter of each crankpin.
Definition of the diameter class of the crankpins (nominal diameter)
CLASS CRANKPINS NOMINAL DIAMETER
1 89.970 – 89.979
2 89.980 – 89.989
3 89.990 – 90.000
2. Check the three number series marked on the front section of the crankshaft to identify crankpin diameter class (see image).
Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the
status of the journals (1 = STD, 2 = - 0.127), the other six digits, taken individually, give the diameter class of each of
the crankpins they refer to (at top).

682 ‒ Engine
364 F3B ENGINE
CRANKCASE CHECKS
.540831. Big-end half-bearing selection (nominal diameter crankpins)

Main action
1. Select the big-end half-bearings with reference to the three
markings on the connecting rod body, in the position indicated
«A».
Note The number indicating the diameter class of the seat
for half-bearings can be: 1, 2 or 3.
47557 Figure 513

Letter indicating the weight class
1 A = 4741 ÷ 4780 g.
A = 4781 – 4820 g.
A = 4821 – 4860 g.
Number indicating the selection of the diameter

of the connecting rod big end bearing seat
2 1 = 94.000 – 94.010 mm
2 = 94.011 – 94.020 mm
3 = 94.021 – 94.030 mm
3 Numbers
identifying the
cap-connecting
rod coupling
2. Determine the type of connecting rod half-bearing to fit on each pin by following the indications in the table.

682 ‒ Engine
F3B ENGINE 365
CRANKCASE CHECKS
Big-end half-bearing selection (nominal diameter crankpins)
STD CLASS 1 2 3
Green Green Green

1
Green Green Green
Red Green Green

2
Red Green Green
Red Red Green

3
Red Red Green
.540831. Big-end half-bearing selection (rectified crankpins)

Main action
Conditions
● Reground crankpins

682 ‒ Engine
366 F3B ENGINE
CRANKCASE CHECKS
Selecting the big-end half-bearings (-0.127)
red/black = 2.028 ÷ 2.038 mm

green/black = 2.039 ÷ 2.048 mm
- 0.127 CLASS 1 2 3

82.843
1
82.852

82.853
2
82.862

82.863
3
82.873
red = 2.092 ÷ 2.102 mm

green = 2.103 ÷ 2.112 mm
- 0.254 CLASS 1 2 3
Red Green Green
82.726
1
82.735
Red Green Green
Red Red Green
82.736
2
82.746
Red Red Green

682 ‒ Engine
F3B ENGINE 367
CRANKCASE CHECKS
red = 2.219 ÷ 2.229 mm

green = 2.230 ÷ 2.239 mm
- 0.508 CLASS 1 2 3
Red Green Green
82.472
1
82.481
Red Green Green
Red Red Green
82.482
2
82.492
Red Red Green
.540815. Checking the timing and oil pump gear control
Technical data
Heating temperature for gear fitting 180 ℃
Main action
1. Check that the toothing of the gear is neither damaged nor worn; if it is, take it out with an appropriate extractor and replace
it.

682 ‒ Engine
368 F3B ENGINE
CRANKCASE CHECKS
2. When fitting the gear (1) on the crankshaft (2), heat it for no
longer than 2 hours in an oven at a temperature of:
Technical data
Heating temperature for gear fitting 180 ℃
3. Let it cool down after pressing.

4. If replacing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.
108836 Figure 514
.540811. Main journal fitting clearance check
Consumables
UTDM oil
Work material
- 1/2" and 3/4"
Torque wrench
Hooks
Hoist
Tightening torques
Lower crankcase inner tightening screws 1. Pre-tightening 120 N⋅m
2. Screw angle tightening: 60°
Phase 1
3. Phase 2 55°

682 ‒ Engine
F3B ENGINE 369
CRANKCASE CHECKS
Main action
1. Mount the oil nozzles (2), making the grub screw match the
hole (3) on the crankcase.
2. Install the half-bearings (1) on the main bearings.
177336 Figure 515
3. Using the hoist and hook(1) assemble the crankshaft (2).

code
Hoist
177335 Figure 516
4. Install the half-bearings (1) on the main bearings in the lower

crankcase (2).
5. Check the assembly clearance between the main journals of
the crankshaft and their bearings, proceeding as shown on the
following pages.
49021 Figure 517

682 ‒ Engine
370 F3B ENGINE
CRANKCASE CHECKS
6. Lay down pieces of calibrated wire on the pins of the crankshaft

(2), parallel to the longitudinal axis; Fit the lower crankcase (1)
by means of a suitable hoist and hooks.
Tool / Material
Hoist
Hooks
60559 Figure 518
7. Lubricate the internal screws (1) with the recommended oil

and tighten them with a torque wrench (3) and a goniometer
(4), following the diagram in the following figure.
Tightening torque
Lower crankcase inner tight- 1. Pre-tightening
ening screws 120 N⋅m
2. Screw angle tightening: Phase 1
60°
3. Phase 2
55°

UTDM oil
Torque wrench
1/2" and 3/4"
Note When assembly is complete: the engine's lower crank-

case fastening screws must always be replaced.
60593 Figure 520

8. DIAGRAM OF TIGHTENING SEQUENCE FOR THE SCREWS FIXING THE LOWER CRANKCASE TO THE CRANK-
CASE.

682 ‒ Engine
F3B ENGINE 371
CRANKCASE CHECKS
9. Remove the lower crankcase.

10. The clearance between the main bearings and their pins is
measured by comparing the width of the calibrated wire (2),
at the point subjected to the greatest crushing forces, with the
graduated scale on the casing (1) containing the calibrated wire.
11. The numbers shown on the scale indicate the clearance in mil-
limetres of the coupling. If a different clearance is found than
what is required, replace the half bearings and repeat the check.
177338 Figure 521
.540817. Checking crankshaft shoulder clearance
Work material
Dial gauge (0-5 mm) 99395603
Main action
▶ Shoulder clearance is checked by placing a magnetic dial gauge
(1) on the crankshaft (2), as shown in the figure. If the value
obtained is higher than specified, replace the rear thrust main
half-bearings and repeat the clearance check.
code
Dial gauge (0-5 mm) 99395603
47588 Figure 522
.540831. Crankpin fitting clearance check
Work material
- 1/2" and 3/4"
Tightening torques
Screws fixing connecting rod cap 1. Phase 1 60 N⋅m
2. Phase 2 60°

682 ‒ Engine
372 F3B ENGINE
PISTON - CONNECTING ROD ASSEMBLY OVERHAUL
Main action
1. Carry out the following operations to measure the clearance.
2. Connect the connecting rods to the relevant journals of the crankshaft, placing a length of calibrated wire on the journals.
Caution!
Fastening screws Minimum diameter check
▶ Before reusing the connecting rod cap fastening screws, measure the diameter of the thread. This must be no less
than 13.4 mm for F3A/F3B engines or 11.4 mm for F2B engines, otherwise replace the screw.
▶ Before installing, lubricate the screw thread with engine oil.
3. Mount the connecting rod caps (1) together with half-bearings;

tighten the connecting rod caps fastening screws (2) to the
prescribed torque. Using the goniometer (3) further tighten
the screws with an angle specified.
Tightening torque
Screws fixing connecting rod 1. Phase 1
cap 60 N⋅m
2. Phase 2
60°

code
1/2" and 3/4"
47594 Figure 523
Note Lubricate screw threads (2) with engine oil before
assembly.
4. Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the
envelope containing the wire.
.5408. PISTON - CONNECTING ROD ASSEMBLY OVERHAUL
Work material
Reamer
Drift
Feeler gauge
Micrometer
Round tipped pliers
Technical data
Bushing diameter 54.019 mm to54.035 mm
Offset between piston circlips in assembly phase 120°

682 ‒ Engine
F3B ENGINE 373
Main action
60607 Figure 524

1 Connecting rod body 6 Slotted oil scraper ring with spiral spring
2 Half-bearings 7 Claw seal ring
3 Connecting rod cap 8 Trapezoidal seal ring
4 Cap fastening screws 9 Pin piston
5 Circlip 10 Piston
1. Make sure the pistons have no signs of seizing, scoring, cracking. Otherwise, replace them.
.540842. Circlips removal

2. Remove the circlips from the piston (2) using pliers (1).
code
Note Pistons are equipped with three circlips: a sealing ring,

with trapezoidal section; a sealing ring with chamfer cut;
the third oil scraper.
Pistons are grouped into classes A and B for diameter.
60608 Figure 525

682 ‒ Engine
374 F3B ENGINE
.540840. Piston removal

3. Remove the piston pin retaining circlips (2) using round tipped
pliers (1).
Tool / Material
Round tipped pliers
49024 Figure 526
4. Remove the piston pin (1). If removal is difficult use the appro-
priate drift.
Tool / Material
Drift
49025 Figure 527
.540840. Measuring the piston diameter

5. Using a micrometer (2), measure the piston diameter (1) to
determine the assembly clearance; The diameter has to be
detected at the value indicated.
Tool / Material
Micrometer
071714A Figure 528

682 ‒ Engine
F3B ENGINE 375
.540841. Measuring the piston pin diameter

6. Pin diameter (1) measuring with a micrometer (2).
Tool / Material
Micrometer
32618 Figure 529
.540841. Conditions for correct pin-piston coupling

7. Lubricate the pin (1) and the relevant seats on the internal pis-
ton hubs with engine oil; Pin must be inserted in the piston with
a light finger pressure and it should not come out by gravity.
49026 Figure 530
.540842. Measuring circlips

8. Check the thickness of the circlip (2) using a micrometer (1).
Tool / Material
Micrometer
16552A Figure 531

682 ‒ Engine
376 F3B ENGINE
9. Check the clearance between the sealing rings (2) and the re-
lated seats on the piston (1) using a feeler gauge (3).
Tool / Material
Feeler gauge
60610 Figure 532
10. The sealing ring (2) of the 1st seat is trapezoidal. Clearance "
X" between the sealing ring and its seat is measured by placing
the piston (1) with its ring in the cylinder liner (3), so that the
sealing ring comes half way out of the cylinder liner.
3513 Figure 533
11. Using a feeler gauge (2), check the end gap of the sealing rings
(1) entered in the cylinder liner (3).
Tool / Material
Feeler gauge
12. If the distance between ends is lower or higher than the value
required, replace circlips.
36134 Figure 534

682 ‒ Engine
F3B ENGINE 377
.540830. Connecting rod checks

Caution!
Connecting rods weight class Warning in assembly
phase
▶ When installing connecting rods, make sure they all
belong to the same weight class.
13. Data concerning the class section of connecting rod seats and
weights are stamped on the connecting rod big end.
47557 Figure 535

1 Letter indicating the weight class
A = 4741 – 4780 g.
A = 4781 – 4820 g.
A = 4821 – 4860 g.
2 Number indicating the selection of the diameter

of the connecting rod big end bearing seat
1 = 94.000 – 94.010 mm
2 = 94.011 – 94.020 mm
3 = 94.021 – 94.030 mm
3 Numbers identifying
the cap-connecting
rod coupling

682 ‒ Engine
378 F3B ENGINE
71716 Figure 536

* Dimension to be obtained after driving the bushing
14. MAIN DATA OF BUSHING, CONNECTING ROD, PIN AND HALF-BEARINGS.
.540830. Checking axes alignment

15. Check the parallelism of the connecting rod axis (1) using a
suitable device (5) proceed as follows.
16. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
17. Set the spindle on the (3) on the prisms «V» resting the con-
necting rod (1) on the stop bar (2).
61696 Figure 537

682 ‒ Engine
F3B ENGINE 379
.540830. Torsion check

18. Check the bend of the connecting rod (5) by comparing two
points (A) and (B) of the pin (3) on the horizontal plane of the
connecting rod axis.
19. Position the mount (1) of the dial gauge (2) so that this pre-
loads by approx. 0.5 mm on the pin (3) at point A and set the
dial gauge to zero (2). Shift the spindle (4) with the connecting
rod (5) and compare any deviation on the opposite side B of
the pin (3): the difference between A and B must not exceed
0.08 mm.
61694 Figure 538
.540830. Bending check

20. Check the bend of the connecting rod (5) by comparing two
points C and D of the pin (3) on the vertical plane of the con-
necting rod axis. Position the vertical support (1) of the dial
gauge (2) so that this rests on the pin (3) at point C.
21. Swing the connecting rod to and fro, establishing the highest
position of the pin and reset the dial gauge (2) in this condition.
22. Move spindle (4) with connecting rod (5) and repeat the
highest point check on opposite side D of pin (3).
23. The difference between points C and D must not exceed 0.08
mm.
61695 Figure 539
.540834. Connecting rod small end bushes check

24. Check that the bushing in the connecting rod small end has not
come loose and shows no sign of seizure or scoring. Otherwise
replace it.
25. The bushing (2) is removed and fitted with a suitable drift (1).
Tool / Material
Drift
26. When refitting take care to make the oil holes on the bushing
coincide with those on the connecting rod small end.
27. Ream the bushing to obtain the specified diameter:
073535 Figure 540

682 ‒ Engine
380 F3B ENGINE
Technical data
Bushing diameter 54.019 mm to54.035 mm
Tool / Material
Reamer
073535 Figure 540
.540840. Piston assembly

28. The piston (1) has to be fitted on the connecting rod (2) so
that the graphic symbol (4), showing the assembly position in
the cylinder liner, and the punch marks (3) on the connecting
rod face each other as shown in the figure.
73536 Figure 541
29. Fit the pin (2) and fasten it on the piston (1) with the circlips
(3).
1
2
74052A Figure 542

682 ‒ Engine
F3B ENGINE 381
.540842. Fitting circlips

30. Use pliers (3) to fit the circlips (1) on the piston (2).
code
31. The rings shall be fitted with the marking «TOP» (4) facing
upwards and their openings shall be displaced with each other:
Technical data
Offset between piston circlips in assembly 120°
phase
60614 Figure 543
.540610. CYLINDER HEAD OVERHAUL
Work material
Injector housing puller 99342149
Tool to remove and refit engine valves (to be used with 99360259
special plates)
Tool for engine valves removal and refitting (use with 99360263
99360259)
Tool for valve guide refitting (use with 99360143) 99360296
Adjuster for gasket assembly on valve guide 99360329
Tool for injector housing cold-heading 99365056
99395603)
Tool for removing injector holder deposits 99390772
Tool to thread injector housing to extract (use with 99390804
99390805)
Cutter to rectify injector holder housing (to be used with 99394041
99394015)
Reamer to regrind bottom of injector sleeve (use with 99394043
99394015)
Dial gauge (0-5 mm) 99395603
Bore gauge
Drift
Feeler gauge
Micrometer
Grinder
Ruler
Metal brush

682 ‒ Engine
382 F3B ENGINE
Technical data
Valve guide standout 30.8 mm to31.2 mm
Injector standout 1.1 mm to1.9 mm
Cylinder head heating temperature 80 ℃ to100 ℃
Main action
1. Before removing cylinder head, check hydraulic tightness using specific tool; in case of leaks not caused by cup plugs or
threaded plugs, replace cylinder head.
Note When replacing the cylinder head, it is supplied as a spare part with a threaded plug, which must be removed during
assembly.
Note In case of plugs dismounting/replacement, on mounting, apply sealant Loctite 270 or 243 on plugs.
.540662. Valve removal

Note Before removing cylinder head valves, number them in view of their remounting in the same position should they not have
to be overhauled or replaced. Intake valves are different form exhaust valves in that they have a notch placed at valve head
centre.
2. Fit the specific tool (2) and fix it with the bracket (4); screw
using the valve assembly/disassembly tool (1) until you can dis-
assemble the cotters (3); take out the tool (2) and extract the
top plate (5), spring (6) and bottom plate (7).
code
99360259)
special plates)
3. Repeat this operation for all the valves.

4. Turn the cylinder head upside down and remove the valves (8).
47583 Figure 544
.540610. Checking the planarity of the head on the cylinder block

5. Check the supporting surface (1) of the head on the cylinder
block with a rule (2) and a feeler gauge (3).
Tool / Material
Ruler
Feeler gauge
6. If you find any deformation, level the head on a surface grinder;

maximum amount of stock removal is 0.2 mm.
Note After levelling, make sure that valve sinking and injector
protrusion are as described in the relative paragraph.
36159 Figure 545

682 ‒ Engine
F3B ENGINE 383
.540662. Valve descale and check

7. Remove all carbon deposits from the valves using a wire brush.
Tool / Material
Metal brush
48625 Figure 546
8. Check that the valves show no signs of seizure or cracking; also

check, using a micrometer, that the diameter of the valve stem
is within the specified values, otherwise replace the valves.
9. Regrind the valve seats, if required, using a grinding machine and
removing as less material as possible.
Tool / Material
Micrometer
Grinder
10. Use a bore gauge to check that the diameter inside the valve
guide corresponds to the value indicated, after fitting.
Tool / Material 71718 Figure 547
Bore gauge MAIN DATA OF VALVES AND VALVE GUIDES
* Measurement to be
made after driving in
the valve guides
.540667. Replacing the valve guides

11. Remove the valve guides by means of a drift.
code
12. They are fitted with the drift equipped with the specific part.
code
13. The specific element determines the exact valve guide fitting
position in the cylinder head; if they are not available, you need
to drive the valve guides into the cylinder head so they protrude
by a value equal to the one given below. 163815 Figure 548

682 ‒ Engine
384 F3B ENGINE
Technical data
Valve guide standout 30.8 mm to31.2 mm

code
14. After installing the valve guides, regrind their bores with a
smoother.
code
163815 Figure 548
.540661. Regrinding - replacing the valve seats

Note The valve seats are reground whenever the valves or the valve guides are ground and replaced.
(1) (2)
73555 Figure 549

1 Intake valve seat 2 Exhaust valve seat
15. During checks, make sure that the specifications of the valve seats are as in the figure.
16. Check the valve seats (2). If there are light scorings or burnings,
regrind them with a suitable tool (1) according to angles shown
in the previous figure.
17. Having to replace them, with the same tool and taking care not
to affect the cylinder head, remove as much material from the
valve seats as possible until it is possible to extract them from
the cylinder head with a punch.
18. Heat the cylinder head to 80 –100 ºC and, using a drift, fit in the
new valve seats (2), chilled beforehand in liquid nitrogen. Using
tool (1), regrind the valve seats according to the angles shown
in the previous figure.
41032 Figure 550

682 ‒ Engine
F3B ENGINE 385
Technical data
Cylinder head heating temperature 80 ℃ to100 ℃
Tool / Material
Drift
19. After reaming the valve seats, use the specific tool and the dial
gauge to make sure that the valve position, with respect to the
cylinder head surface, is the following:
Technical data

code
99395603)
Dial gauge (0-5 mm) 99395603
.540613. Injector sleeves removal

20. To replace the injector sleeve (2), act as follows.
21. Thread the sleeve (2) using the specific tool (1).
code
Tool to thread injector housing to extract (use with 99390804
99390805)
22. The steps described in the following figures need to be carried

out by fixing the tools, with the bracket A, to the cylinder head.
60619 Figure 551

682 ‒ Engine
386 F3B ENGINE
23. Fasten the extractor (2) to housing (3), by tightening the nut
(1), and pull out the housing from cylinder head.
code
Injector housing puller 99342149
60620 Figure 552
24. Remove any residue (2), with specific tool (1), from the cylin-
der head groove.
code
Tool for removing injector holder deposits 99390772
60621 Figure 553

682 ‒ Engine
F3B ENGINE 387
.540613. Injector sleeves assembly

25. Lubricate sealing rings (3) and fit them to the case (4); using
a specific tool (2) secured to the cylinder head by means of
bracket A, install the new holder, tighten the screw (1), upset-
ting the holder lower part.
code
Tool for injector housing cold-heading 99365056
60622 Figure 554
26. Use the borer (1-2) to regrind the sleeve hole (3).
code
Cutter to rectify injector holder housing (to be used with 99394041
99394015)
60623 Figure 555

682 ‒ Engine
388 F3B ENGINE
27. Using the milling cutter (1-2) and bush, regrind the injector seat
in the holder (3).
code
Reamer to regrind bottom of injector sleeve (use with 99394043
99394015)
60624 Figure 556
.775010. Checking protrusion of injectors

28. Check injector protrusion (2) using a magnetic dial gauge (1).
This value must not exceed the value shown below.
Technical data
Injector standout 1.1 mm to1.9 mm
47585 Figure 557

682 ‒ Engine
F3B ENGINE 389
29. INSTALLATION LAYOUT FOR INJECTOR SLEEVE.
163816 Figure 558
.540665. Valve spring check

30. Before assembly, check the valve spring flexibility using a suitable
tool.
70000 Figure 559
31. Compare the load and elastic deformation data with those of
the new springs given in the figure.
108842 Figure 560

682 ‒ Engine
390 F3B ENGINE
.540662. Valve assembly

32. Lubricate the valve stem and insert the valves in the respective
valve guides; fit the lower plates (1). Use the keying device to
fit the oil seal (2) on the valve guides (3) of the exhaust valves;
then fit the valves as follows.
code
Adjuster for gasket assembly on valve guide 99360329
Note Should valves not have been overhauled or replaced,

remount them according to the numbering performed
on dismounting.
Intake valves are different form exhaust valves in that
they have a notch placed at valve head centre.
87051 Figure 561
33. Fit springs (6), upper plate (5).

34. Fit the specific tool (2) and fix it with the bracket (4); screw the
lever (1) until you can assemble the cotters (3); remove the
tool (2).
code
99360259)
special plates)
86290 Figure 562

682 ‒ Engine
F3B ENGINE 391
5412 COMPLETE TIMING SYSTEM OVERHAUL

Timing system drive
Timing control component parts
1 Camshaft 5 Output shaft control gear
2 Bushing 6 Idler gear
3 Pin 7 Twin idler gear
4 Rod 8 Crankshaft driving gear
86925 Figure 563
541253 Idler gear pin
108840 Figure 564

682 ‒ Engine
392 F3B ENGINE
541253 Twin intermediate gear pin
86934 Figure 565
.541254. Bushing replacement

Technical data
Rated assembly clearance idle gear pin/bushing 0.045 mm to0.085 mm
Rated assembly clearance twin idle gear pin/bushing 0.045 mm to0.085 mm
Main action
1. Bushings (2) can be replaced when they are worn.
86925 Figure 566

682 ‒ Engine
F3B ENGINE 393
2. After driving the bushing, bore it to obtain the diameter shown

in either the second or third figure.
Note The bushing must be driven into the gear in the direc-
tion of the arrow setting the latter to the dimension
shown in either the second or third figure.
108840 Figure 567
3. Rated assembling clearance between gear bushings and pins:

Technical data
Rated assembly clearance idle gear 0.045 mm to0.085 mm
pin/bushing
Rated assembly clearance twin idle gear 0.045 mm to0.085 mm
pin/bushing
86934 Figure 568
.541211. Checking cam lift and journals alignment
Work material
Technical data
Assembly clearance 0.150 mm
Supporting pins alignment 0.030 mm

682 ‒ Engine
394 F3B ENGINE
Main action
47506 Figure 569

1. Place the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) using a dial gauge (2). The values are shown in
the "Specifications and data" table.
Tool / Material
47507 Figure 570

2. Still with the camshaft (4) set on the tailstocks (1), check the alignment of the journals (3) with the dial gauge (2); it must not
exceed 0.030 mm. If the misalignment is greater than this value, replace the camshaft.
Technical data
Supporting pins alignment 0.030 mm
Tool / Material

682 ‒ Engine
F3B ENGINE 395
47505 Figure 571

3. In order to check the installation clearance, measure the bushing inner diameter and the camshaft pin (1) diameter; the real
clearance is obtained by their difference. If you find any clearances over 0.150 mm, replace the bushings and, if necessary, the
camshaft as well.
Technical data
Assembly clearance 0.150 mm
108841 Figure 572

4. The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth; Whereas, if they show any
signs of seizing or scoring, you should replace the shaft and the relevant bushings.
Tolerance characteristics
TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL
ORIENTATION Perpendicularity
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation
Class of importance product characteristics

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL
IMPORTANT

682 ‒ Engine
396 F3B ENGINE
108841 Figure 572
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
SECONDARY
.541213. Camshaft bushings check
Work material
Bore gauge

682 ‒ Engine
F3B ENGINE 397
Main action
60627 Figure 573

1. Verify that the surface of the bushings shows no sign of seizing or scoring; replace them if they do.
2. Measure the bushing inner diameters with a bore meter and replace them, if the value measured exceeds the tolerance value.
Tool / Material
Bore gauge
3. To remove and refit the bushings, use the proper drift.

.541213. Replacing camshaft bushings using beater
Work material
Drift

682 ‒ Engine
398 F3B ENGINE
Drift
107217 Figure 574

A Drift with seat for bushings to insert/extract. F Guide line.
B Dowel pin for positioning bushings. G Guide bushing to secure to the seventh bushing
C Reference mark to insert seventh bushing correctly. mount.
D Reference mark to insert bushings 1, 2, 3, 4, 5, 6 cor- H Plate fixing bushing G to cylinder head.
rectly (red marks). I Grip.
E Guide bushing. L Extension coupling.
Main action
.541213. Disassembly
1. The sequence for removing the bushings is 7, 6, 5, 4, 3, 2, 1. The
bushings are extracted from the front of each seat. Removal
does not require the drift extension for bushings 5, 6 and 7 and
it is not necessary to use the guide bushing.
code
Note For bushings 1, 2, 3 and 4 it is necessary to use the

extension and the guide bushings.
Note Position the drift accurately during the phase of re-

moval.
71725 Figure 575

682 ‒ Engine
F3B ENGINE 399
.541213. assembly
2. Assemble the drift together with the extension.
Tool / Material
Drift
3. To insert bushings 1, 2, 3, 4 and 5, proceed as follows:

4. Position the bushing to insert on the drift (A) making the grub
screw on it coincide with the seat (B) on the bushing.
5. Position the guide bushing (E) and secure the guide bushing
(G) on the seat of the 7th bushing with the plate (H).
6. While driving in the bushing, make the reference mark (F)
match the mark (M). In this way, when it is driven home, the
lubrication hole on the bushing will coincide with the oil pipe in
its seat.
Note The bushing is driven home when the 1st red reference
mark (D) is flush with the guide bushing (G). 71725 Figure 576
7. To insert the bushing (6), proceed as follows:

8. Unscrew the grip (I) and the extension (N).
9. Position the extension (N) and the guide bushing (E) as shown
in the figure.
10. Position the bushing to insert on the drift (A) making the grub
screw on it coincide with the seat (B) on the bushing.
11. Position the guide bushing (E) and secure the guide bushing
(G) on the seat of the 7th bushing with the plate (H).
12. While driving in the bushing, make the reference mark (F)
match the mark (M). In this way, when it is driven home, the
lubrication hole on the bushing will coincide with the oil pipe in
its seat. 71723 Figure 577
Note The bushing is driven home when the 1 red reference
st
mark (D) is flush with the guide bushing (G).
13. To insert the bushing (7), proceed as follows.

14. Unscrew the grip (I) and the extension (N).
15. Refit the guide (G) from the inside as shown in the figure.
16. Position the bushing on the drift (A) and bring it close up to the
seat, making the bushing hole match the lubrication hole in the
head. Drive it.
17. The 7th bushing is driven in when the reference mark (C) is
flush with the bushing seat.
71724 Figure 578

682 ‒ Engine
400 F3B ENGINE
.541233. Rocker shaft check
Note The cams of the camshaft control the rocker arms directly: 6 for injectors and 12 for valves. Injectors and intake valves
control rocker arms are keyed on rocker arms shaft directly. Exhaust valve rocker arms are keyed on rocker arm shaft
putting in between the levers with engine brake control eccentric pin. Rocker arms slide directly on the cam profiles via
rollers. The other end acts on a bar directly supported by the two valve stems. A pad is placed between the rocker arm
adjustment screw and the bar. Two lubrication holes are obtained inside the rocker arms.
Main action
44925 Figure 579

1. Rocker arm shaft must be detached by length equal to the cylinder heads, in order to reach all parts underneath.
073557 Figure 580

2. Check the shaft surface shows any trace of scoring or seizure. otherwise, replace it.

682 ‒ Engine
F3B ENGINE 401
ENGINE ASSEMBLY
.541239. Pump injector rocker arms check
Main action
▶ The bushing surfaces must not show any trace of scoring of
excessive wear; otherwise, replace bushes or the whole rocker
arm.
071728A Figure 581
Main action
▶ The bushing surfaces must not show any trace of scoring of
excessive wear; otherwise, replace bushes or the whole rocker
arm.
071729A Figure 582
.540110. ENGINE ASSEMBLY
Consumables
Engine oil
LOCTITE 243
LOCTITE 5970 (IVECO N. 2995644)
Work material
daNm)
Key to fit crankshaft front gasket 99346250

682 ‒ Engine
402 F3B ENGINE
ENGINE ASSEMBLY

Tool to check timing (use with 99395606) 99370400
- 1/2" and 3/4"
Gauge to determine centre distance between camshaft 99395229
and high pressure pump
Dial gauge (0-30 mm) 99395606
Centring ring of crankshaft front gasket cover 99396035
Torque wrench
Box wrench
Hooks
Hoist
Tightening torques
Lower crankcase inner tightening screws 1. Pre-tightening 160 N⋅m
2. Angle tightening 90°
Outer screws fixing lower crankcase 1. 30 N⋅m
2. 60°
Screws fixing connecting rod cap 1. Pre-tightening 70 N⋅m
Cylinder head fastening screws (pre-tightening) 1. Pre-tightening 75 N⋅m
2. Pre-tightening 150 N⋅m
Cylinder head fastening screws (angle tightening) 1. Angle tightening 90°
Oil pump fastening screws 22 N⋅m to27 N⋅m
Screws fixing engine flywheel bolt 1. Pre-tightening 120 N⋅m
High-pressure pump flange support screw 22 N⋅m to27 N⋅m
Shoulder plate fastening screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5
21 N⋅m to27 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 - 10
21 N⋅m to27 N⋅m
Idle gear pin screws 1. Pre-tightening 30 N⋅m
Injector bracket fastening screws 18 N⋅m to24 N⋅m
Engine brake cylinder fastening screws 22 N⋅m to27 N⋅m

682 ‒ Engine
F3B ENGINE 403
ENGINE ASSEMBLY
Rail fastening screws 21 N⋅m to27 N⋅m

Electro-injector bracket fastening screws 18 N⋅m to24 N⋅m
High-pressure fuel pipe couplings (injector side) 33 N⋅m to37 N⋅m
High-pressure fuel pipe couplings (rail side) 38 N⋅m to42 N⋅m
Rail supply high pressure fuel pipes couplings 40 N⋅m to46 N⋅m
Fuel return pipe coupling from the rail to cylinder head 33 N⋅m to37 N⋅m
Fastening screws for rocker arm shaft 1. Tightening sequence: 1 - 7
80 N⋅m
90°
High-pressure pump flange support screw 24.5 ±2.5 N⋅m
Shoulder plate locking screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 - 10
20 ±2 N⋅m
Fixing screw for the idle gears play adjustment connecting rod 20 ±2 N⋅m
Screws securing high pressure pump 35 N⋅m to40 N⋅m
Nut for high pressure pump gear 235 N⋅m to265 N⋅m
Fuel filter fastening screws 22 N⋅m to27 N⋅m
Screws fixing the timing gear cover 9 N⋅m to11 N⋅m
Screws securing Blow-by filter 7 N⋅m to10 N⋅m
Suction strainer fastening screws 22 N⋅m to27 N⋅m
Oil sump fastening screws 40 N⋅m to49 N⋅m
Control unit bracket to crankcase fastening screws 21 N⋅m to27 N⋅m
Control unit to bracket fastening screws 9 N⋅m to11 N⋅m
Screws securing intake manifold to cylinder head 45 N⋅m to55 N⋅m
Starter motor fastening screws 66 N⋅m to82 N⋅m
Screws securing heat exchanger 1. 8 N⋅m to15 N⋅m
2. 22 N⋅m to27 N⋅m
Oil filter mount fastening screws 21 N⋅m to26 N⋅m
Turbocharger captive fastening screws 55 N⋅m to65 N⋅m
Exhaust manifold fastening screws 1. Phase 1 35 N⋅m to45 N⋅m
2. Phase 2 65 N⋅m to75 N⋅m
Oil drain and inlet pipe couplings 21 N⋅m to27 N⋅m
Thermostat case fastening screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5 - 6 - 7
22 N⋅m to27 N⋅m
2. Tightening sequence: 8 - 9 - 10 - 11 - 12 - 13 -
14
22 N⋅m to27 N⋅m
Screw fixing the automatic belt tensioner 45 N⋅m to55 N⋅m
Screws fixing crankshaft pulley 1. 70 ±5 N⋅m
2. 50°
Securing the steady tensioner 100 N⋅m to110 N⋅m
Alternator top and bottom brackets fastening screws 22 N⋅m to27 N⋅m

682 ‒ Engine
404 F3B ENGINE
ENGINE ASSEMBLY
Alternator fastening screws 40 N⋅m to48 N⋅m

Oil pressure regulator valve 21 N⋅m to26 N⋅m
Screws securing air conditioner compressor 74 N⋅m to80 N⋅m
Technical data
Cam timing dial gauge value 5.95 ±0.05 mm
Main action
1. Fasten the crankcase to the stand using the specific brackets.
.540414. Oil sprayer assembly

2. Mount the oil nozzles (2), making the grub screw match the
hole (3) on the crankcase.
47586 Figure 583
.540816. Main bearings assembly

3. Install the half-bearings (1) on the main bearings in the crank-
case (2).
Note Refit the main bearings that have not been replaced, in
the same position found at removal.
4. If you have to replace the bearings, choose them according
to selection described in chapters Main half-bearings selection
(nominal diameter pins) ( ➠ Page 359) and Main half-bearings
selection (rectified) ( ➠ Page 359).
49021 Figure 584

682 ‒ Engine
F3B ENGINE 405
ENGINE ASSEMBLY
.540810. Crankshaft assembly

5. Lubricate the half-bearings.
6. Using the specific hoist and hook (1) assemble the crankshaft
(2).
code
Hoist
47570 Figure 585
.540416. Lower crankcase assembly

7. Install the half-bearings (1) on the main bearings in the lower
crankcase (2).
49021 Figure 586
8. Apply the silicone onto the crankcase using an appropriate (1)

tool.
Tool / Material
47595 Figure 587

682 ‒ Engine
406 F3B ENGINE
ENGINE ASSEMBLY
9. Apply the sealant following the diagram in the figure.

Note Fit the lower crankcase within 10' of the application of
the sealant.
60632 Figure 588
10. Fit the lower crankcase (1) by means of a suitable hoist and
hooks.
Tool / Material
Hoist
Hooks
60559 Figure 589
11. Using a torque wrench (3) tighten the internal screws (1) to
the required torque, then using a specific tool (4) tighten them
in two phases to the specific angles, following what is indicated
in the chapter Diagram of tightening sequence for main engine
parts ( ➠ Page 143).
Tightening torque
Lower crankcase inner tight- 1. Pre-tightening
ening screws 160 N⋅m
2. Angle tightening
90°
3. Angle tightening
60°

Torque wrench
1/2" and 3/4"
Note Always use new screws each time you assemble the
bedplate.

682 ‒ Engine
F3B ENGINE 407
ENGINE ASSEMBLY
12. Using a torque wrench (2), tighten the outer hex-socket screws
(1) to the prescribed torque, then using the specific tool (3)
tighten to an angle.
Tightening torque
Outer screws fixing lower 1. 30 N⋅m
crankcase 2. 60°

code
1/2" and 3/4"
47581 Figure 591
.540831. Big-end half-bearing fitting

13. Lubricate the half-bearings (1 ) and fit them in the connecting
rod and the cap.
Note Not finding it necessary to replace the big-end bearings,
you need to fit them back in exactly the same sequence
and position as in removal.
If you have to replace the big-end bearings, choose
them according to selection described in chapter Se-
lecting the main half-bearings ( ➠ Page 357) and Select-
ing the big-end half-bearings ( ➠ Page 361).
Note Do not make any adjustment on the half-bearings.
155951 Figure 592
.540840. Assembling connecting rod - piston assemblies in the cylinder liners

14. Rotate the crankcase placing it vertically.
15. Lubricate the pistons, circlips and inside the cylinder liners.
16. Using the clamp (1), mount the piston-connecting rod assem-
blies (2) into the cylinder liners as shown in the diagram, making
sure that the number of each connecting rod corresponds to
the cap coupling number, and that the graphic symbol stamped
on the crown of each piston faces the engine flywheel; or the
recess in the piston skirt matches the position of oil nozzles.
code
Note The pistons are supplied as spare parts in class A and

can also be fitted in class B cylinder liners. 60616 Figure 593

682 ‒ Engine
408 F3B ENGINE
ENGINE ASSEMBLY
Note Before reusing the screws, measure the diameter of

the thread; this has not to be lower than 13.4 mm;
otherwise replace the screw. Before installing, lubricate
the screw thread with engine oil.
60616 Figure 593
Caution!
Connecting rods Precautions for cylinder liners
▶ During assembly, pay utmost attention to prevent the connecting rod from hitting against the cylinder liner walls.
17. Connect the connecting rods to the relevant pins of the crank-
shaft, mount the connecting rod caps (1) together with half-
bearings; Tighten the connecting rod caps fastening screws
(2) to the specified torque. Using the goniometer (3) further
tighten the screws with an angle specified.
Tightening torque
Screws fixing connecting rod 1. Pre-tightening
cap 70 N⋅m
2. Angle tightening
60°

code
1/2" and 3/4" 47594 Figure 594
18. By means of centring ring (2), check the exact cover position (1), otherwise act as necessary and tighten the screws (3).

682 ‒ Engine
F3B ENGINE 409
ENGINE ASSEMBLY
.540442. Crankshaft front gasket installation

19. By means of centring ring (2), check the exact cover position
(1), otherwise act as necessary and tighten the screws (3).
code
221514 Figure 595
20. Fit precisely the gasket (1), fit the specific keying device (2),
drive in the gasket (1) by screwing the nut (3).
code
Key to fit crankshaft front gasket 99346250
221515 Figure 596
.540610. Cylinder head assembly

21. Check that the pistons: 1 and 6 are exactly at the T.D.C.
22. Put the gasket (2) on the crankcase.
23. Place the cylinder heads (1) on the crankcase.
60515 Figure 597

682 ‒ Engine
410 F3B ENGINE
ENGINE ASSEMBLY
61270 Figure 598

24. Tighten the fastening screws in the sequence shown in the figure.
Note New screws must be used at each assembly of the head.
Lubricate the thread of the screws with engine oil before assembly.
25. Pre-tighten using the torque wrench (1):

Tightening torque
Cylinder head fastening 1. Pre-tightening
screws (pre-tightening) 75 N⋅m
2. Pre-tightening
150 N⋅m
Tool / Material
Torque wrench
60565 Figure 599
26. Perform angle tightening with specific tool (1):

Tightening torque
Cylinder head fastening 1. Angle tightening
screws (angle tightening) 90°
2. Angle tightening
90°

code
1/2" and 3/4"
60566 Figure 600

682 ‒ Engine
F3B ENGINE 411
ENGINE ASSEMBLY
.543010. Installing the oil pump

27. Fit the oil pump (2) and tighten the fastening screws(1).
Tightening torque
Oil pump fastening screws 22 N⋅m to27 N⋅m
221501 Figure 601
28. Install the connecting rod (2) and tighten the screw (1) to the
prescribed torque.
221500 Figure 602
29. Install the double gear (2) and tighten the screws (1) to the
prescribed torque.
Note Lubricate the screws (1) with engine oil before as-
sembly.
221499 Figure 603

682 ‒ Engine
412 F3B ENGINE
ENGINE ASSEMBLY
.540463. Fitting flywheel box

30. Apply the prescribed silicon on the flywheel case using the spe-
cific tool (1) as shown in the figure.
Tool / Material
Note Fit the flywheel housing within 10' after sealant applica-
tion.
47592 Figure 604
31. Use a torque wrench to tighten the screws to the specific tight-
ening torque in the sequence shown in the figure.
182145 Figure 605
.540462. Crankshaft rear gasket assembly

32. Fit precisely the gasket (1), fit the device (2), drive in the gasket
by screwing the nut (3).
code
60568 Figure 606

682 ‒ Engine
F3B ENGINE 413
ENGINE ASSEMBLY
.540850. Engine flywheel assembly

33. Position the flywheel (3) on the crankshaft, lubricate the thread
of the screws (2) with engine oil and screw them down.
34. Block the engine flywheel rotation using the specific tool (1);
tighten the screws (2) in two steps.
code
35. Tighten using a torque wrench .

Tightening torque
Screws fixing engine flywheel 1. Pre-tightening
bolt 120 N⋅m
Lubricant
2. Angle tightening
Engine oil
90°
Tool / Material
221496 Figure 607
Torque wrench
36. Tighten at angle with specific tool (1).

code
1/2" and 3/4"
49036 Figure 608
.541210. Fitting camshaft

37. Install the high pressure pump support (2) flange and tighten
the fastening screws (1).
160624 Figure 609

682 ‒ Engine
414 F3B ENGINE
ENGINE ASSEMBLY
38. Fit the specific gauge (1) to position the high pressure pump
support flange (2) properly and tighten the screws to the pre-
scribed torque.
Tightening torque
High-pressure pump flange support 22 N⋅m to27 N⋅m
screw

code
Gauge to determine centre distance between camshaft and 99395229
high pressure pump
221516 Figure 610
39. Position the crankshaft with the pistons 1 - 6 at the T.D.C. This
situation occurs when:
40. The hole with one reference mark (5) of the engine flywheel
(4) can be seen through the inspection window.
41. The specific tool (1), through the seat (2) of the engine speed
sensor, enters the hole (3) in the flywheel (4).
code
ately.
code
182251 Figure 611
45. Lubricate the seal ring (3) and fit it on the shoulder plate (2).
46. Fit the shoulder plate (2) with the sheet metal gasket (1) and
tighten the screws (5) to the required torque and according
to the sequence shown in relative chapter DIAGRAM OF
TIGHTENING SEQUENCE FOR MAIN ENGINE PARTS
( ➠ Page 143).
Tightening torque
Shoulder plate fastening 1. Tightening sequence: 1 - 2 - 3 - 4 -
screws 5
21 N⋅m to27 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 -
10
21 N⋅m to27 N⋅m
182146 Figure 612

682 ‒ Engine
F3B ENGINE 415
ENGINE ASSEMBLY
47. Position the gauge (1). Check and adjust the position of the link
rod (3) for the idle gear; tighten the screw (2) to the specified
torque.
code
160654 Figure 613
48. Fit the idle gear (1) back on and lock the screws (2) to the
required torque.
Tightening torque
Idle gear pin screws 1. Pre-tightening
30 N⋅m
2. Angle tightening
90°
sembly.
221495 Figure 614
49. Position the gear (2), without fully tightening the screws (5),
on the camshaft, positioning it so that the 4 eyelet holes are
centred with regard to the camshaft fastening holes.
sembly.
50. With a magnetic dial gauge (1) check clearance between gears
(2, 3), which must be between 0.074 – 0.195 mm, otherwise
adjust the clearance as indicated hereafter.
51. Loosen the screws (4) fixing the idle gear (3).
52. Loosen the connecting rod fastening screw (2), move the con-
necting rod (3) in order to obtain the required clearance.
53. Lock the rod fastening screw (2) and the idle gear fixing screws
(4) to the required torque. 182149 Figure 615

682 ‒ Engine
416 F3B ENGINE
ENGINE ASSEMBLY
.775010. Injector assembly

54. Replace the sealing gasket (2) on the injectors(1).
169828 Figure 616
55. Fit the retaining brackets on the injectors (5) and position them
in the relevant seats in the cylinder head.
56. Before tightening the screws (4) to torque, fit the high pressure
fuel pipes referring to the indications provided in chapterRail
installation ( ➠ Page 416) (Operation 774510).
57. After having fitted the fuel pipes, lock the screws (4) securing
the injector brackets to the specified torque.
Tightening torque
Injector bracket fastening 18 N⋅m to24 N⋅m
screws (4)
Tool / Material
Torque wrench
58. Fit the engine brake cylinders (1) and (2), using a torque 183455 Figure 617
wrench, fix them to specified torque.
Tightening torque
Engine brake cylinder fastening 22 N⋅m to27 N⋅m
screws
Tool / Material
Torque wrench
59. Mount the guide braces (3) on the valve stem, all with the
largest hole in the same direction.
.774510. Rail installation

Note The high pressure fuel pipes cannot be re-used but must be replaced each time they are removed

682 ‒ Engine
F3B ENGINE 417
ENGINE ASSEMBLY
221506 Figure 618

60. Connect the oil supply pipe (1) to the engine brake actuators (2) and engine brake solenoid valve (3).
221504 Figure 619

61. Fit the rail (10) onto the head and tighten the fastening screws (9) to the specified torque.
Tightening torque
Rail fastening screws 21 N⋅m to27 N⋅m
62. Connect the high pressure fuel pipes and tighten the fittings by hand in the sequence (1, 2, 3, 6, 5, 4) to the rail and the
injectors.
Note Before tightening the couplings to torque make sure that the pipes are not touching each other.
63. Complete injector assembly operations by tightening the fastening screws to the specified torque.
Tightening torque
Electro-injector bracket fastening screws 18 N⋅m to24 N⋅m
64. Complete assembly of HP fuel pipes(1, 2, 3, 6, 5, 4) by first tightening the injector side couplings and then those on the rail
side.

682 ‒ Engine
418 F3B ENGINE
ENGINE ASSEMBLY
221504 Figure 619
Tightening torque
High-pressure fuel pipe couplings (injector side) 33 N⋅m to37 N⋅m
High-pressure fuel pipe couplings (rail side) 38 N⋅m to42 N⋅m
65. Connect the HP fuel supply pipes (8) and tighten them to the prescribed torque.
Tightening torque
Rail supply high pressure fuel pipes couplings 40 N⋅m to46 N⋅m
66. Connect the fuel return pipe (7) from the rail and tighten to the prescribed torque.
Tightening torque
Fuel return pipe coupling from the rail to cylinder head 33 N⋅m to37 N⋅m
.541230. Fitting rocker shaft assembly

Note Before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws have been fully unscrewed.
67. Refit the cross members (3) on the cylinder head.

code
221503 Figure 620

682 ‒ Engine
F3B ENGINE 419
ENGINE ASSEMBLY
69. Screw the screws in four steps as follows:

Tightening torque
Fastening screws for rocker 1. Tightening sequence: 1 - 7
arm shaft 80 N⋅m
90°

code
Torque wrench
1/2" and 3/4"
183461 Figure 621
70. Fit the engine brake lever retainer springs (1).
221502 Figure 622
71. Use cable clamps to appropriately secure the electrical connec-

tions (1) to the injectors.
221505 Figure 623

682 ‒ Engine
420 F3B ENGINE
ENGINE ASSEMBLY
.5412. Camshaft timing

72. Position the crankshaft with the pistons 1 and 6 at the top dead
centre (T.D.C.).
code
Note This situation occurs when:

The hole with one reference mark (5) of the engine
flywheel (4) can be seen through the inspection win-
dow.
The specific tool (1), through the seat (2) of the engine
ately.
75. Install the high pressure pump support (2) flange and tighten
160624 Figure 625
76. Fit the gauge (1) to position the high pressure pump support
flange (2) properly and tighten the screws to the prescribed
torque.
Tightening torque
High-pressure pump flange support 24.5 ±2.5 N⋅m
screw
160655 Figure 626

682 ‒ Engine
F3B ENGINE 421
ENGINE ASSEMBLY
78. Lubricate the seal ring (3) and fit it on the shoulder plate (2).
79. Mount the shoulder plate (2) with the sheet metal gasket (1)
and tighten the screws (5) to the required torque and accord-
ing to the sequence shown in the relative chapter.
Tightening torque
Shoulder plate locking screws 1. Tightening sequence: 1 - 2 - 3 - 4 -
5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 -
10
20 ±2 N⋅m
182146 Figure 627
80. Position the gauge (1). Check and adjust the position of the link
rod (3) for the idle gear; tighten the screw (2) to the specified
torque.
Tightening torque
Fixing screw for the idle gears play 20 ±2 N⋅m
adjustment connecting rod (2)

code
160654 Figure 628
81. Fit the idle gear (1) back on and tighten the screws (2) without
locking to the required torque.
182148 Figure 629

682 ‒ Engine
422 F3B ENGINE
ENGINE ASSEMBLY
82. Position the gear (2) and (7), without fully tightening the
screws (3), on the camshaft, positioning it so that the 4 eyelet
holes are centred with regard to the camshaft fastening holes.
sembly.
83. With a magnetic dial gauge (1) check clearance between gears
(2, 6), which must be between 0.08 ÷ 0.185 mm, otherwise
adjust the clearance as indicated hereafter.
84. Loosen the screws (5) fixing the idle gear (6).
85. Loosen the connecting rod fastening screw (4), move the con-
necting rod in order to obtain the required clearance.
86. Lock the rod fastening screw (4) and the idle gear fastening
screws (5) to the required torque.
sembly.
217886 Figure 630
87. Apply the specific tool (6) and the specific spacer (7) to the
gear casing (3).
code
Note The arrow shows the direction of rotation of the en-

gine when running.
88. Using the above-mentioned tool, turn the engine flywheel (1)
in the direction of engine rotation so as to take the piston of
cylinder no. 1 to 54° before T.D.C. in the phase of compression
(cylinder 6 in discharge phase).
Note This condition is verified when the hole with two
notches (5) on the engine flywheel (1) is visible
through the small inspection window (2).
216019 Figure 631

682 ‒ Engine
F3B ENGINE 423
ENGINE ASSEMBLY
engine speed sensor; in this condition, the flywheel is located in
the reference position (piston no. 1 to 54° before T.D.C.).
code
appropriately.
code
71774 Figure 632
92. Carefully clean the surface of the head on which the rocker arm
cover rests.
93. Using the specific magnetic support (2), as indicated in the fig-
ure, place the dial gauge (1) with the flat base rod (3) posi-
tioned on the roller (4) of the rocker arm that controls the
exhaust valves of no. 3 and preload it to at least 7 mm.
code
Tool to check timing (use with 99395606) 99370400
Dial gauge (0-30 mm) 99395606
185253 Figure 633
Caution!
Dial gauge pointer Pointer correct positioning
▶ Position the flat base dial gauge needle (see drawing) so that its axis passes through the centre of the roller on
which it rests.
Caution!
Tolerances measure Checking and overhauling values
▶ During CHECKS, and not engine overhaul, the allowed measurement tolerance ranges from -0.05 ÷ to +0.12 mm.
▶ The allowed measurement tolerance during OVERHAUL is ± 0.05 mm.

682 ‒ Engine
424 F3B ENGINE
ENGINE ASSEMBLY
177714 Figure 634

94. Using the specific tool turn the crankshaft in the opposite direction of the operating direction until the pointer of the dial
gauge reaches the minimum value beyond which it can no longer fall.
Note The measurement must be taken holding the rocker arm roller in contact with the profile of the exhaust cam of the
camshaft.
95. Reset the dial gauge.

Note Dial gauge zeroing must be done with the rocker arm
roller in contact with the base radius of the cam profile.
To this end, turn the flywheel until passing the protru-
sions (A-B) and (B-C) on the cam profile connected
to engine brake operation. This occurs when the fly-
wheel is turned in the opposite direction of the operat-
ing direction approx. 1 and 1/4 rotations.
185524 Figure 635

α Camshaft rotation D Cam lift in corres-
angle pondence of 54° be-
Y Cam lift based on the fore the top dead
rotation angle of the centre, 1st cylinder
camshaft end of compression

682 ‒ Engine
F3B ENGINE 425
ENGINE ASSEMBLY
96. Turn the engine flywheel in the engine operating direction until
the dial gauge indicates the required camshaft lift value.
Technical data
97. Check that the required cam lift values are displayed under the
following conditions:
code
◁ The hole with two notches (5) is visible through the small
inspection window.
◁ The specific tool (1), through the seat (2) of the engine
185523 Figure 636
98. Perform the following if the conditions stated have not been
obtained:
99. Turn the engine flywheel until the dial gauge indicates the re-
quired cam lift.
100. Slacken screws (3) that fix gears (1) and (4) to camshaft and
make use of the slots (2) present.
101. Act on the flywheel to obtain the conditions indicated and while
keeping the cam lift value unchanged.
102. Lock the screws (3) and repeat timing check as described
above.
Note Restore the clearance between the timing system gears
during the procedure.
103. Tighten the screws (3) to the specified torque.
104. When adjustments via slots is insufficient to recover offset,
proceed as follows:
105. Lock the screws (3) and turn the engine flywheel a 1/2 turn in
the opposite direction of the operating direction.
106. Turn the engine flywheel in the engine operating direction until 217885 Figure 637
the dial gauge indicates the required camshaft lift value.
Technical data
107. Take out the screws (3) and remove the gears (1) and (4)
from the camshaft.

682 ‒ Engine
426 F3B ENGINE
ENGINE ASSEMBLY
108. Turn the flywheel (4) again until the following conditions occur:
code
◁ The hole with two notches (5) is visible through the small
inspection window.
◁ The specific tool (1), through the seat (2) of the engine
185523 Figure 638
109. Mount the gears (1) and (4) with the 4 slots (2) centred with
the fixing holes of the camshaft. Lock the relevant screws (3) to
the required torque.
110. Recover the clearance between the timing system gears by
turning the flywheel in the opposite direction of the engine
rotation direction and subsequently turning it in the engine
rotation direction until the dial gauge shows the specific value.
Check the previously described conditions.
Technical data
217885 Figure 639

682 ‒ Engine
F3B ENGINE 427
ENGINE ASSEMBLY
111. Position the high pressure pump (1) into its cradle and tighten
216018 Figure 640
112. Direct the HP pump drive shaft so that the key (2) faces the
hole (1) on the distribution gearbox.
216020 Figure 641

682 ‒ Engine
428 F3B ENGINE
ENGINE ASSEMBLY
113. Mount the gear (2) aligning the key on the pump shaft with its
seat on the gear seat.
Note In this condition, the pump and phonic wheel/timing
sensor are timed with the crankshaft.
115. Screw the fastening nut (3).
117. If there is interference between the drive gear teeth of the
pump (5) and (2) proceed as follows.
◁ Unscrew the screws (6) and remove the blow-by filter
(7).
◁ Slacken the screws (4) and, taking advantage of the slots,
turn the gear (5) so that it is possible to mount, without
any interference between teeth, the gear (2) and fit the
pin (1) through the hole on the gear into the gearbox seat.
◁ Tighten the fixing screws (4) and nut (3) of the pump 217692 Figure 642
gear (2) to torque.
◁ Replace the blow-by filter (7).
◁ Remove the pin (1).
.771010. High pressure pump assembly

118. Bring the flywheel to 36° before TDC of the first cylinder.
Note This position can be obtained by turning the engine flywheel in the direction opposite of the operating direction to
the 30° position marked by THREE notches (4) and continuing to turn the flywheel in the same direction until reach-
ing the next hole (by 6°).
If the engine flywheel does not have 3 notches, to identify the reference hole simply: rotate the flywheel in a direction
contrary to the operating direction until reaching the position marked with 2 notches (54° before the T.D.C. cyl. 1);
continue rotating in the engine operating direction for 3 holes (remember that each hole corresponds to a flywheel
rotation of 6°).
119. Insert the specific tool through the seat of the flywheel sensor in the corresponding flywheel hole.

682 ‒ Engine
F3B ENGINE 429
ENGINE ASSEMBLY
120. Mount the HP pump and make sure that the seat of the key (1)
on the pump shaft is facing the pump intakes (2).
187918 Figure 643
121. Tighten the high pressure pump (4) fastening screws (3).
Tightening torque
Screws securing high pressure pump 35 N⋅m to40 N⋅m
122. Connect the fuel pipes (1,2) and tighten the fittings to the
prescribed torque.
Note Make sure that the pipe is not damaged after mounting
and that there are no fuel leaks while engine is running.
The HP pipes that are disassembled cannot be used
again and must be replaced.
221492 Figure 644

682 ‒ Engine
430 F3B ENGINE
ENGINE ASSEMBLY
123. Install the gear (2) and tighten the nuts (1) to the prescribed
torque.
Tightening torque
Nut for high pressure pump gear 235 N⋅m to265 N⋅m
124. Remove the specific tool.

code
221490 Figure 645

very carefully.

682 ‒ Engine
F3B ENGINE 431
ENGINE ASSEMBLY
187916 Figure 646


682 ‒ Engine
432 F3B ENGINE
ENGINE ASSEMBLY
6, 2 - 5 and 3 - 4.
nut (1).
Tool / Material
Box wrench
114287 Figure 647
129. Insert the thickness gauge blade (3) corresponding to the op-
erating clearance shown in the "Characteristics and data"
table.
tion.
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle degree [°]
120
5 2
Angle degree [°]
120
1 6
Angle degree [°]
120
4 3
Angle degree [°]
120
2 5
Angle degree [°]

682 ‒ Engine
F3B ENGINE 433
ENGINE ASSEMBLY
.540630. Tappet cover assembly

134. Position the cover and insert all the screws.
135. Replace the screws in the sequence 1-10-20-21-9 and then in
the sequence shown in the figure until contact.
136. Tighten the screws 1-24 in the sequence shown to the required
torque.
Tightening torque
117545 Figure 648
.542011. Fuel filter assembly

137. Fit the fuel filter mount (2) and tighten the screws to the spe-
cified torque.
Tightening torque
Fuel filter fastening screws 22 N⋅m to27 N⋅m
138. Screw the fuel filter (4) onto the support (2) to the required
torque.
139. Mount the pipes (1).
140. Connect the electrical connections (3).
221476 Figure 649
.540452. Timing gear assembly cover mounting

141. Fit the gasket onto the blow-by case(1).
142. Fit the blow-by case (1).
143. Tighten the screws (2) to the specified torque.
Tightening torque
Screws fixing the timing gear cover 9 N⋅m to11 N⋅m
221517 Figure 650

682 ‒ Engine
434 F3B ENGINE
ENGINE ASSEMBLY
.540486. Blow-by filter fitting

144. Mount the blow-by case (2) and tighten the screws (1) to the
specified torque.
Tightening torque
Screws securing Blow-by filter 7 N⋅m to10 N⋅m
Tool / Material
LOCTITE 243
Note Upon assembly, apply LOCTITE 243 to the screws (1).
221484 Figure 651
.540480. Blow-by case fitting

145. Fit the blow-by case (2) and tighten the screws (1) to the spe-
cified torque.
221483 Figure 652
.543060. Suction strainer installation

146. Turn the engine and fit the oil suction strainer (1).
Tightening torque
Suction strainer fastening screws 22 N⋅m to27 N⋅m
60517 Figure 653

682 ‒ Engine
F3B ENGINE 435
ENGINE ASSEMBLY
.540430. Oil sump assembly

147. Arrange the gasket (4) on oil sump (1), position the spacer (3)
and fit the sump on crankcase screwing up the screws (2) at
prescribed torque.
Tightening torque
Oil sump fastening screws 40 N⋅m to49 N⋅m
60665 Figure 654
.766161. Engine control unit assembly

148. Assemble the engine ECU (1) by tightening the screws (2) to
the prescribed torque.
Tightening torque
Control unit bracket to crankcase 21 N⋅m to27 N⋅m
fastening screws
Control unit to bracket fastening 9 N⋅m to11 N⋅m
screws
221488 Figure 655
.540710. Inlet manifold assembly

149. Refit the intake manifold (2) and tighten the screws (1) to the
specified torque.
Tightening torque
Screws securing intake manifold to 45 N⋅m to55 N⋅m
cylinder head
150. Mount the support (3) for engine start and stop buttons.
221487 Figure 656

682 ‒ Engine
436 F3B ENGINE
ENGINE ASSEMBLY
.760810. Starter motor assembly

151. Mount the starter motor (1) and tighten the relative screws to
Tightening torque
Starter motor fastening screws 66 N⋅m to82 N⋅m
221489 Figure 657
.543110. Heat exchanger assembly

152. Fit the heat exchanger (2) with the relative gasket and tighten
the fastening screws (1) following the order indicated below.
221474 Figure 658
180274 Figure 659

153. Tighten the fastening screws to the prescribed torque.
Tightening torque
Screws securing heat exchanger 1. 8 N⋅m to15 N⋅m
2. 22 N⋅m to27 N⋅m

682 ‒ Engine
F3B ENGINE 437
ENGINE ASSEMBLY
.543070. Oil filter assembly

154. Fit the oil filter support (1) and tighten the screws to the spe-
cified torque.
Tightening torque
Oil filter mount fastening screws 21 N⋅m to26 N⋅m
155. Oil and fit new seals.

156. Screw the filter (2) until the seals come in contact with the
resting bases.
157. Tighten the filter to the specified torque.
221473 Figure 660
.542410. Turbocharger assembly

158. Fit the turbocharger (2) with a new gasket on the exhaust man-
ifold (3).
159. Tighten the turbocharger fastening screws to the specified
torque.
Tightening torque
Turbocharger captive fastening 55 N⋅m to65 N⋅m
screws
221472 Figure 661

682 ‒ Engine
438 F3B ENGINE
ENGINE ASSEMBLY
.540720. Exhaust manifold assembly

160. Fit the exhaust manifold (3) with new gaskets together with the
turbocharger (2).
221472 Figure 662
180272 Figure 663

161. Tighten the exhaust manifold fastening screws to the specified torque.
Tightening torque
Exhaust manifold fastening screws 1. Phase 1
35 N⋅m to45 N⋅m
2. Phase 2
65 N⋅m to75 N⋅m
162. Connect the air pipe(3) from the turbocharger to the inter-
cooler.
163. Connect the oil delivery pipe (1) and the sump oil return pipe
(2) to the turbocharger. Tighten the couplings to the recom-
mended torque.
Tightening torque
Oil drain and inlet pipe couplings 21 N⋅m to27 N⋅m
221471 Figure 664

682 ‒ Engine
F3B ENGINE 439
ENGINE ASSEMBLY
.543251. Thermostat case assembly

164. Fit the thermostat case (2) with a new gasket and tighten the
fastening screws (1) to the specific torque, following the order
shown in the next figure.
221513 Figure 665
165. Tighten the fastening screws, following the tightening order

shown in the figure.
Tightening torque
Thermostat case fastening 1. Tightening sequence: 1 - 2 - 3 - 4 -
screws 5-6-7
22 N⋅m to27 N⋅m
2. Tightening sequence: 8 - 9 - 10 - 11
- 12 - 13 - 14
22 N⋅m to27 N⋅m
181827 Figure 666
.543411. Water pump assembly

166. Fit the automatic belt tensioner (1).
Tightening torque
Screw fixing the automatic belt 45 N⋅m to55 N⋅m
tensioner
167. Fit the pulley (3) and tighten the screws (2) to the specified
torque.
Tightening torque
Screws fixing crankshaft pul- 1. 70 ±5 N⋅m
ley 2. 50°
168. Fit the water pump (4).

Tightening torque
Screws securing water pump 22 N⋅m to27 N⋅m 221482 Figure 667
169. Fit the pulley (6) and tighten the screw (5).

682 ‒ Engine
440 F3B ENGINE
ENGINE ASSEMBLY
Tightening torque
Securing the steady tensioner 100 N⋅m to110 N⋅m
221482 Figure 667
.760310. Alternator assembly

170. Fit the alternator (2) and tighten the screws (1) to the required
torque.
Tightening torque
Alternator top and bottom brackets 22 N⋅m to27 N⋅m
fastening screws
Alternator fastening screws 40 N⋅m to48 N⋅m
221480 Figure 668

682 ‒ Engine
F3B ENGINE 441
ENGINE ASSEMBLY
.543411. Coolant pump/alternator drive belt assembly

171. To fit the belt (2), use suitable equipment to act on the belt
tensioner (1).
Note Belt tensioner is automatic; therefore, no further ad-
justments are to be made after mounting.
221479 Figure 669
172. Upon assembly, check the correct installation as shown in the

figure.
108844 Figure 670

1 Alternator 3 Water pump
2 Electromagnetic con- 4 Crankshaft
nector

682 ‒ Engine
442 F3B ENGINE
ENGINE ASSEMBLY
.540860. Damper flywheel installation

173. Fit the damper flywheel (2) by turning the 6 fastening screws
(1).
Tool / Material
Engine oil
Note Before installing, lubricate the screw thread (1) with

engine oil.
221481 Figure 671
.543420. Fan assembly

174. Fit the fan (1) on the electromagnetic connector (2).
71701 Figure 672
.540110. Removing the engine from the stand

175. Refill the engine with required oil quantity.
176. Remove engine from rotary stand and take off brackets securing the engine.

682 ‒ Engine
F3B ENGINE 443
ENGINE ASSEMBLY
.543075. Oil pressure adjustment valve assembly

177. Fit the oil pressure adjustment valve (1) and tighten the fasten-
ing screws to the required torque.
Tightening torque
Oil pressure regulator valve 21 N⋅m to26 N⋅m
60486 Figure 673
.553239. Air conditioning compressor assembly

178. Fit the air conditioner compressor (1) together with the mount,
tightening the retainers to the specific torque, following the
sequence indicated in the chapter Tightening diagram for main
engine components ( ➠ Page 143).
Tightening torque
Screws securing air conditioner 74 N⋅m to80 N⋅m
compressor
221478 Figure 674
.543910. Air conditioner compressor belt assembly

Caution!
Air conditioner compressor belt Replacement warnings

682 ‒ Engine
444 F3B ENGINE
ENGINE ASSEMBLY
179. Fit the spring belt (1) as shown in the figure following the pro-
cedure described below.
221477 Figure 675
Caution!
Air conditioner compressor belt Assembly precautions
▶ The installation of the climate control unit compressor flexible belt requires the use of the guide for flexible belt
(4). Different methods may cause tensions impairing spring belt.
180. Apply the specific tool (2) with the specific spacer to the gear
case (1).
code
181. Install the spring belt (3) onto the crankshaft pulley, install the
specific guide (4) on the air conditioner compressor pulley (5).
code
182. Position the spring belt (3) in the opening of tool marked with
"cursor 10/13".
183. By specific tool (2), rotate crankshaft according to the direction
of the arrow (→) until spring belt (3) is correctly positioned on
compressor pulley (5).
code
106224 Figure 676
Note While operating, keep the specific tool (4) in contact

with the pulley and at the same time guide the spring

682 ‒ Engine
DENOX SYSTEM 445
Contents
Contents
DeNOx General information . . . . . . . . . . . . . . . 447

operation . . . . . . . . . . . . . . . . . . . . . . . . . 448
MAIN COMPONENTS OF THE SYSTEM . . . . . . . 449

Exhaust silencer . . . . . . . . . . . . . . . . . . . . . 449
AdBlue pump module . . . . . . . . . . . . . . . . . . 450
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Diverter valve . . . . . . . . . . . . . . . . . . . . . . 451
Nitrogen oxides detecting sensor . . . . . . . . . . 452
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
AdBlue Pipes . . . . . . . . . . . . . . . . . . . . . . . 453
Water separator filter - oil . . . . . . . . . . . . . . 455
Temperature sensor for exhaust gas . . . . . . . . 455
DCU (Dosing Control Unit) . . . . . . . . . . . . . 456
REPAIR INTERVENTIONS ON DeNox

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Replacing the AdBlue tank . . . . . . . . . . . . . . . 456
AdBlue level indicator replacement . . . . . . . . . 458
Replace the AdBlue pump module . . . . . . . . . . 459
Replacing the AdBlue filter . . . . . . . . . . . . . . . 461
Replacing the AdBlue prefilter . . . . . . . . . . . . 463
Replacing the diverter valve. . . . . . . . . . . . . . . 464
AdBlue Injector replacement . . . . . . . . . . . . . 465
Replacing the AdBlue system air filter
cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . 465
Replacing the AdBlue system ECU. . . . . . . . . . 466
Replacing inlet exhaust gas temperature
sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Replacement of the outlet exhaust gas
temperature sensor . . . . . . . . . . . . . . . . . . . 468
Replacing the nitrogen oxide detection
sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 469

682 ‒ Engine
446 DENOX SYSTEM

682 ‒ Engine
DENOX SYSTEM 447
DeNOx General information
DENOX SYSTEM
5074 DeNOx General information
DeNOx system diagram
218363 Figure 677

1 Pump module that internally contains air and AdBlue 8 Diverter valve
solution mixer. 9 AdBlue Injector
2 Compressed air control solenoid valve 10 Inlet exhaust gas temperature sensor
3 Water separator filter - oil 11 Catalytic converter
4 Air reservoir 12 Outlet exhaust gas temperature sensor
5 AdBlue level sensor 13 Nitrogen oxide (NOx) detecting sensor
6 AdBlue tank 14 DCU - DeNOx Control Unit
7 Engine (engine cooling system circuit) 15 ECU - Engine control unit
A Air - urea mixture D CAN line

B H20 E Input/output signals
C Air F Power supply
To restrict the nitrogen oxide (NOx) emissions in the exhaust to within the limits prescribed by Euro 4, with low fuel consumption
levels, the vehicles have been fitted with a system for post-treatment of the substances present in the exhaust gases, basically com-
prising an electronically controlled catalytic converter.

682 ‒ Engine
448 DENOX SYSTEM
DeNOx General information
The system, by means of the SCR (Selective Catalytic Reduction) process, transforms nitrogen oxides (NOx) into inert
compounds: free nitrogen (N2) and water vapour (H2O).
The SCR process is based on a series of chemical reactions that, by the reaction of the ammonia with the oxygen in the exhaust gas,
results in the reduction of nitrogen oxides (NOx) present in the exhaust fumes. The optimal temperature range for SCR process
ranges between 180 °C and 350 °C. At lower temperatures, conversion is not yet complete and the reduction of the required
nitrogen oxides is not guaranteed, whilst at higher temperatures antagonist reactions take place, such that 5 to 10% of ammonia is
lost during this reaction.
The process uses a water based solution of urea that yields ammonia.
operation
The SCR system is electronically managed by the DCU (Dosing Control Unit) incorporated in the pump module, which according
to the number of engine revs, the torque delivered, the exhaust temperature, the amount of nitrogen oxides and humidity in the
incoming air, adjusts the flow rate of the reagent solution to be put into the system.
The pump delivers the solution from the reagent reservoir, sends it under pressure in the dosing module where it is multiplexed
together with the compressed air coming from pneumatic system of the vehicle and sprayed by the injector upstream of the cata-
lyst.
The first phase of the process takes place in the first part of the catalytic converter: due to the effect of the exhaust gas temperat-
ure, the reagent solution evaporates instantly and is hydrolysed to ammonia (2NH3) and carbon dioxide (CO2) at the same time,
solution evaporation lowers the exhaust gas temperature to levels close to the optimal temperature required for the process.
Exhaust fumes, charged with ammonia and at reaction temperature, are introduced into the catalytic converter, where the second
phase of the process takes place: by reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N)
and water vapour (H2O).

682 ‒ Engine
DENOX SYSTEM 449
MAIN COMPONENTS OF THE SYSTEM
5074 MAIN COMPONENTS OF THE SYSTEM

507130 Exhaust silencer
218364 Figure 678

The exhaust silencer acts as a catalyst and muffler in order to reduce the nitrogen oxides (NOx) and engine noise.

682 ‒ Engine
450 DENOX SYSTEM
507410 AdBlue pump module
158362 Figure 679

1 Metering module - UDS 5 Mixture output (urea +air)
2 Compressed air control solenoid valve 6 Urea inlet
3 Compressed air intake 7 Urea outlet (return)
4 Metering module (Connector)
The AdBlue pump module consists essentially of a pump that draws the AdBlue from the tank and sends it to the injector when
atomized.
Atomization takes place thanks to the intervention of the compressed air.
The pump module can be equipped with a circuit connected to the engine cooling system that, in case of low temperatures, pre-
vents the freezing of AdBlue.
The amount of AdBlue sent to the injector and the injection pressure are controlled by the DCU and depend on the operating
conditions of the engine and the signals sent by the sensors.

682 ‒ Engine
DENOX SYSTEM 451
507431 Injector
218373 Figure 680

The injector (1) sprays the AdBlue-compressed air solution into the exhaust pipe (2) after the SCR catalytic converter.
507433 Diverter valve
218365 Figure 681

The diverter valve is a 2-way solenoid valve that allows heating of AdBlue tank and pipes with the engine coolant.

682 ‒ Engine
452 DENOX SYSTEM
507435 Nitrogen oxides detecting sensor
218366 Figure 682

The nitrogen oxides detection sensor detects the amount of nitrogen oxides present in the exhaust gases from the catalytic con-
verter.
On the basis of this information the engine control unit adjusts the amount of AdBlue injected and is also able to measure the effi-
ciency of the catalytic converter.

682 ‒ Engine
DENOX SYSTEM 453
507420 Tank
218367 Figure 683

The tank is provided with a level gauge control containing the reducing substance needed for the SCR process; this consists of a
35% aqueous urea solution, named AdBlue.
When dealing with low temperatures, the AdBlue is heated by the engine cooling circuit.
5074 AdBlue Pipes
218368 Figure 684

Pump pipe - injector

682 ‒ Engine
454 DENOX SYSTEM
218369 Figure 685

Pump - tank heated pipe
218370 Figure 686

Pump - tank unheated pipe

682 ‒ Engine
DENOX SYSTEM 455
5074 Water separator filter - oil
218371 Figure 687

The filter separates oil and water contained in the compressed air.
507434 Temperature sensor for exhaust gas
102303 Figure 688

The exhaust gas temperature sensor has the function of sending information to the control unit regarding the temperature of the
exhaust gas entering and exiting the catalytic converter that is necessary for calculating the amount of AdBlue to inject in the sys-
tem.

682 ‒ Engine
456 DENOX SYSTEM
REPAIR INTERVENTIONS ON DeNox SYSTEM
5074 DCU (Dosing Control Unit)
218374 Figure 689

The DCU acquires various parameters such as engine rpm, fuel consumption and catalytic converter temperature via CAN line and
sensors.
These parameters make it possible to calculate the AdBlue that must be injected into the exhaust pipe.
The system for controlling the injection can adjust its operating parameters to adapt to the real work situation.
.5074. REPAIR INTERVENTIONS ON DeNox SYSTEM

Main action
▶ Whenever AdBlue pipes are disconnected from the relative AdBlue system components, it is recommended to clean painted
parts from any trace of AdBlue fluid, which is non-toxic and non-corrosive, in order to prevent scaling.
.507420. Replacing the AdBlue tank
Main action
.507420. Removal
1. Drain the engine coolant from radiator.
2. Tilt the cab.

682 ‒ Engine
DENOX SYSTEM 457
3. Remove the side guard (1) acting on the screws that fix it to
the chassis.
217723 Figure 690
4. Place a suitable container beneath the drain plug (1) of the

AdBlue tank (2).
5. Remove the plug (1) and drain the urea in the AdBlue tank (2).
217721 Figure 691
6. From the level indicator (1) disconnect the AdBlue fluid pipes
(5) acting on the quick release red buttons (4).
7. Disconnect the engine coolant pipes(2) acting on the metal
fasteners (6).
8. Disconnect the electric connector (3).
217722 Figure 692

682 ‒ Engine
458 DENOX SYSTEM
9. Sling the AdBlue tank (1) using a suitable cord and hook it to an
adequate lifter.
10. Remove the metal fasteners (2) that support the AdBlue tank
(1) by acting in the top and bottom fasteners (3).
11. Remove the AdBlue tank (1) from the vehicle with the lifter
previously positioned in place.
217724 Figure 693
.507420. Refitting
12. To refit, repeat the operations described for removal but in the reverse order, tightening the screws and ensuring that the
connection of the pipes and the electrical connection to the level indicator is correct.
13. After refitting, fill engine cooling system and AdBlue tank.
.507424. AdBlue level indicator replacement
Main action
.507424. Removal
2. Tilt the cab.
fasteners (6).
217722 Figure 694

682 ‒ Engine
DENOX SYSTEM 459
6. Turn the cover (3) of the level indicator (2).

7. Remove the AdBlue level indicator (2) lifting it from the AdBlue
tank (1).
217725 Figure 695
.507424. Refitting
connection of the pipes and the electrical connection to the AdBlue level indicator is correct.
9. Once refitting has been terminated, fill engine cooling system.
.507410. Replace the AdBlue pump module
Main action
.507410. Removal
2. Tilt the cab.
3. Remove the side guard (1) acting on the screws that fix it to
the chassis.
217723 Figure 696

682 ‒ Engine
460 DENOX SYSTEM
4. Working from above the vehicle.

5. Remove the fasteners (4) that secure the pipes (3) located on
the top part.
6. Remove the fasteners (1) of the brackets (2) that support the
AdBlue assembly (5) ; to make removal of the AdBlue pump
module easier.
Note We recommend also disconnecting the electrical con-
nections that may hinder removal of the pump module.
217726 Figure 697
7. Working from below the vehicle.

8. Remove all fasteners (2) that secure the pipes (1) in order to
clear space required for pump module removal (3).
217727 Figure 698
9. Mark the position of all pipes (5 - 2) using a marker; for the

next installation.
10. Remove the fastener (1) that secures the pipes (5 - 2).
11. Remove the pipes (5) that convey coolant and AdBlue, acting
on the quick release buttons (6).
12. Remove the air pipe (2) disconnecting it from the snap-on
coupling.
217728 Figure 699

682 ‒ Engine
DENOX SYSTEM 461
13. Remove the electrical connection (2) from the AdBlue pump
module (1).
217729 Figure 700
14. Remove the four retainers (1) for the AdBlue pump module
(2).
15. Remove the AdBlue pump module (2) from underneath the
vehicle turning slightly to simplify removal.
217730 Figure 701
.507410. Refitting
16. For refitting, reverse operations described for removal, tightening the screws to the prescribed torque and ensuring correct
connection of pipes and electrical connections.
.507413. Replacing the AdBlue filter

Main action
2. Tilt the cab.

682 ‒ Engine
462 DENOX SYSTEM
fasteners (6).
217722 Figure 702

tank (1).
217725 Figure 703
8. Remove the filter (1) from the AdBlue level indicator (2) and
replace with a new filter.
217731 Figure 704

682 ‒ Engine
DENOX SYSTEM 463
.507414. Replacing the AdBlue prefilter

Main action
1. Remove the cap (1) from the AdBlue reservoir (2).
2. Remove the fixing screws (3) of the fastening collar (4).
217732 Figure 705
3. Remove the fastening collar (1) from reservoir (2).
217733 Figure 706
4. Remove the AdBlue pre-filter (1) from the AdBlue tank (2).
5. Replace the AdBlue filter (1) with a new one.
217734 Figure 707

682 ‒ Engine
464 DENOX SYSTEM
.507433. Replacing the diverter valve.
Main action
.507433. Removal
2. Tilt the cab.
3. Remove all fasteners (1) of the pipes (2) in order to free space
to reach the diverter valve (3).
217735 Figure 708
4. Remove the pipes (2) by acting on the metal clips (3).

5. Disconnect the diverter valve (5) electrical connection (4).
6. Remove the four fasteners (1) from the diverter pump(5).
7. Remove the diverter valve (5) from the vehicle.
218201 Figure 709
.507433. Refitting
connection of the pipes and the electrical connection to the diverter valve is correct.

682 ‒ Engine
DENOX SYSTEM 465
.507432. AdBlue Injector replacement
Main action
.507432. Removal
1. Disconnect the AdBlue supply pipe (4) by acting on the quick
release button (3).
2. Remove the AdBlue fluid injector (2) acting on the fastener (1).
218202 Figure 710
.507432. Refitting
3. To refit, perform the removal operations in the reverse order, tightening the injector fasteners to the catalytic converter and
ensuring the correct connection to the AdBlue injector pipe.
.798815. Replacing the AdBlue system air filter cartridge.
Main action
.798815. Removal
1. Working from below the vehicle.
2. Disconnect the air pipe (3) exiting the air filter body (4) and
that runs to the air filter body (5).
3. Disconnect the air pipe (1) that enters the air filter body (4).
4. Remove the fasteners (2) from the air filter body (4).
5. Remove the air filter body (4) from under the vehicle.
6. Bring the air filter body to the workbench (4) and replace the
filter cartridge in the body (4) of the air filter.
218203 Figure 711

682 ‒ Engine
466 DENOX SYSTEM
.798815. Refitting
7. After replacing the air filter cartridge with a new one, refit the air filter body.
8. For refitting, reverse operations described for removal, tightening the screws and ensuring correct connection of the air filter
body air pipes.
.507411. Replacing the AdBlue system ECU.
Main action
.507411. Removal
1. Working from above the vehicle.
2. To remove the AdBlue system ECU (3) remove the fasteners
(2) that secure the water pipes (1).
218204 Figure 712
3. Remove the electrical connection (1) from the control unit (2).
4. Remove the four retainers (3) of the control unit (2).
5. Remove the control unit (2) from the vehicle, detaching it from
the support (4).
218205 Figure 713
.507411. Refitting
Caution!

682 ‒ Engine
DENOX SYSTEM 467

gnostic instrument:
6. To refit, repeat the operations described for removal but in the reverse order, tightening the screws and ensuring that elec-
trical connection is correct.
7. At the end of refitting connect the diagnostic tool to the diagnostic socket (EOBD) and launch the replacement procedure.
8. Complete the replacement procedure by following the instructions provided on the diagnostic instrument (installation report
carried out successfully).
.507434. Replacing inlet exhaust gas temperature sensor
Main action
.507434. Removal
1. Disconnect the electrical system current by disconnecting the negative cable from the battery.
2. Remove all the clips (5) that secure the electric cables.
3. The exhaust gas temperature sensor at the inlet (2) is located
on the top side of the cylindrical exhaust (1).
4. Remove the electrical connection (3) of the inlet exhaust gas
temperature sensor (2).
5. Remove the inlet exhaust gas temperature sensor (2) acting on
the retainer (4).
218208 Figure 714
.507434. Refitting
6. To refit, repeat the operations described for the removal process in reverse order, tightening the sensor nut and the screws
7. Make sure that the electrical connection is correctly connected.

682 ‒ Engine
468 DENOX SYSTEM
.507434. Replacement of the outlet exhaust gas temperature sensor
Main action
.507434. Removal
2. The exhaust gas temperature sensor (3) is located on the bot-

tom side of the cylindrical exhaust (1) near the NOx sensor (2)
that detects nitrogen oxide.
3. Slacken the fastener (4) of the exhaust gas temperature sensor
(3).
218209 Figure 715
4. Remove the clips (2) that secure the electric cables.

5. Disconnect the electrical connection (1) of the outlet exhaust
gas temperature sensor.
6. Then remove the outlet exhaust gas temperature sensor previ-
ously loosened.
218210 Figure 716
.507434. Refitting
7. To refit, repeat the operations described for the removal process in reverse order, tightening the sensor nut and the screws
8. Make sure that the electrical connections are correctly connected.

682 ‒ Engine
DENOX SYSTEM 469
.507435. Replacing the nitrogen oxide detection sensor
Main action
.507435. Removal
2. From underneath the vehicle.

3. The NOx sensor (3) that detects nitrogen oxide is located on
the exhaust pipe (1).
4. Remove the NOx nitrogen oxide inlet detection sensor (3) by
acting on the fastening nut (2).
218206 Figure 717
5. Remove the plate (5) complete with the electrical connection

(3) by acting on the plate (5) retainers (4).
6. Disconnect the electrical connection (1) from the chassis, then
remove the plate (5) together with the electrical connector
(3) and the NOx nitrogen oxide detection sensor which was
removed previously and connected to the electric cable (2).
218207 Figure 718
.507435. Refitting
7. To refit, repeat the operations described for the removal process in reverse order, tightening the sensor nut and the screws.
8. Make sure that the electrical connections are correctly connected.

682 ‒ Engine
470 DIAGNOSTICS

682 ‒ Engine
DIAGNOSTICS 471
Contents
Contents
The engine does not start . . . . . . . . . . . . . . . . . 473
The engine lacks power . . . . . . . . . . . . . . . . . . . 474
Abnormal engine knock . . . . . . . . . . . . . . . . . . . 474
The engine stops . . . . . . . . . . . . . . . . . . . . . . . 475
The engine does not stop . . . . . . . . . . . . . . . . . 475
Insufficient or excessive oil pressure . . . . . . . . . . . 475
Engine overheats . . . . . . . . . . . . . . . . . . . . . . . 476
Main electronic - electric malfunctions . . . . . . . . . 476

DTC control unit EDC 7 UC31 (Cursor 9) . . . . 477
DTC control unit EDC17 CV44 (Cursor
13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
DTC Denox control unit (DCU) . . . . . . . . . . . 558

682 ‒ Engine
472 DIAGNOSTICS

682 ‒ Engine
DIAGNOSTICS 473
The engine does not start
DIAGNOSTICS
Main mechanical malfunctions
The engine does not start

No. Possible cause Check Remedy
1 Inefficient connections to battery terminals Cause confirmed ▶ Clean, check and tighten or replace
the cable terminal nuts.
Cause not confirmed Check: 2
2 Batteries inefficient. Cause confirmed ▶ Carry out the checks described in the
section Impianto elettrico.
3 Inefficient starter motor Cause confirmed ▶ Carry out the checks described in the
section Impianto elettrico.
4 CNG solenoid valve inefficient Cause confirmed ▶ Check for voltage, with the key on
MAR (ON), the power comes on for
2 seconds.
▶ Restart power supply when the engine
exceeds 50 rpm.
5 Methane gas supply inefficient Cause confirmed ▶ Check the bottles, pressure regulator,
solenoid valve, pressure down stream
of the reducer with pressure gauge
6 Rev. sensor on flywheel Cause confirmed ▶ Check the electric connection, sensor
cleaning, sensor efficiency, distance
from the flywheel
7 Injectors Cause confirmed ▶ Check injectors opening/closing
through active diagnosis.
8 Inefficient ignition Cause confirmed ▶ Check spark plugs, spark plug cables,
ignition coils.
9 Electronic control unit inefficient Cause confirmed ▶ replace.
10 Not required compression ratio Cause confirmed ▶ Overhaul the engine or limit repairs to
parts concerned (valves, rings, elastics,
etc.).
Cause not confirmed ▶ Contact the service network.

682 ‒ Engine
474 DIAGNOSTICS
The engine lacks power
The engine lacks power

1 Inefficient spark plugs Cause confirmed ▶ Check electrode opening (0.6
mm+0-0.1) replace if necessary.
2 Throttle valve does not open completely Cause confirmed ▶ Adjust.
3 Air delivery system inefficient Cause confirmed ▶ Check for leaks, wastegate operation.
4 The pressure regulator does not work prop- Cause confirmed ▶ Check or replace.
erly ▶ Insert pressure gauge downstream of
the reducer (9 ± 0.5 bar).
Tool for gas pressure test
5 Wrong ignition advance Cause confirmed ▶ Check, adjust as necessary.
6 Turbocharger not working Cause confirmed ▶ Check wastegate valve.
7 Overpressure regulation unit inefficient Cause confirmed ▶ Check or adjust.
8 Not required compression ratio Cause confirmed ▶ Check using a suitable tool and carry
out the necessary repair operations.
9 Gas control valve inefficient Cause confirmed ▶ Check step motor operation, idle con-
trol valve.
10 Pressure compensation tube inefficient Cause confirmed ▶ Check for leaks.
Abnormal engine knock

1 Knock detected in crankshaft Cause confirmed ▶ Check: clearance and ovalization of
main journals; connecting rod cap
fastening screws and engine flywheel;
oil pressure.
▶ Replace the parts or overhaul the
engine.
2 Knock identified in piston rods Cause confirmed ▶ Check: clearance and ovalization of
crankpin; tightness of connecting rod
cap screws and connecting rod square-
ness.
engine.

682 ‒ Engine
DIAGNOSTICS 475
The engine stops

3 Knock identified in pistons Cause confirmed ▶ Check: clearance between pistons and
cylinder liners; integrity of the circlips;
pin clearance - piston hubs.
engine.
4 Knock identified in cylinder head Cause confirmed ▶ Check: operating clearance between
rocker-arms and valves; methane gas
quality, excessive supply pressure, igni-
tion advance.
5 Knock identified in timing system Cause confirmed ▶ Check and replace gears if necessary.
6 Knock found in the air compressor Cause confirmed ▶ overhaul or replace the air
compressor.
The engine stops

1 Fuel cylinder without refuelling (methane Cause confirmed ▶ Refuel.
pressure) Cause not confirmed Check: 2
2 Inefficient ignition system Cause confirmed ▶ Check, adjust or replace parts if neces-
sary.
3 Idle speed irregular. Cause confirmed ▶ Check: idle valves, LAMBDA probe or
control unit.
The engine does not stop

1 Supply on ignition Cause confirmed ▶ Checking ignition block.
Insufficient or excessive oil pressure

1 Pressure regulation valve does not work Cause confirmed ▶ Check and replace if necessary.
properly Cause not confirmed Check: 2
2 Oil pump and delivery pipes inefficient Cause confirmed ▶ Check and replace if necessary.
3 Main and connecting rod bearings inefficient Cause confirmed ▶ Replace the bearings and grind the
crankshaft if necessary.
4 Engine oil SAE viscosity not correct Cause confirmed ▶ Replace the engine oil with oil of ap-
propriate viscosity.

682 ‒ Engine
476 DIAGNOSTICS
Engine overheats

4 Engine oil SAE viscosity not correct Cause not confirmed ▶ Contact the service network.
Engine overheats
1 Coolant level not exact Cause confirmed ▶ Check for leaks and top up.
2 Hydraulic fan control system inefficient Cause confirmed ▶ Check oil level and pressure adjust-
ment valve operation.
3 Water pump inefficient Cause confirmed ▶ Overhaul or replace the assembly.
4 Thermostat inefficient Cause confirmed ▶ replace.
5 Radiator inefficient Cause confirmed ▶ Wash well, check for leaks, replace the
part if necessary.
6 Clean or replace defective parts. Cause confirmed ▶ Inefficient air filter and circuit piping.
79 Main electronic - electric malfunctions

Troubleshooting ABS/EDC/IBC2/IC/DCU systems faults can be done via Cluster or E.A.SY. diagnostic tool. Diagnosis using the
cluster allows you to evaluate the situation of the faults found in the system in advance, whereas the diagnostic tools are essential
in carrying out a thorough diagnosis and taking appropriate measures with regard to the individual faults. The device displays the
diagnosis and repair help.

DTC control unit EDC 7 UC31 (Cursor 9)
DTC FMI Faulty com- Error type Visible fault Possible Cause Repair operation Controls to Meas- Values Notes
ponent be carried uring to be
out condi- detected
tions
0x0111 SENSOR/SIGNAL The error is caused by Check the tachograph
(273) FOR VEHICLE a wiring short circuit or and speedometer
SPEED faulty sensor. sensor (40032) us-
ing the diagnosis
instrument, instru-
– – – ment cluster ECU – – – –
- measurable para-
meters. Check the
unit's operation; if the
readings are incorrect
replace the sensor.
0x0112 ACCELERATOR Vehicle acceler- Accelerator pedal Check the accelerator
(274) PEDAL ation very slow. and brake pressed pedal signal and
Engine idle simultaneously (for pedal mechanical
– – – – – –
speed: 500rpm. too long); Accelerator movement.
pedal blocked or faulty;
Incorrect use of vehicle.
(275) PEDAL/BRAKE ation very slow. and brake pressed pedal signal and
PEDAL PLAUSIB- Engine idle simultaneously (for pedal mechanical
– – – – – –
ILITY speed: 500rpm. too long); Accelerator movement.
Main electronic - electric malfunctions
682 - Engine
DIAGNOSTICS
477
478
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x0114 MULTIPOS- Problems with multi- Check the opera-
(276) ITION SE- position PTO switch. tion of the switch
LECTOR / PTO between Expansion
Module connector
X3 pin 5 and ground,
when the switch
is operated there
should be a short cir-
– – – – – – –
cuit to ground. The
other PTO switch
positions must be
measured between
connector X3 pin
6 and ground, con-
nector X3 pin 7 and
ground.
0x0115 CRUISE CON- Cruise con- Error on the Cruise Check the CAN
(277) TROL SWITCH trol device Control system speed message. |With
UNIT not available. memorisation signal SAE J1939: CAN
Reduction in message CCVS
– – – – – –
vehicle power. (cruise control/vehicle
speed) |With IES:
CAN message ID-592
|
0x0116 CLUTCH SIG- The parameter Clutch switch faulty Check clutch pedal
(278) NAL PLAUSIBIL- reading shows or wiring problems in switch and wiring.
– – – – – –
ITY that the clutch pedal.
is pressed.
0x0117 BRAKE PEDAL Slight power Main and secondary Check the syn-
(279) SIGNAL ERROR reduction brake switch not synchronisation of both
– – chronised. One of switches (signal) and – – – –
the two brake pedal wiring.
switches may be stuck.
0x0118 ENGINE BRAKE Error generated by Check operation
(280) PRESELECTION engine brake se- and electrical contact
– – – – – – –
BUTTON lector/activator control of all buttons and
routine switches.
out condi- detected
tions
0x0119 PLAUSIBILITY Possible mechanical Check harness.
(281) – +15 – – problem (in pawl) or – – – –
electrical problem.
0x011A PLAUSIBILITY Long engine Monitoring signal
(282) +50 ignition times duration on terminal
50 (start-up), the fault
occurs for time-out
(over 25 sec.). check
– – – – – – –
battery charge status
and engine ignition
parts (starter motor)
for proper working
status.
0x011B CAN MESSAGE: MIL warning Communication error Check the electrical
(283) WHEEL SPEED light on. on the CAN line with connection between
the EDC system the CAN line and the
engine control unit
is correct. Check all
– – CAN line connected – – – –
control units for
correct power supply
and operation. Check
the CAN terminal
resistance.

0x011C WATER IN THE Water separator tank Replace gasoline filter.
– – – – – – –
(284) FUEL FILTER full
0x011E EXCESSIVE The urea dosing system Check the Ad-Blue
(286) AMMONIA (UDS) is not operating dosage unit, Nox
FROM THE correctly sensor, connections
CATALYTIC between sensors,
682 - Engine
CONVERTER Nox pressure - tem-
DIAGNOSTICS
– – – perature - moisture – – – –
value plausibility;
check proper oper-
ation of the catalytic
converter and excess-
ive urea in the tank.
479
480
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x011F PLAUSIBILITY Inaccurate/defective Check wiring and
(287) FAULT IN THE temperature sensor temperature sensor
CATALYTIC before/after catalytic signals. Let the vehicle
CONVERTER converter, or defective cool in the shade and
SYSTEM wiring. measure the temper-
ature detected by the
three sensors (sensor
before catalytic con-
– – – – – – –
verter, sensor after
catalytic converter
and ambient temp.
sensor). If the differ-
ence between the
temperatures exceeds
20°C, replace the
faulty sensor.
0x0121 SPEED LIMITER Short circuit or defect- Check wiring.
(289) – WARNING – – ive wiring. – – – –
LIGHT
0x0122 WARNING Warning light Short circuit or defect- Check wiring.
(290) – LIGHT EOBD – permanently ive wiring. – – – –
off.
0x0123 EDC WARNING Short circuit or defect- Check wiring.
– – – – – – –
(291) LIGHT ive wiring.
0x0124 COLD START Short circuit or defect- Check wiring.
– – – – – – –
(292) LAMP ive wiring.
0x0125 MAIN RELAY Possible prob- Relay short circuit to Check wiring
(293) – DEFECT – lems during battery positive or between ECM and – – – –
after-run. earth. battery.

0x0126 BATTERY Possible prob- Alternator or battery Check wiring. Replace
(294) VOLTAGE lems during defective. Possible alternator regulator
– – after-run. wiring problem. or battery. Replace – – – –
the alternator if
necessary.
0x0127 ENGINE BRAKE Engine brake Relay or wiring short- Check wiring. Replace
(295) – SOLENOID – not operational. circuited or interrupted. relay if necessary. – – – –
VALVE
out condi- detected
tions
0x0128 MAIN RELAY Possible prob- Relay short circuit to Check wiring
(296) – SHORT CIR- lems during battery positive or between ECM and
– – – – – –
CUIT TO BAT- after-run. earth. Relay may be battery. Replace relay
TERY faulty. if necessary.
0x0129 AIR- Possible prob- Relay short circuit to Check wiring
(297) CONDITIONER lems during battery positive or between ECM and
– COMPRESSOR – after-run. earth. Relay may be battery. Replace relay – – – –
RELAY / FUEL faulty. if necessary.
FILTER HEATER
0x012A RELAY FOR Possible prob- Relay short circuit to Check wiring The relay of
(298) ENGINE BRAKE lems during battery positive or between ECM and the exhaust
SOLENOID after-run. earth. Relay may be battery. Replace relay brake butterfly
VALVE faulty. if necessary. valve at the
– – – – – exhaust is
connected to
pins 55 and 58
of connector
"B"
0x012B THERMO- Heater not Relay or wiring short- Check wiring. Replace
(299) STARTER working. circuited or interrupted. relay if necessary.
– – – – – –
RELAY 1
(HEATER)
0x012C THERMO- Heater not Relay or wiring short- Check wiring. Replace
(300) – STARTER RE- – working. circuited or interrupted. relay if necessary. – – – –

LAY 2
0x012D TEST FOR Faulty internal relay Check wiring and
(301) INTERNAL AIR or problems with the connectors, check
HEATER wiring. that the switch is in-
– – – – – – –
tact and replace the
wiring or faulty com-
682 - Engine
ponent if necessary.
DIAGNOSTICS
0x012E MANAGE- Grid heater al- Grid heater short Check wiring and
(302) MENT SYS- ways operating. circuited to earth. component.
– TEM PRE/POST- – – – – –
HEATING (ACT-
IVE)
481
482
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x012F RELAY FOR AIR Run an
(303) CONDITIONER air-conditioner
COMPRESSOR ECU faults memory
reading and consult
its troubleshooting
guide to solve the
problem. If the error
– – – – occurs again, check – – – –
the CAN ECB line,
taking measurements
shown. In case of
different values, check
the ECB line and the
interconnected
control units.
0x0131 COOLANT Slight power Sensor short-circuited Check the wiring.
(305) – TEMPERATURE – reduction or value implausible. Replace sensor if – – – –
SENSOR necessary.
0x0132 COOLANT Slight power Operation in extreme Ensure the engine is
(306) TEMPERATURE reduction environmental condi- not working in ex-
SENSOR (TEST) tions or sensor inaccur- treme environmental
– – ate. conditions. Check the – – – –
wiring and the sensor
accuracy. Replace
sensor if necessary.
0x0133 AIR TEMPERAT- Slight power Sensor short-circuited Check the wiring.
(307) – URE SENSOR – reduction or value implausible. Replace sensor if – – – –
BOOST AIR necessary.
0x0134 TUR- No reaction Sensor short-circuited Check the wiring.

(308) BOCHARGED perceivable or difference between Also check the ambi-
AIR PRESSURE by driver. ambient pressure ent pressure sensor.
– – – – – –
SENSOR Parameter and turbo pressure Replace sensor if ne-
recovery value: implausible. cessary.
2700 mbar.
0x0135 FUEL TEMPER- Slight power Sensor short-circuited Check the wiring.
(309) – ATURE – reduction or value implausible. Replace sensor if – – – –
necessary.
out condi- detected
tions
0x0136 RAIL PRESSURE Possible loss of Rail sensor value above Check connections
(310) SENSOR OR performance. threshold. Sensor short- and correct operation
– – – – – –
SIGNAL ERROR circuited or faulty. of Rail sensor (para-
meter acquisition).
0x0137 PRV VALVE Possible loss of Rail pressure sensor Check connections
(311) MANAGEMENT performance. value above threshold. and correct operation
(RAIL OVER- Sensor faulty or injec- of Rail pressure
– – – – – –
PRESSURE) tion incorrect. sensor (parameter
acquisition) and
injection components.
0x0138 OIL PRESSURE No reaction Sensor short-circuited Check the wiring
(312) SENSOR perceivable or value implausible. and oil level. Replace
by driver. sensor if necessary.
– – – – – –
Parameter
recovery value:
3000 mbar.
0x013A ENGINE OIL No reaction Sensor short-circuited Check the wiring.
(314) TEMPERATURE perceivable by or value implausible. Replace sensor if
SENSOR driver. Para- necessary.
meter recovery
– – value: Coolant – – – –
temperature
value (if in-
tact) otherwise

120°C.
0x013C ATMOSPHERIC No reaction Sensor short-circuited Check the wiring.
(316) TEMPERATURE perceivable or value implausible. Replace sensor if
SENSOR (IF by driver. necessary.
– – – – – –
PRESENT) Parameter
recovery value:
682 - Engine
40°C.
DIAGNOSTICS
0x013D FUEL PRESSURE The error is caused by Check the wiring and
(317) SENSOR (LOW a wiring short circuit or the correct working
– PRESSURE – – faulty sensor. of the sensor. If – – – –
CIRCUIT) necessary, replace
it.
483
484
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x0141 CRANKSHAFT Slight power Signal interrupted or Check wiring and
(321) SPEED SENSOR reduction wiring problem. Sensor installation. Replace
– – – – – –
installation may not be sensor if necessary.
correct.
0x0142 ENGINE No reaction No rpm signal from Check the connection In the event of
(322) WORKING perceivable by the sensor on the en- cables between the a sensor failure,
ONLY WITH driver. gine flywheel. Possible flywheel rpm sensor the ECM unit
CAMSHAFT causes: Wiring faults, and the engine ECU. on the engine
SENSOR faulty sensor or incor- Check the sensor flywheel adopts
– – rect installation. efficiency. The sensor – – – a recovery
resistor is 880 - strategy using,
920ohm. as a reference,
the signal of
the sensor on
the camshaft.
0x0143 CAMSHAFT No reaction Signal interrupted or Check wiring and
(323) SENSOR perceivable by wiring problem. Sensor installation. Replace
– – – – – –
driver. installation may not be sensor if necessary.
correct.
0x0144 PLAUSIBILITY Slight power Signal interrupted Check wiring and
(324) BETWEEN reduction or wiring problem. installation of both
– FLYWHEEL – Flywheel and timing sensors. – – – –
SENSOR AND sensor installation may
CAMSHAFT be incorrect.
0x0145 FAN RELAY No reaction Short circuit or fan Check the wiring
(325) perceivable by actuator faulty. and the fan actuator.
– – – – – –
the driver. Fan Replace the actuator
off. if necessary.
0x0146 SECOND SPEED The error is caused by Check wiring, con-

(326) FAN RELAY a wiring short circuit or nector and com-
– – – – – – –
faulty sensor. ponent; If necessary,
change faulty sensor.
0x0147 FAN SPEED The error is caused by Check the wiring and
(327) SENSOR a wiring short circuit or the correct working
– – – faulty sensor. of the sensor. If – – – –
necessary, replace
it.
out condi- detected
tions
0x0148 AIR- Air conditioner Wiring or relay short- Check the wiring.
(328) CONDITIONER always off. circuited. Replace relay if
– – – – – –
COMPRESSOR necessary.
RELAY
0x0149 PRE-HEATING Filter heater Wiring or filter heater Check the wiring.
(329) – RELAY FUEL – not working. short-circuited. Replace the filter – – – –
FILTER heater if necessary.
0x014A STARTING BUT- Motor starter button Possible button short The error
(330) TON FROM in working position circuit, check the can also be
ENGINE COM- (closed) for more than correct opening of originated if
PARTMENT 20 seconds the circuit in standby the operator
and correct closure hold down the
when pressed. Check button to start
for problems with the engine for
contact closure mech- more than 20
– – – – – –
anism or possible seconds; in this
mechanical jamming case cancel the
faults memory
and start the
engine again,
holding down
the button for
a shorter time
0x014D ENGINE OVER- Engine overspeed. No action required. This is an

(333) SPEED Perform a general information
– – – – – –
inspection of the system failure
vehicle. (InfoFailure).
682 - Engine
DIAGNOSTICS
485
486
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x014E TURBOCOM- Turbocharger control Use the wiring dia-
(334) POUND MON- device - engine speed grams to check the
ITORING limited at low temper- conformity of the
ature wiring and the in-
tegrity of the con-
– – – nectors. Check the – – – –
integrity of the com-
ponent. If the fault
persists, please con-
tact the market THD
or the CET.
0x014F TORQUE LIM- INFO: OBD Fault relative to emis- Analyse the fault
(335) ITER ACT- LEGISLATIVE sions memory of the ECU
IVE DUE TO PERFORM- for any faults resulting
EMISSION ANCE RE- in output power
– – – – – –
THRESHOLD STRICTION limitation => Identify
EXCEEDING INTERVEN- the fault that caused
TION this error and makes
repairs as indicated
0x0151 RAIL PRESSURE Possible loss of Possible pressure Check the possible
(337) MANAGEMENT performance. regulator seized or causes listed above.
– – – – – –
ERROR (POSIT- excessive pressure
IVE DEVIATION) upstream of pump.
0x0152 RAIL PRESSURE Possible loss of High pressure system: Check the possible
(338) MANAGEMENT performance. - possible leaks; - causes listed above.
ERROR (POSIT- injectors stuck open;
IVE DEVIATION) - High-pressure pump
faulty. Low pressure
– – – – – –
system: - low pressure
upstream of pump; -
Fuel filter clogged or
leak upstream of high
pressure pump.
out condi- detected
tions
(339) MANAGEMENT performance. regulator seized or causes listed above.
– ERROR (NEG- – excessive pressure – – – –
ATIVE DEVI- upstream of pump.
ATION)
(340) ERROR (TOO performance. - possible leaks; - causes listed above.
LOW) injectors stuck open;
- High-pressure pump
– – – – – –
upstream of pump; -
pressure pump.
(341) ERROR (TOO performance. regulator seized or causes listed above.
– – – – – –
HIGH) excessive pressure
upstream of pump.
0x0156 PRESSURE Possible loss of High pressure system: Check the possible
(342) DROP IN THE performance. - possible leaks; - causes listed above.
RAIL GREATER injectors stuck open;
THAN THE - High-pressure pump
EXPECTED faulty. Low pressure
– – – – – –

VALUE system: - low pressure
upstream of pump; -
pressure pump.
682 - Engine
DIAGNOSTICS
487
488
out condi- detected

DIAGNOSTICS
682 - Engine
tions
(343) REGULATOR performance. - possible leaks; - causes listed above.
SETPOINT injectors stuck open;
VALUE NOT - High-pressure pump
PLAUSIBLE faulty. Low pressure
– – – – – –
(OVERRUN) system: - low pressure
upstream of pump; -
pressure pump.
0x0158 MPROP: Possible loss of High pressure system: Check the possible
(344) QUANTITY performance. - rail pressure sensor causes listed above.
OF FUEL faulty; - High-pressure
– BELOW THE – pump faulty. Possible – – – –
CALCULATED problem also with
LIMIT low pressure system
(MPROP)
0x0159 PRESSURE Possible loss of Wiring damaged or Check wiring and
(345) MPROP REGU- performance. disconnected; possible pressure regulator;
– – – – – –
LATOR ERROR defective relay or replace relay if neces-
pressure regulator. sary.
0x015A MPROP PRES- Possible mechanical Check the connec-
(346) SURE REGU- fault in the pressure tions, the relay and
– LATOR ERROR – – regulator. the rail pressure – – – –
(ADC) regulator (replace if
faulty)
0x015B HIGH PRESSURE (INFO FAIL- High pressure test in Wait for test to be This is an
(347) TEST ACTIVE URE) progress. completed. information
– – – – –
system failure
(InfoFailure).
out condi- detected
tions
0x015F NOX This fault indicates that Find the failure that Long Term
(351) EMISSIONS NOx emissions are too cause high NOx emis- fault.
THRESHOLD high due to a failure sions and eliminate
EXCEEDED in the fuel injection the problem.
DUE TO system.
– GROUP – – – – –
FAULTS:
SUPPLY/
INJECTION
SYSTEM (LONG
TERM FAULT)
0x0161 INJECTOR One or more Possible short circuit in Check wiring. Possible
(353) CYLINDER injectors (bank connections. Possible internal problem also
– 1 / SHORT – 1 or bank 2) problem in injector coil. in ECM. Replace the – – – –
CIRCUIT not operating. Possible problem in injector if necessary.
control unit.
control unit.

control unit.
682 - Engine
control unit.
DIAGNOSTICS
control unit.
489
490
out condi- detected

DIAGNOSTICS
682 - Engine
tions
control unit.
0x0167 INJECTOR One or more Possible injector con- Check wiring. Possible
(359) CYLINDER 1 / injectors (bank nection problem (or internal problem also
OPEN CIRCUIT 1 or bank 2) disconnected intern- in ECM. Replace the
– – – – – –
not operating. ally). Possible problem injector if necessary.
in control unit (con-
denser).
– – – – – –
denser).
– – – – – –
denser).
0x016A INJECTOR One or more Possible injector con- Check wiring. Possible
– – – – – –
denser).
0x016B INJECTOR One or more Possible injector con- Check wiring. Possible
– – – – – –
denser).
out condi- detected
tions
0x016C INJECTOR One or more Possible injector con- Check wiring. Possible
– – – – – –
denser).
0x016D COMPRESSION Compression Test in After carrying out
(365) TEST IN PRO- progress. the compression test,
– – – – – – –
GRESS turn the key OFF
(after-run).
0x016E THE MINIMUM More than 2 See individual faults in
(366) NUMBER OF injectors not injectors.
INJECTIONS operating.
– WAS NOT – – – – – –
REACHED: EN-
GINE SWITCH
OFF
0x016F ADDITIVE The urea dosing system Check the Ad-Blue
(367) VALVE AC- (UDS) is not operating dosage unit, Nox
TUATOR correctly sensor, connections
between sensors,
Nox pressure - tem-
value plausibility;

check proper oper-
0x0171 BENCH 1 CC One or more Possible defective Check wiring. Possible
(369) injectors (bank injector connections. internal problem also
– – – – – –
682 - Engine
1 or bank 2) Injectors short-circuited. in ECM. Replace the
DIAGNOSTICS
not operating. injector if necessary.
0x0172 BENCH 1 CA One or more Possible defective Check wiring. Possible
– – – – – –
1 or bank 2) in ECM. Replace the
491
492
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x0173 BENCH 2 CC One or more Possible defective Check wiring. Possible
– – – – – –
1 or bank 2) Injectors short-circuited. in ECM. Replace the
0x0174 BENCH 2 CA One or more Possible defective Check wiring. Possible
– – – – – –
1 or bank 2) in ECM. Replace the
0x0175 NO COMBUS- Power reduc- Amount of fuel is in- Check: - injector wir-
(373) TION CYLIN- tion. sufficient for reaching ing and connector,
DER 1 idle due to blocked if necessary repair
or faulty injector, wir- or replace wiring; -
ing interrupted or injector operation,
disconnected. Mech- checking that com-
– – – – – –
anical problem due to bustion is regular (test
compression or the running at idle or
exhaust/intake valve. accelerating), if the
error persists, replace
the injector; - cylinder
compression.
– – – – – –

compression.
out condi- detected
tions
– – – – – –
compression.
– – – – – –
compression.

– – – – – –
682 - Engine
DIAGNOSTICS
compression.
493
494
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x017A NO COMBUS- Power reduc- Amount of fuel is in- Check: - injector wir-
– – – – – –
compression.
0x017B NO COMBUS- Power reduc- Amount of fuel is in- Check: - injector wir-
(379) TION tion. sufficient for reaching ing and connector,
idle due to blocked if necessary repair
– – – – – –
compression.
0x017C BENCH 1 One or more Fault in control unit. Replace the engine
(380) INJECTORS injectors (bank control unit.
– CHECK (IN- – 1 or bank 2) – – – –
TERNAL ECU) may not be
operating.
out condi- detected
tions
0x017D COMMON Power reduc- Amount of fuel is in- Check: - injector wir-
(381) FAULT IN COM- tion. sufficient for reaching ing and connector,
BUSTION MON- idle due to blocked if necessary repair
ITORING or faulty injector, wir- or replace wiring; -
– – – – – –
compression.
0x017E IT IS NOT POS- The engine control Carry out a Faults
(382) SIBLE TO MAN- unit carries out a Cancel Memory and if
AGE THE RE- check comparing the necessary reprogram
QUIRED MULTI- expected injections again the ECU.
INJECTIONS for correct engine
– – – operation and the – – – –
actual injections. If the
injection system is not
able to perform the
injections requested, a
fault is detected.
0x0181 INDUCTION High exhaust gas back- The error may be

(385) EXHAUST pressure value caused caused by the exhaust
DIFFERENTIAL by clogging of the par- gas temperature
PRESSURE ticulate filter or by a sensor, before the
faulty differential pres- particulate filter,
sure sensor. Warning: which is measuring
a raised backpressure incorrect values.
– – – – – – –
682 - Engine
value could damage the Check wires and
DIAGNOSTICS
engine. connectors for the
correct contact
(corrosion). Check
that the sensor is
working correctly and
replace if necessary.
495
496
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x0184 TIMEOUT OF MIL warning Communication error Check the electrical
(388) CAN MESSAGE light on. on the CAN line with connection between
SRA2EDC the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.
0x0187 ERROR ON EGR The error could be Check the wiring and
(391) REGULATION due to: - short circuit the EGR valve con-
(POSITIVE in wiring; - injection nections. Carry out
– DEVIATION) – – system problems; - the active diagnosis – – – –
EGR valve problems. of the EGR valve to
check the functional-
ity.
0x0188 ERROR ON EGR The error could be Check the wiring and
(392) REGULATION due to: - short circuit the EGR valve con-
(NEGATIVE in wiring; - injection nections. Carry out
– DEVIATION) – – system problems; - the active diagnosis – – – –
ity.
0x0189 EGR POWER No fault per- Short circuit or EGR Check harness. Re-
(393) ST. SHORT TO ceived by the actuator faulty. place the EGR actu-
– – – – – –
BATT. driver. EGR not ator if necessary.
working.
0x018A SUPPLY BYPASS By-pass valve down- Check wiring and
(394) INTERCOOLER stream of filter blocked connectors.Check
– – – – – – –
VALVE open or uncalibrated. for a fault in the
component.
out condi- detected
tions
0x018B SHORT CIR- TVA Valve: current Check the connec- If there is a
(395) CUIT TO BATT above the threshold tions and the TVA permanent
FOR THROTTLE valve (replace if not fault, the TVA
– – – – – –
VALVE ACTU- working) solenoid valve
ATOR POWER assumes the
ST. rest position
0x018F SUPPLY FOR The error is caused by Check wiring, con-
(399) HEATER a wiring short circuit or nector and com-
– – – – – – –
LAMBDA faulty sensor. ponent; If necessary,
SENSOR 1 change faulty sensor.
0x0191 TURBOCHAR- Poor perform- VGT actuator or wiring Check VGT wiring
(401) GER ACTU- ance. defective. and actuator.
– ATOR CON- – – – – –
TROL SOLEN-
OID VALVE
0x0192 TURBOCHAR- Poor perform- VGT actuator or wiring Check VGT wiring
(402) GER ACTU- ance. defective. and actuator.
ATOR CON-
TROL SOLEN-
– – – – – –
OID VALVE
SHORT CIR-
CUIT TO POSIT-
IVE
0x0193 TURBINE Poor perform- Air filter blocked or Check the air filter

(403) WHEEL REVS ance. turbine rpm sensor and check parameters
SENSOR signal implausible. linked with the tur-
– – – – – –
bine by performing a
road test (parameter
acquisition).
682 - Engine
DIAGNOSTICS
497
498
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x0194 FAULT ON The error may be Check the exhaust The pressure
(404) AT LEAST caused by: - Fault in the pipe and the power sensor is integ-
TWO OF THE wiring - Faulty sensors - supply pressure actu- rated with the
FOLLOWING leaks or obstructions in ator. Check the wir- temperature
SENSORS: TUR- the exhaust pipe. ing and the sensors sensor.
– BINE SPEED, – – concerned and re- – – –
BOOT PRES- place if necessary.
SURE AND
EXHAUST
GAS PRESSURE
(EPCTL)
0x0195 BOOST PRES- MIL warning Air pressure sensor on Use the wiring dia- The pressure
(405) SURE TOO light on. intake manifold in short grams to check the sensor is integ-
HIGH (EPCTL) circuit or open circuit. correct connections rated with the
and detect possible temperature
– – anomalies in the con- – – – sensor.
nections. Then check
the integrity of the
sensor and replace it
if necessary.
0x0196 EXHAUST GAS High exhaust gas back- The error may be
(406) PRESSURE TOO pressure value caused caused by the exhaust
HIGH (EPCTL) by clogging of the par- gas temperature
ticulate filter or by a sensor, before the
– – – – – – –

correct contact
(corrosion). Check
that the sensor is
out condi- detected
tions
0x0197 TURBOCHAR- Poor perform- Turbo sensor or actu- Check turbine
(407) GER SPEED ance. ator may be faulty. Air sensors and actuator
TOO HIGH filter may be blocked. (parameter
– – – – – –
(EPCTL) acquisition). Check
whether air filter is
blocked.
0x0198 FAULT ON Poor perform- Sensor signal implaus- Determine which
(408) AT LEAST ance. ible. Sensor may be turbine component
TWO OF THE faulty. caused the problem.
FOLLOWING
SENSORS: TUR-
– – – – – –
BINE SPEED,
BOOT PRES-
SURE AND
EXHAUST GAS
PRESSURE (PCR)
0x0199 BOOST PRES- Poor perform- Turbo sensor or actu- Check turbine
(409) SURE CON- ance. ator may be faulty. Air sensors and actuator
TROL (PCR): filter may be blocked. (parameter
– – – – – –
PRESSURE TOO acquisition). Check
HIGH OR TOO whether air filter is
LOW blocked.
0x019A TURBOCHAR- Poor perform- Turbo sensor or actu- Check turbine
(410) GER SPEED ance. ator may be faulty. Air sensors and actuator

TOO HIGH filter may be blocked. (parameter
– – – – – –
(PCR) acquisition). Check
whether air filter is
blocked.
0x019B TURBINE IN Poor perform- Air filter blocked or Check the air filter
(411) OVERSPEED ance. turbine rpm sensor and check parameters
682 - Engine
(THE FAULT signal implausible. linked with the tur-
DIAGNOSTICS
IS NOT DIS- bine by performing a
– PLAYED IF IT – road test (parameter – – – –
IS CAUSED BY acquisition).
A LOW AT-
MOSPHERIC
PRESSURE)
499
500
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x019C EXHAUST GAS High exhaust gas back- The error may be
(412) PRESSURE TOO pressure value caused caused by the exhaust
HIGH (PCR) by clogging of the par- gas temperature
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
0x019D TORQUE LIM- Error transmitted over Refer to the specific
(413) ITATION FROM ECB CAN line from diagnostics for the
– PERFORM- – – Denoxtronic 2 ECU Denoxtronic 2 ECU – – – –
ANCES LIM- to diagnose the
ITATION specific fault
0x019E TORQUE RE- Torque reduction to No action required; if
(414) DUCTION DUE limit fume emissions. power loss continues,
TO SMOKE LIM- find other possible
– – – – – – –
ITATION faults in control unit
memory that might
cause it.
0x019F ERROR ON No effect Sensor signal implaus- Check the NOx
(415) – NOX VALUE – perceived by ible. NOx sensor may sensor. – – – –
the driver. be faulty.
0x01A1 ELECTRICAL The error is caused by Check the wiring and

(417) FAULTS ON a wiring short circuit or the correct working
– NOX SENSOR – – faulty sensor. of the sensor. If – – – –
necessary, replace
it.
out condi- detected
tions
0x01A2 NOX SENSOR NOX SENSOR Faulty NOx sensor Replace the NOx It is not pos-
(418) ERROR PLAUSIBILITY (signal out of limits) sensor sible to test
FAULT sensor signal
and accuracy
– – – – –
in the work-
shop (special
lab equipment
required).
0x01A3 NOX SENSOR FAULTY NOX NOx Sensor Faulty Replace the NOx Wiring dam-
(419) HEATER ERROR SENSOR (electrical problem) sensor aged between
sensor elec-
– – – – – tronics and
sensor element
or damaged
sensor element.
0x01A4 NOX SENSOR Missing CAN message Check sensor con-
(420) CAN TIMEOUT from NOx sensor. nections and CAN
Possible electrical or line; proper sensor
– – – – – – –
wiring failure of NOx operation and relative
sensor. supply power; Check
the wiring.
0x01A5 TIMEOUT OF No effect Problems in the Den- Check wiring. Check
(421) CAN MESSAGE perceived by oxtronic (on the CAN and correct any faults
– – – – – –
DM1DCU the driver. line). in the Denoxtronic

control unit.
0x01A6 TIMEOUT OF No effect CAN configuration Check CAN line
(422) CAN MESSAGE perceived by incorrect. CAN con- wiring. Check Den-
– SCR1 – the driver. nections defective. oxtronic control unit – – – –
Terminal resistance not wiring and operation.
suitable.
682 - Engine
0x01A7 LOW ADBLUE Low Ad-Blue level. Fill the Ad-Blue tank
DIAGNOSTICS
(423) – LEVEL – – Level sensor is faulty. and check the level – – – –
501
502
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x01A8 PROTECTION This fault indicates Run a diagnostic This is an
(424) OF THE DOS- that the Denoxtronic session of the Den- information
ING VALVE system is not capable oxtronic system and system failure
FROM TOO to ensure proper comply with the in- (InfoFailure).
HIGH TEMPER- cooling of the metering formation contained
ATURE module. This may in the Repair Guide.
appear after the engine
is stopped and followed
by start-up within the
– – – – – –
following 100s, or
when the battery is
disconnected from
the vehicle soon after
performing an after-
run, thus allowing the
AdBlue circuit to drain
(that occurs within
90s).
0x01AA ADBLUE The urea dosing system Check the Ad-Blue
(426) STATUS: (UDS) is not operating dosage unit, Nox
CAN VALUE correctly sensor, connections
IMPLAUSIBLE between sensors,
Nox pressure - tem-
value plausibility;
check proper oper-

0x01AB EXHAUST GAS The error is caused by Check the wiring and
(427) TEMPERATURE a wiring short circuit or the correct working
SENSOR UP- faulty sensor. of the sensor. If
– – – – – – –
STREAM THE necessary, replace
TURBOCHAR- it.
GER
out condi- detected
tions
0x01AC ERROR ON The error could be Check the possible
(428) HEATER EGR due to: - short circuit causes listed above.
SENSOR in wiring; - problems
– – – with the heater or – – – –
the sensor; - injection
system problems; -
EGR valve problems.
0x01AD TEMPERATURE The error is caused by Check the wiring and
(429) ERROR OF EGR a wiring short circuit or the correct working
– SENSOR – – faulty sensor. of the sensor. If – – – –
necessary, replace
it.
0x01AE HUMIDITY No effect Sensor short-circuited Move the shift lever
(430) SENSOR perceived by or faulty. and verify the value
– – – – – –
the driver. changes. Replace
0x01AF SERIOUS EOBD INFO: FAULT
(431) FAULT FROM 1 DCU
DENOX- VIA CAN
– – – – – – – –
TRONIC (EOBD DM1DCU
FLASHING MESSAGE
LIGHT)
0x01B1 ERROR ON No effect CAN configuration Check CAN line wir-
(433) CAN CON- perceived by incorrect. CAN con- ing. Check terminal

– TROLLER A – the driver. nections defective. resistances. – – – –
Terminal resistance not
suitable.
– TROLLER B – the driver. nections defective. resistances. – – – –
682 - Engine
DIAGNOSTICS
suitable.
– TROLLER C – the driver. nections defective. resistances. – – – –
suitable.
503
504
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x01B4 TIMEOUT No effect CAN configuration Check CAN line
(436) CAN MESSAGE perceived by incorrect. CAN con- wiring. Check B.C.
– BC2EDC1 – the driver. nections defective. wiring and operation – – – –
suitable.
(437) CAN MESSAGE perceived by incorrect. CAN con- wiring. Check VCM
– VM2EDC – the driver. nections defective. wiring and operation. – – – –
suitable.
0x01B6 TIMEOUT CAN MIL warning Communication error Check the electrical
(438) MESSAGE WSI light on. on the CAN line with connection between
engine control unit
control units for
the CAN terminal
resistance.
0x01B7 ERROR ON No effect CAN configuration Check CAN line
(439) MESSAGES CAN perceived by incorrect. CAN con- wiring. Check ECM
– IN TRANSMIS- – the driver. nections defective. wiring and operation. – – – –
SION Terminal resistance not
suitable.
0x01B8 GEARBOX Gear change request Failure description:
(440) REQUEST NOT not permitted. Engine does not
PLAUSIBLE react on TCU torque

command. Failure
reset condition:
– – – receiving of plausible – – – –
signal. If failure reset
condition is fulfilled,
system reaction is
reset after ignition
off.
out condi- detected
tions
0x01B9 MIL No effect MIL/Body Controller Consult the This is an
(441) perceived by warning light defective. Body Controller information
– – the driver. troubleshooting guide – – – system failure
and check the CAN (InfoFailure).
line.
0x01BA CAN MESSAGE No effect CAN messages from Consult the VCM
(442) DASH DISPLAY perceived by VCM inconsistent. troubleshooting guide
– – – – – –
TIMEOUT the driver. and check the CAN
line.
0x01BB TIMEOUT MIL warning Communication error Check the electrical
ERC1DR the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.
0x01BC TIMEOUT CAN No effect CAN messages from Consult the VCM
(444) MESSAGE AMB- perceived by VCM inconsistent. troubleshooting guide
– – – – – –
COND the driver. and check the CAN
line.

0x01BD TIMEOUT CAN No effect CAN messages from Consult the VCM/BC
(445) MESSAGE CCVS perceived by VCM or BC inconsist- troubleshooting guide
– – – – – –
the driver. ent. and check the CAN
line.
0x01BE PLAUSIBILITY Error generated by
(446) ERROR: overtorque / anti-
682 - Engine
DYNAMIC slip control routine.
DIAGNOSTICS
VEHICLE Cancel error from
– – – – – – – –
CHECK memory using the
diagnosis instrument
and check that error
does not recur.
505
506
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x01BF TIMEOUT CAN MIL warning Communication error Check the electrical
(447) MESSAGE RX- light on. on the CAN line with connection between
ENGTEMP2 the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.
0x01C1 ERROR MES- MIL warning Communication error Check the electrical
(449) SAGE CAN light on. on the CAN line with connection between
EBC1 the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.
0x01C2 ERROR MES- No effect CAN messages from Check the ETC
(450) – SAGE CAN – perceived by ETC (gearbox) incon- connection with the – – – –
ETC1 the driver. sistent. CAN line.
0x01C3 ERROR MES- No effect CAN messages from Check the TCO
(451) – SAGE CAN – perceived by TCO inconsistent. connection with the – – – –
TC01 the driver. CAN line.
0x01C4 ERROR MES- No effect CAN messages from Check the TCU
(452) SAGE CAN perceived by TCU (Transmission connection with the
– – – – – –
TSC1-AE the driver. Control Unit) inconsist- CAN line.
ent.
out condi- detected
tions
TSC1-DE the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.
TSC1-PE the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.

TSC1-TE the EDC system the CAN line and the
engine control unit
control units for
682 - Engine
DIAGNOSTICS
the CAN terminal
resistance.
– – – – – –
TSC1-VE the driver. Control Unit) inconsist- CAN line.
ent.
507
508
out condi- detected

DIAGNOSTICS
682 - Engine
tions
(457) SAGE CAN TF light on. on the CAN line with connection between
engine control unit
control units for
the CAN terminal
resistance.
0x01D1 INTERNAL ECU No effect Electrical interference If the fault persists,
(465) FAULT (SPI perceived by or internal control unit contact the Help
– – – – – –
COMMUNICA- the driver. problems. Desk.
TION FAILURE)
0x01D2 INTERNAL ECU No effect Poor control unit Reprogram the
(466) FAULT (EEP- perceived by programming/flash. central unit. If the
– ROM FAILURE) – the driver. Possible internal fault. error is repeated, – – – –
replace the central
unit, if needed.
(467) FAULT (ECU perceived by programming/flash. central unit. If the
– RECOVERY – the driver. Possible internal fault. error is repeated, – – – –
LOCKED) replace the central
unit, if needed.
0x01D4 INTERNAL ECU No effect Ecu internal failure. If the fault persists,
(468) FAULT MICRO- perceived by contact the Help
– CONTROLLER – the driver. Desk. – – – –
WATCHDOG
FAILURE)
0x01D5 INTERNAL ECU MIL warning The error is detected if Carry out a Faults If the fault
(469) ERROR light on. the check of the ECU Cancel Memory and if persists, contact
– – – – –
memory is not correct. necessary reprogram the Help Desk.
again the ECU.
out condi- detected
tions
0x01D6 ECU INTERNAL Control unit Electronic interference Check the engine
(470) ERROR (TPU) deactivation. or control unit faulty. control unit con-
nector and wiring. If
– – – – – –
the problem persists,
contact the reference
THD.
0x01D7 INTERNAL EDC warning ECU error detected by Perform Stand Alone
(471) ECU ERROR light flashing internal check, prob- reprogramming
(VARIANT lems with programmed of the dataset, if
AREA) Variant dataset reprogramming is not
successful, contact
– – the market THD, – – – –
supplying the results
of the actions taken
for a more in-depth
check of the control
unit.
– – – – –
again the ECU.
– – – – –

again the ECU.
0x01DA ERROR IN THE Error in diesel/torque Perform an engine
(474) CONVERSION mapping test and contact the
MAP TORQUE / market THD with the
– FUEL QUANT- – – results, to check the – – – –
ITY ECU programming
682 - Engine
and potential need to
DIAGNOSTICS
reprogram it
0x01E1 STARTER RE- Short to earth. Check connection.
(481) – LAY – BATTERY – – – – – –
SIDE FAILURE
509
510
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x01E2 IMMOBILIZER The engine fails Problem in CAN line Check the Immob-
(482) to start. or Immobilizer control ilizer control unit is
unit. correctly connected.
– – Enter the Immobilizer – – – –
PIN code during the
"emergency proced-
ure".
0x01E3 THE CON- No effect Ecu internal failure. If the fault persists,
(483) TROL OF THE perceived by contact the Help
– INJECTIONS – the driver. Desk. – – – –
DURATION
HAS FAILED
0x01E4 REDUNDANCY No effect Ecu internal failure. If the fault persists,
(484) OF ENGINE perceived by contact the Help
REVS DURING the driver. Desk.
– THE INJEC- – – – – –
TIONS DUR-
ATION CON-
TROL
0x01E5 SENSORS SUP- No effect Excessive/insufficient Check battery voltage
(485) PLY ERROR perceived by battery voltage or or connections with
– – – – – –
(12V) the driver. possible internal control the ECM. If necessary,
unit problem. replace the ECU.
out condi- detected
tions
0x01E6 SENSOR 1 (SENSOR No effect Excessive / low battery Check battery voltage Disconnect
(486) POWER SUPPLY 1 POWER perceived by voltage or defective and make sure that the battery
SUPPLY) the driver. wiring. Oil pressure the sensor supply and re-connect
sensor/ turbocharging is correct. If the after 1 minute;
sensor / fuel pressure sensor is dirty, clean successively.
sensor / deltaP sensor it thoroughly. Before read the faults
of faulty particulate fil- replacement, check memory again.
– ter or possible problem efficiency using the – – – If the problem
inside the control unit. sensor of a similar persists, contact
vehicle (if available). the Technical
Help Desk
providing the
results obtained
before repla-
cing the ECM.
0x01E7 SENSOR No effect Excessive / low battery Check battery voltage Disconnect
(487) POWER SUPPLY perceived by voltage or defective and make sure that the battery
2 the driver. wiring. Defective hu- the humidity sensor and re-connect
midity sensor or pos- supply is correct. after 1 minute;
sible internal problem Clean the air filter; successively.
of the control unit. thoroughly clean the read the faults
sensor; check continu- memory again.
– – ity of connections and – – – If the problem
check for moisture. persists, contact
If the error persists: the Technical

replace the sensor Help Desk
(P/N 504109620) and providing the
tighten to the max results obtained
torque of 25Nm. before repla-
cing the ECM.
682 - Engine
DIAGNOSTICS
511
512
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x01E8 SENSORS 3 No effect Excessive / low battery Check battery voltage Disconnect
(488) POWER SUPPLY perceived by voltage or defective and make sure that the battery
the driver. wiring. Defective hu- the sensor supply is and re-connect
midity sensor or pos- correct. after 1 minute;
sible internal problem successively.
of the control unit. read the faults
memory again.
– – – – – If the problem
persists, contact
the Technical
Help Desk
providing the
results obtained
before repla-
cing the ECM.
0x01E9 INTERNAL ECU No effect Excessive/insufficient Check battery voltage
(489) TEMPERATURE perceived by battery voltage or or connections with
– – – – – –
TOO HIGH the driver. possible internal control the ECM. If necessary,
0x01EA INTERNAL ECU No effect Excessive/insufficient Check battery voltage
(490) VOLTAGE LOW perceived by battery voltage or or connections with
– – – – – –
the driver. possible internal control the ECM. If necessary,
0x01EB ATMOSPHERIC No reaction Fault in sensor inside Contact the refer-
(491) PRESSURE perceivable control unit. ence THD or the
SENSOR by the driver. Technical Expert
– – – – – –
Parameter Centre.
recovery value:
700 mbar.
0x01EC RUN UP TEST RUN UP TEST ACTIVE WAIT FOR TEST TO
– – – – – – –
(492) ACTIVE TERMINATE
0x01ED RUN UP TEST RUN UP TEST ACTIVE WAIT FOR TEST TO
– – – – – – –
(493) ACTIVE TERMINATE
0x01EF MASS OF SOOT The error is caused by Check wiring, con-
(495) IN OIL BEYOND a wiring short circuit or nector and com-
– – – – – – –
PRESCRIBED faulty sensor. ponent; If necessary,
LIMIT change faulty sensor.
out condi- detected
tions
0x01F1 PARTICLE TRAP The error is caused by Check the wiring and
(497) DIFFERENTIAL a wiring short circuit or the correct working
– PRESSURE – – faulty sensor. of the sensor. If – – – –
SENSOR DE- necessary, replace
FECT it.
0x01F2 RESISTANCE High exhaust gas back- The error may be
(498) FLOW pressure value caused caused by the exhaust
CONTROL by clogging of the par- gas temperature
OF THE ticulate filter or by a sensor, before the
EXHAUSTED faulty differential pres- particulate filter,
GAS ON sure sensor. Warning: which is measuring
PARTICLE TRAP a raised backpressure incorrect values.
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
0x01F3 EXHAUST GAS The error is caused by Check the wiring and
necessary, replace
it.

0x01F4 PARTICULATE Possible freezing of removal, cleaning
(500) FILTER DIFFER- pressure sensor - and reassembly of
ENTIAL PRES- incorrect readings the sensor, if this
SURE SENSOR operation does not
– FROZEN: SIG- – – lead to a significant – – – –
NAL NOT result, the sensor
682 - Engine
PLAUSIBLE may be damaged and
DIAGNOSTICS
therefore must be
replaced
513
514
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x01F5 DIFFERENTIAL High exhaust gas back- The error may be
(501) PRESSURE pressure value caused caused by the exhaust
TOO HIGH ON by clogging of the par- gas temperature
PARTICULATE ticulate filter or by a sensor, before the
FILTER (ENGINE faulty differential pres- particulate filter,
PROTECTION) sure sensor. Warning: which is measuring
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
(502) PRESSURE ON pressure value caused caused by the exhaust
TRAP PARTICLE by clogging of the par- gas temperature
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
0x01F7 PARTICULATE The error is caused by Check the wiring and

(503) FILTER PRE a wiring short circuit or the correct working
– TEMPERATURE – – faulty sensor. of the sensor. If – – – –
SENSOR necessary, replace
it.
0x01F8 EXHAUST GAS The error is caused by Check the wiring and
necessary, replace
it.
out condi- detected
tions
0x01F9 TOO HIGH Regeneration of par- Carry out the re-
(505) NUMBER OF ticulate filter failed, or generation of the
REGENERA- filter or other part of particulate filter via
– – – – – – –
TIONS DE- the exhaust system the tester, check the
MAND blocked. filter and exhaust sys-
tem.
0x01FA TOO HIGH No reaction Particulate filter may be Check filter.
(506) NUMBER perceivable blocked.
OF REGEN- by the driver.
– – – – – –
ERATION Too many filter
REQUESTS regenerations
BLOCKED carried out.
0x01FB CATALYTIC No reaction Catalytic converter not Check catalytic con-
(507) – CONVERTER – perceivable by installed or damaged. verter visually. – – – –
NOT PRESENT driver.
0x01FC TEMPERATURE No reaction Temperature sensors Check fitting and
(508) DIFFERENCE perceivable by damaged or incorrectly condition of sensors.
OVER NORMAL driver. fitted.
RANGE
– BETWEEN UP- – – – – –
STREAM/DOWNSTREAM
OF THE
CATALYTIC
CONVERTER

0x01FD EXHAUST GAS Check exhaust tem- Check Oxicat & DPF
(509) TEMPERATURE perature: exhaust gas inlet temperature
REGULATOR temperature plausibility sensors. Check ex-
(OUTER CON- error haust line integrity
– – – – – – –
TROL LOOP) and remove gas losses
if present. Check in-
682 - Engine
jectors. Check DPF
DIAGNOSTICS
integrity.
515
516
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x01FE MASS OF FUEL The error is caused
(510) IN OIL BEYOND by excessive dilu-
CAUTION LIMIT tion of lubrication
oil caused by post-
injections required
during particulate trap
– – – – regeneration. Check – – – –
lubrication oil and
runt he ENGINE OIL
CHANGE proced-
ure in component
replacement environ-
ment in Easy.
0x01FF MASS OF FUEL The error is caused
(511) IN OIL BEYOND by excessive dilu-
ACTION LIMIT tion of lubrication
oil caused by post-
injections required
during particulate trap
– – – – regeneration. Check – – – –
lubrication oil and
runt he ENGINE OIL
CHANGE proced-
ure in component
replacement environ-
ment in Easy.
0x0211 SPEED VEHICLE Defective speed sensor. Check device and
(529) – SENSOR/SIGNAL – – CAN line configura- – – – –
(CAN) tion.
(530) PEDAL 2 ation very slow. and brake pressed pedal signal and
Engine idle simultaneously (for pedal mechanical
– – – – – –
speed: 500rpm. too long); Accelerator movement.
out condi- detected
tions
0x0215 CRUISE CON- Possible component Check switch opera-
(533) TROL IRRE- malfunction. tion and wiring.
– – – – – – –
VERSIBLE ER-
ROR
0x021B VDC CAN MIL warning Communication error Check the electrical
(539) MESSAGE: light on. on the CAN line with connection between
DYNAMIC the EDC system the CAN line and the
VEHICLE engine control unit
CHECK is correct. Check all
control units for
the CAN terminal
resistance.
0x021D CATALYTIC Catalytic converter Follow the procedure
(541) CONVERTER ageing. for catalytic converter
– – – – – – –
AGEING LIMIT replacement.
EXCEEDED
682 - Engine
DIAGNOSTICS
517
518
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x021E CATALYTIC EFFICIENCY If the controls of the Even if (at the mo- FPT and Bosch
(542) CONVERTER OF SCR system do not show ment) the UDST are currently
AGEING UN- CATALYTIC any failure described in test is OK: Check working to
DER LIMIT CONVERTER step 0 -> step 5, there the faults memory of improve the
BELOW is a high probability the DCU in search monitoring
THE FIRST that the DTC 21E is of DTC items that of the failure
THRESHOLD caused by a temporary may be correlated mode <nozzle
blockage of the nozzle to nozzle blockage: blockage> in
Process Description - DTC-71 - DTC- order to bet-
-> Crystallization of 97 - DTC-99 If one ter integrate
urea inside the 'nozzle (or more) DTCs the function
port to the nozzle lock- are present, there Trouble-
ing (stop of injection), is confirmation that Shooting for
– – – – –
with consequent high there was a tem- this type of
NOx emission (... which porary blockage of fault
causes the DTC-21E ...) the nozzle -> No
-> in the following, an reparative action is
increase in the temper- required -> Clear the
ature of exhaust helps memory failure of the
to dissolve the crys- DCU / ECU and start
tals of urea inside the
nozzle and, therefore,
results in a "self-repair"
effect (... nozzle open
again, the injection can
continue ....)
0x021F TURBINE AC- Slight power Actuator coil faulty or Check actuator
(543) – TUATOR CUR- – reduction not within specified condition. – – – –
RENT tolerance limits.

0x0224 COOLANT The error can be Check: - control
(548) W/LIGHT caused by faults in unit connector and
the wiring or by faulty relative connection
components. wiring; - component
– – – – – – –
and its wiring, repair
or replace the faulty
wiring or component
if necessary.
out condi- detected
tions
0x0225 INTERRUPTED Slight power The control unit is Check wiring and
(549) AFTER-RUN reduction turned off by the then replace the
general switch instead "main relay".
– – of by the key (K15). – – – –
Possible problem
in "main relay" or
connections.
0x0228 MAIN RELAY Slight power Short circuit to ground Check the wiring
(552) – SHORT reduction of the relay main 1, and all components
CIRCUIT TO failure in one of the connected to the
GROUND connected components main relay 1; if the
– – or main relay 1 faulty. fault remains, the – – – –
main relay inside the
control unit may be
defective, replace the
control unit.
0x022A PARTICULATE Regeneration of par- Carry out the re-
(554) FILTER LAMP ticulate filter failed, or generation of the
filter or other part of particulate filter via
– – – – – – –
the exhaust system the tester, check the
blocked. filter and exhaust sys-
tem.
0x022D TEST FOR Faulty internal relay Check wiring and
(557) INTERNAL AIR or problems with the connectors, check

HEATER wiring. that the switch is in-
– – – – – – –
tact and replace the
wiring or faulty com-
ponent if necessary.
0x0232 PLAUSIBILITY Slight power Extreme environmental Ensure the engine is
(562) TEST reduction conditions or sensor working in non-critical
682 - Engine
COOLANT incorrectly adjusted. conditions. Check the
– – – – – –
DIAGNOSTICS
TEMPERATURE sensor connections
and accuracy. Replace
519
520
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x0236 RAIL PRESSURE Possible loss of Rail pressure sensor Check connections
(566) SENSOR OFF- performance. value above threshold. and correct operation
SET of rail sensor (para-
– – – – – –
meter acquisition).
Replace sensor if ne-
cessary.
0x0238 OIL LOW PRES- Slight reduction The DTC triggers Check the engine oil
(568) SURE in power. when, for a few mo- lubrication system
ments, the oil pressure and particularly the
is below the reference pressure control
values indicated below: valve, oil filter, oil
– – • Rpm 200 --> Bar 0.0 pump, bypass valve, – – – –
• Rpm 550 --> Bar 1.5 heat exchanger and
• Rpm 1200 --> Bar injectors.
3.0 • Rpm 1500 -->
Bar 3.0 • Rpm 200 -->
Bar 3.0
0x023A HIGH OIL TEM- Slight power Sensor incorrectly Check the sensor
(570) PERATURE reduction adjusted or faults in connections and
– – – – – –
lubrication system. accuracy. Check the
lubrication system.
0x023D FUEL PRESSURE The error is caused by Check the wiring and
(573) SENSOR NOT a wiring short circuit or the correct working
– PLAUSIBLE – – faulty sensor. of the sensor. If – – – –
(TEST) necessary, replace
it.
0x024A ENGINE COM- Mechanical/electrical Check push-button
(586) PARTMENT failure of start push- and wiring.
– – – – – – –
STOP BUTTON button.
IS STUCK
out condi- detected
tions
(593) MANAGEMENT performance. - possible leaks; - causes listed above.
ERROR (POSIT- injectors stuck open;
IVE DEVIATION) - High-pressure pump
– – – – – –
upstream of pump; -
pressure pump.
(601) MPROP REG- performance. disconnected; possible pressure regulator;
ULATOR ER- defective relay or replace relay if neces-
– – – – – –
ROR (SHORT pressure regulator. sary.
CIRCUIT TO
POSITIVE)
THRESHOLD high due to a incorrect sions and eliminate
EXCEEDED injection time. the problem.
DUE TO
GROUP
– – – – – –
FAULTS:
INJECTION

TIME
CONTROL
(LONG TERM
FAULT)
682 - Engine
DIAGNOSTICS
521
522
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x0275 LEAKAGE OR Power reduc- Amount of fuel is in- Check: - injector wir-
(629) MISFIRING IN tion. sufficient for reaching ing and connector,
CYLINDER 1 idle due to blocked if necessary repair
– – – – – –
compression.
– – – – – –
compression.

– – – – – –
compression.
out condi- detected
tions
– – – – – –
compression.
– – – – – –
compression.

0x027A LEAKAGE OR Power reduc- Amount of fuel is in- Check: - injector wir-
– – – – – –
682 - Engine
DIAGNOSTICS
compression.
523
524
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x027C BANK 2 INJECT- One or more Fault in control unit. Replace the engine
(636) ORS CHECK injectors (bank control unit.
– (INTERNAL – 1 or bank 2) – – – –
ECU) may not be
operating.
0x0287 EGR VALVE The error could be Check the wiring and
(647) GOVERNOR due to: - short circuit the EGR valve con-
POSITIVE DE- in wiring; - injection nections. Carry out
– VIATION IN – – system problems; - the active diagnosis – – – –
REGENERA- EGR valve problems. of the EGR valve to
TION check the functional-
ity.
0x0288 EGR VALVE The error could be Check the wiring and
(648) NEGATIVE due to: - short circuit the EGR valve con-
DEVIATION in wiring; - injection nections. Carry out
– – – system problems; - the active diagnosis – – – –
ity.
0x0289 SHORT The error is caused by Check the wiring and
(649) CIRCUIT TO problems in the EGR the EGR valve con-
GROUND ON solenoid valve wiring. nections. Carry out
– EGR VALVE – – the active diagnosis – – – –
of the EGR valve to
ity.
0x028A SUPPLY BYPASS By-pass valve down- Check wiring and
(650) INTERCOOLER stream of filter blocked connectors.Check
– – – – – – –
VALVE open or uncalibrated. for a fault in the
component.
0x028B THROTTLE The error should not
(651) VALVE be generated in the
Iveco configuration as
– – – – – – – –
the throttle valve in-
take comes from the
CAN bus messages.
out condi- detected
tions
0x0292 TURBINE Poor perform- VGT actuator or wiring Check VGT wiring
(658) ACTUATOR ance. defective. and actuator.
CONTROL
– SOLENOID – – – – –
VALVE SHORT
CIRCUIT TO
GROUND
0x0293 TURBOCHAR- Power reduc- A fault has been de- Use the wiring dia- The turbine
(659) GER SPEED tion to protect tected in the turbine grams to check the speed sensor
VALUATION the turbine and speed control circuit. conformity of the resistance at a
limit speed. wiring and the in- temperature of
tegrity of the con- 20° C is 340
– – nectors. Check the – – – ohm.
tact the market THD
or the CET.
0x029D TORQUE LIMIT- Power loss to protect No action required; if This is an
(669) ATION DUE TO mechanical compon- power loss continues, information
NTC ents. find other possible system failure
– – – – – –
faults in control unit (InfoFailure).
memory that might
cause it.

0x029E TORQUE LIM- Torque limitation due No action required
(670) ITATION FROM to: turbocharger if this is the only
TURBOCHAR- fault present. If the
GER power reduction is
indeed due to this
– – – defect, the fault that – – – –
682 - Engine
triggers the torque
DIAGNOSTICS
limitation should also
be present in the
fault memory. Refer
to this second fault.
525
526
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x02A1 ERROR ON The error is caused by Check the wiring and
(673) NOX SENSOR a wiring short circuit or the correct working
– SIGNAL – – faulty sensor. of the sensor. If – – – –
necessary, replace
it.
0x02A2 NOX SENSOR FAULTY NOX Faulty NOx sensor Replace the NOx It is not pos-
(674) DRIFT OUT OF SENSOR sensor sible to test
RANGE DRIFT sensor signal
and accuracy
– – – – –
in the work-
shop (special
lab equipment
required).
0x02A6 TIMEOUT OF No effect Problem in the Den- Check the faults in
(678) CAN MESSAGE perceived by oxtronic (on the CAN the Denoxtronic and
– SCR2 – the driver. line). consult the control – – – –
unit troubleshooting
guide. Check wiring.
0x02A7 LOW ADBLUE Low Ad-Blue level. Fill the Ad-Blue tank
(679) – LEVEL – – Level sensor is faulty. and check the level – – – –
0x02AA ADBLUE CON- The urea dosing system Check the Ad-Blue
(682) DUCTIVITY (UDS) is not operating dosage unit, Nox
ERROR correctly sensor, connections
between sensors,
Nox pressure - tem-
value plausibility;
check proper oper-

0x02AB EXHAUST PRES- The error is caused by Check the wiring and
(683) SURE SENSOR a wiring short circuit or the correct working
– BEFORE TUR- – – faulty sensor. of the sensor. If – – – –
BINE necessary, replace
it.
out condi- detected
tions
0x02AC TIMEOUT CAN MIL warning - Problem with the Check sensor con-
(684) EGR SENSOR light on. wiring. - Problem on nections and CAN
the EGR valve position line; proper sensor
– – – – – –
sensor operation and relative
supply power; Check
the wiring.
0x02AE HUMIDITY No effect Sensor short-circuited Move the shift lever
(686) SENSOR perceived by or faulty. and verify the value
– – – – – –
the driver. changes. Replace
0x02AF SERIOUS EOBD No effect Problems in Ad-Blue Check the faults in This is an
(687) FAULT FROM perceived by dosing system. the Denoxtronic and information
DENOX- the driver. consult the control system failure
– – – – –
TRONIC (EOBD unit troubleshooting (InfoFailure).
FLASHING guide.
LIGHT)
(692) CAN MESSAGE perceived by incorrect. CAN con- wiring. Check B.C.
– BC2EDC2 – the driver. nections defective. wiring and operation – – – –
suitable.
0x02C2 TIMEOUT OF CAN Message from Check for the pres-
(706) CAN MESSAGE ETC (Electronic Trans- ence and correct
ETC2 mission Controller) connection of ETC

– – – timed out; ETC con- and CAN control- – – – –
nection missing or ler efficiency. Check
damaged. Short circuit power supply and
in connection. connections.
682 - Engine
DIAGNOSTICS
527
528
out condi- detected

DIAGNOSTICS
682 - Engine
tions
TSC1-AR the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.
TSC1-DR the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.
TSC1-PE (PASS- the EDC system the CAN line and the
IVE) engine control unit
control units for

the CAN terminal
resistance.
out condi- detected
tions
TSC1-TR the EDC system the CAN line and the
engine control unit
control units for
the CAN terminal
resistance.
– – – – – –
TSC1-VR the driver. Control Unit) inconsist- CAN line.
ent.
0x02C9 ERROR MES- No effect CAN messages from Check the tachograph
(713) – SAGE CAN – perceived by TC (tachograph) incon- connection with the – – – –
TIMEDATE the driver. sistent. CAN line.
(723) FAULT (ECU perceived by programming/flash. central unit. If the
– RECOVERY – the driver. Possible internal fault. error is repeated, – – – –
SUPPRESSED) replace the central
unit, if needed.
0x02E1 STARTER RE- Short to battery. Check connection.

(737) LAY – LOW
– – – – – – –
SIDE FAILURE
(GND)
0x02F2 ATMOSPHERIC The error is caused by Check the wiring and
(754) PRESSURE a wiring short circuit or the correct working
682 - Engine
necessary, replace
DIAGNOSTICS
it.
529
530
out condi- detected

DIAGNOSTICS
682 - Engine
tions
(755) PRESSURE OF pressure value caused caused by the exhaust
PARTICULATE by clogging of the par- gas temperature
FILTER NOT ticulate filter or by a sensor, before the
PLAUSIBLE faulty differential pres- particulate filter,
(TEST) sure sensor. Warning: which is measuring
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
0x02F6 CHECK OF EX- High exhaust gas back- The error may be
(758) HAUSTED GAS pressure value caused caused by the exhaust
TEMPERAT- by clogging of the par- gas temperature
URE BEFORE ticulate filter or by a sensor, before the
CATALYTIC faulty differential pres- particulate filter,
CONVERTER sure sensor. Warning: which is measuring
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
out condi- detected
tions
0x02F7 CHECK OF High exhaust gas back- The error may be
(759) EXHAUSTED pressure value caused caused by the exhaust
PARTICULATE faulty differential pres- particulate filter,
FILTER sure sensor. Warning: which is measuring
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
(760) EXHAUSTED pressure value caused caused by the exhaust
PARTICULATE faulty differential pres- particulate filter,
FILTER sure sensor. Warning: which is measuring
– – – – – – –
correct contact
(corrosion). Check

that the sensor is
0x02FA PERMANENT Regeneration of par- Carry out the re-
(762) REGENERA- ticulate filter failed, or generation of the
682 - Engine
TION filter or other part of particulate filter via
– – – – – – –
DIAGNOSTICS
tem.
531
532
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x02FD CHECK OF EX- High exhaust gas back- The error may be
(765) HAUST GAS pressure value caused caused by the exhaust
TEMPERATURE by clogging of the par- gas temperature
(INNER CON- ticulate filter or by a sensor, before the
TROL LOOP) faulty differential pres- particulate filter,
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
0x02FF OIL DILUTION Slight power Oil too diluted. Change the engine oil.
– – – – – –
(767) reduction
0x0311 SPEED VEHICLE The error is caused by Check the tachograph
(785) SENSOR/SIGNAL a wiring short circuit or and speedometer
(EXCEEDING faulty sensor. sensor (40032) us-
RANGE) ing the diagnosis
instrument, instru-
– – – ment cluster ECU – – – –
- measurable para-
meters. Check the
unit's operation; if the
readings are incorrect
replace the sensor.
0x0315 CRUISE CON- Possible component Check switch opera-
(789) – TROL REVERS- – – malfunction. tion and wiring. – – – –

IBLE ERROR
out condi- detected
tions
0x031D DCU STATE DCU STATUS Urea-Dosing-System Read the faults Perform a
(797) MONITORING MONITORING (UDS) does not work memory of the DCU UDST (Urea
properly. The DCU (Dosing Control Unit) Dosing System
does not achieve => Inspect the sys- Test) is needed.
– – normal status (or stand- tem and make repairs – – – Follow the test
by) within a set time. based on the fault troubleshooting
codes (DTC) guide to find
and resolve
problems.
0x031E CATALYTIC EFFICIENCY If the controls of the Even if (at the mo- FPT and Bosch
(798) CONVERTER OF SCR system do not show ment) the UDST are currently
AGEING UN- CATALYTIC any failure described in test is OK: Check working to
DER LIMIT CONVERTER step 0 -> step 5, there the faults memory of improve the
BELOW THE is a high probability the DCU in search monitoring
SECOND that the DTC 31E is of DTC items that of the failure
THRESHOLD caused by a temporary may be correlated mode <nozzle
blockage of the nozzle to nozzle blockage: blockage> in
Process Description - DTC-71 - DTC- order to bet-
-> Crystallization of 97 - DTC-99 If one ter integrate
urea inside the 'nozzle (or more) DTCs the function
port to the nozzle lock- are present, there Trouble-
ing (stop of injection), is confirmation that Shooting for
– – – – –
with consequent high there was a tem- this type of
NOx emission (... which porary blockage of fault
causes the DTC-31E ...) the nozzle -> No

-> in the following, an reparative action is
increase in the temper- required -> Clear the
ature of exhaust helps memory failure of the
to dissolve the crys- DCU / ECU and start
tals of urea inside the
682 - Engine
nozzle and, therefore,
DIAGNOSTICS
results in a "self-repair"
effect (... nozzle open
again, the injection can
continue ....)
533
534
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x031F TOO HIGH Possible deteriora- Check AD Blue
(799) EFFICIENCY OF tion of the catalytic metering module;
CATALYTIC converter; Excessive the Denoxtronic
CONVERTER Ad-Blue deposit; NOx fault memory; the
– SYSTEM – – sensors or temperature actual efficacy of the – – – –
sensor up/down stream moisture sensors
the catalytic converter and of the various
are not accurate. pressure/temperature
sensors.
0x0332 ENGINE TEM- A general fault has Use the wiring dia-
(818) PERATURE been detected in the grams to check the
CHECK temperature sensor in- conformity of the
side the engine control wiring and the in-
unit. tegrity of the con-
– – – nectors. Check the – – – –
tact the market THD
or the CET.
0x0338 OIL PRESSURE MIL warning The oil Check that the pres-
(824) WARNING light on. pressure/temperature sure/temperature
LIGHT sensor is faulty. sensor is intact and
Incorrect engine oil working efficiently.
level. The oil pump is Check the engine oil
– – – – – –
not working correctly. level. Check that the
Possible blockages in oil pump is working
the oil filter and pipes. correctly. Check for
blockages in the oil

filter and in the pipes.
(857) MPROP REG- performance. disconnected; possible pressure regulator;
ULATOR ER- defective relay or replace relay if neces-
– – – – – –
ROR (SHORT pressure regulator. sary.
CIRCUIT TO
GROUND)
out condi- detected
tions
THRESHOLD high due to incorrect sions and eliminate
EXCEEDED operation of the air the problem.
DUE TO intake/boost air system.
– – – – – –
GROUP
FAULTS: AIR
CONTROL
(LONG TERM
FAULT)
0x0389 EGR VALVE: The error may be due Check the wiring and
(905) OPEN CIRCUIT to an open circuit or a the correct working
– OR TOO HIGH – – short circuit to positive of the sensor. If – – – –
TEMPERATURE in the wiring or by a necessary, replace
faulty sensor. it.
0x038B NO LOAD OR TVA Valve: open circuit Check the connec- If there is a
(907) TOO HIGH on the power stage of tions and the TVA permanent
TEMPERAT- the H-Bridge circuit valve (replace if not fault, the TVA
URE OF TVA working) solenoid valve
(THROTTLE assumes the
– VALVE) POWER – – – – – rest position
STAGE (TVA
VALVE: OPEN
CIRCUIT OR

TOO HIGH
TEMPERATURE)
0x0392 TURBOCHAR- Poor perform- Connection damaged. Check VGT connec-
(914) GER ACTU- ance. Battery voltage excess- tion and actuator.
ATOR CON- ive (ECU overheating).
TROL SOLEN-
682 - Engine
OID VALVE
– – – – – –
DIAGNOSTICS
(TURBOCH.
ACT. VALVE:
OPEN CIRCUIT
OR TOO HIGH
TEMPERATURE)
535
536
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x039D TORQUE LIM- Power drop due to a Check reparative This is an
(925) ITER ACT- fault detected by the guide on the fault information
IVE DUE TO control unit. which triggered this system failure
– – – – – –
EMISSION limitation. (InfoFailure).
THRESHOLD
EXCEEDING
0x039E INDICATES Power reduction to No action required; if This is an
(926) TORQUE LIM- limit turbine rpm. power loss continues, information
ITATION DUE find other possible system failure
– – – – – –
TO TURBO faults in control unit (InfoFailure).
CHARGER PRO- memory that might
TECTION cause it.
0x03A2 NOX SENSOR: Defective/inaccurate Check the Ad-Blue
(930) PLAUSIBILITY Nox sensor. Other dosage unit, Nox
TEST possible failures: sensor sensor, connections
connection; Ad-Blue between sensors,
injection valve faulty; Nox pressure - tem-
– – – excessive Ad-Blue perature - moisture – – – –
quantity in the system. value plausibility;
check proper oper-
0x03A7 ADBLUE - MIL warning Faulty sensor or wiring. Carry out the follow- The AdBlue
(935) TEMPERAT- light is on. ing checks: - Tem- tank level
URE/PRESSURE/LEVEL perature sensor ef- sensor is in-
- IMPLAUSIBLE ficiency. - Efficiency tegrated with
VALUES of the wiring con- the temperat-
– – – – –
nection between the ure sensor.
sensor and the en-
gine control unit. -
No oxidation in the
connectors.
out condi- detected
tions
0x03AA ADBLUE CON- The urea dosing system Check the Ad-Blue
(938) CENTRATION (UDS) is not operating dosage unit, Nox
ERROR correctly sensor, connections
between sensors,
Nox pressure - tem-
value plausibility;
check proper oper-
0x03AF SERIOUS EOBD No effect Problems in Ad-Blue Check the faults in
(943) FAULT FROM perceived by dosing system. the Denoxtronic and
DENOX- the driver. consult the control
– – – – – –
TRONIC (EOBD unit troubleshooting
FLASHING guide.
LIGHT)
TSC1-AE (PASS- the EDC system the CAN line and the
control units for

the CAN terminal
resistance.
682 - Engine
DIAGNOSTICS
537
538
out condi- detected

DIAGNOSTICS
682 - Engine
tions
TSC1-DE (PASS- the EDC system the CAN line and the
control units for
the CAN terminal
resistance.
TSC1-TE (PASS- the EDC system the CAN line and the
control units for
the CAN terminal
resistance.
0x03C8 TIMEOUT OF MIL warning Communication error Check the electrical
TSC1-VE (PASS- the EDC system the CAN line and the
control units for

the CAN terminal
resistance.
0x03C9 ERROR MES- No effect CAN configuration Check CAN line
(969) SAGE CAN perceived by incorrect. CAN con- wiring. Check B.C.
– HRDV – the driver. nections defective. wiring and operation – – – –
suitable.
out condi- detected
tions
– – – – –
again the ECU.
0x03F3 DIFFEREN- High exhaust gas back- The error may be
(1011) TIAL PRES- pressure value caused caused by the exhaust
SURE VALUE by clogging of the par- gas temperature
IMPLAUSIBLE ticulate filter or by a sensor, before the
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
0x03F6 TEMP. DIF- The value read by the Check wiring and The turbine
(1014) FERENCE following temperature temperature sensor speed sensor
UPSTREAM sensors is compared, signals. Let the vehicle resistance at a
FROM OXID- if one reading shows cool in the shade and temperature of
ATION CATA- a value which is too measure the temper- 20° C is 340
LYTIC CON- great compared to the ature detected by the ohm.

VERTER OF others, a fault is de- three sensors (sensor
BANK 1 AND tected. - The exhaust before catalytic con-
2 EXCEEDED gas temperature sensor verter, sensor after
THRESHOLD upstream from the catalytic converter
– – – – – –
DOC oxidation catalytic and ambient temp.
converter. - The ex- sensor). If the differ-
682 - Engine
haust gas temperature ence between the
DIAGNOSTICS
sensor upstream from temperatures exceeds
the SCR. - The exhaust 20°C, replace the
gas temperature sensor faulty sensor.
downstream from the
SCR. It could be due to
a rapid variation in the
539
ambient temperature.
540
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x03F7 TEMP. DIF- The error is caused by Check wiring, con-
(1015) FERENCE UP- a wiring short circuit or nector and com-
STREAM FROM faulty sensor. ponent; If necessary,
PARTICULATE change faulty sensor.
– – – – – – –
FILTER OF
BANK 1 AND
2 EXCEEDED
THRESHOLD
(1016) PARTICULATE pressure value caused caused by the exhaust
FILTER TEMPER- by clogging of the par- gas temperature
ATURE ticulate filter or by a sensor, before the
– – – – – – –
correct contact
(corrosion). Check
that the sensor is
0x03FA REGENERA- No effect Too many regenera- Check particulate
(1018) – TION DEMAND – perceived by tions carried out. filter and faults in – – – –
NUMBER 2 the driver. sensors.
0x041E CATALYTIC The error is caused Reprogram central
(1054) CONVERTER by an incorrect con- unit with correct
– – – – – – –
(SCR) NOT figuration of the ECM configuration.
PRESENT control unit

out condi- detected
tions
0x045F NOX (INFORMA- Faulty NOx sensor Analyse the ECU
(1119) EMISSIONS TION: NOX fault memory and
THRESHOLD SYSTEM search for other
EXCEEDED LONG TERM faults regarding the
DUE TO FAULT) NOx DTC sensor
GROUP that may trigger error
– – – – – –
FAULTS: NOX 45F: 1A2 / 1A3 /
SYSTEM (LONG 1A4 / 2A2 / 3A2
TERM FAULT) =>identify the fault
that causes this error
and follow the repair
guide for that fault.
0x049D INDICATES Regeneration of par- Carry out the re-
(1181) TORQUE LIMIT- ticulate filter failed, or generation of the
ATION DUE TO filter or other part of particulate filter via
– – – – – – –
PARTICULATE the exhaust system the tester, check the
FILTER blocked. filter and exhaust sys-
tem.
0x049E INDICATES Power loss to protect No action required; if This is an
(1182) TORQUE LIM- mechanical compon- power loss continues, information
ITATION DUE ents. Possible excessive find other possible system failure
– TO TURBO – – torque request, ex- faults in control unit – – – (InfoFailure).
CHARGER PRO- cessive engine speed memory that might
TECTION reached or excessive cause it.

temperature.
0x04A7 TIMEOUT The error is caused by Check wiring, con-
(1191) FOR ADBLUE a wiring short circuit or nector and com-
– – – – – – –
SENSOR faulty sensor. ponent; If necessary,
change faulty sensor.
0x04AF SERIOUS EOBD (INFO FAIL- No effect Problems in Ad-Blue Check the faults in This is an
682 - Engine
(1199) FAULT FROM URE) perceived by dosing system. the Denoxtronic and information
DIAGNOSTICS
– – – –
FLASHING guide.
LIGHT)
541
542
out condi- detected

DIAGNOSTICS
682 - Engine
tions
TSC1-AR (PASS- the EDC system the CAN line and the
control units for
the CAN terminal
resistance.
TSC1-DR (PASS- the EDC system the CAN line and the
control units for
the CAN terminal
resistance.
TSC1-TR (PASS- the EDC system the CAN line and the
control units for

the CAN terminal
resistance.
out condi- detected
tions
0x04C8 TIMEOUT OF MIL warning Communication error Check the electrical
TSC1-VR PASS- the EDC system the CAN line and the
IVE engine control unit
control units for
the CAN terminal
resistance.
0x04F3 PARTICULATE The error is caused by Check the wiring and
(1267) FILTER SENSOR: a wiring short circuit or the correct working
– SIGNAL NOT – – faulty sensor. of the sensor. If – – – –
PLAUSIBLE necessary, replace
it.
0x04F6 MON- The value read by the Check wiring and The turbine
(1270) ITOR.TEMPERATURE following temperature temperature sensor speed sensor
UPSTREAM sensors is compared, signals. Let the vehicle resistance at a
OF TURBO if one reading shows cool in the shade and temperature of
CHARGER a value which is too measure the temper- 20° C is 340
great compared to the ature detected by the ohm.
others, a fault is de- three sensors (sensor
tected. - The exhaust before catalytic con-

gas temperature sensor verter, sensor after
upstream from the catalytic converter
– – – – – –
DOC oxidation catalytic and ambient temp.
converter. - The ex- sensor). If the differ-
haust gas temperature ence between the
sensor upstream from temperatures exceeds
682 - Engine
the SCR. - The exhaust 20°C, replace the
DIAGNOSTICS
gas temperature sensor faulty sensor.
downstream from the
SCR. It could be due to
a rapid variation in the
ambient temperature.
543
544
out condi- detected

DIAGNOSTICS
682 - Engine
tions
0x04FA REGENERA- No effect Too many regenera- Check particulate
(1274) – TION DEMAND – perceived by tions carried out. filter and faults in – – – –
NUMBER 3 the driver. sensors.
0x055F NOX (INFORMA- SCR system fault Analyse the ECU
(1375) EMISSIONS TION: LONG fault memory and
THRESHOLD TERM SCR search for other
EXCEEDED SYSTEM faults regarding the
DUE TO FAULT) SCR DTC system
GROUP that may trigger error
FAULTS: SCR 55F: 11F / 21E / 31D
– – – – – –
CHECK (LONG / 31E / 31F / 1A5 /
TERM FAULT) 1A6 / 2A6 / 1AE /
13C / 21D =>identify
the fault that causes
this error and follow
the repair guide for
that fault.
0x059D TORQUE LIM- Power reduction due No action required; if This is an
(1437) ITATION DUE to excessive catalytic power loss continues, information
CATALYTIC converter temperature. find other possible system failure
– – – – – –
CONVERTER faults in control unit (InfoFailure).
TEMPERATURE memory that might
TOO HIGH cause it.
0x059E TORQUE LIMIT- (INFO FAIL- Power reduction to No action required; if This is an
(1438) ATION DUE TO URE) limit noise. power loss continues, information
NOISE REDUC- find other possible system failure
– – – – –
TION faults in control unit (InfoFailure).
memory that might
cause it.
0x05AF SERIOUS EOBD No effect Problems in Ad-Blue Check the faults in This is an
(1455) FAULT FROM perceived by dosing system. the Denoxtronic and information
– – – – –
FLASHING guide.
LIGHT)
out condi- detected
tions
0x0601 LAMBDA The error could be Check the con-
(1537) SENSOR: due to: - short circuit in nectors, wiring and
– WIRING – – wiring; - Faulty lambda lambda sensor. Check – – – –
PROBLEMS sensor; - problems with correct operation of
the injection system. the lambda sensor.
0x0603 LAMBDA Faulty Lambda sensor Check gas exhaust
(1539) SENSOR: CO2 or problems in the system. Check flow
– VALUE OUT – – injection system. meter accuracy. – – – –
OF NORMAL Check lambda sensor
RANGE wiring and accuracy.
0x0604 LAMBDA The error could be Check: - wiring effi-
(1540) PROBE HEATER due to: - short circuit in ciency, eliminating any
wiring; - Faulty lambda short circuits; - effi-
sensor; - Lambda ciency of the Lambda
– – – – – – –
sensor heater is faulty. sensor, replace if ne-
cessary; - efficiency
of the Lambda sensor
heater.

– VALUE OUT – – injection system. meter accuracy. – – – –
682 - Engine
DIAGNOSTICS
545
546
out condi- detected

DIAGNOSTICS
682 - Engine
tions
(1543) FEELER: or problems in the system. Check flow
– CALIBRATION – – injection system. meter accuracy. – – – –
ERROR Check lambda sensor
wiring and accuracy.
0x0608 LAMBDA The error could be Check: - wiring
(1544) SENSOR: due to: - short circuit in efficiency, eliminating
INTERNAL wiring; - Faulty lambda any short circuits;
RESISTANCE sensor; - faulty sensor - efficiency of the
PROBLEMS inside the Lambda Lambda sensor,
– – – – – – –
sensor. replace if necessary;
- efficiency of the
resistor inside the
Lambda sensor,
0x0609 INTERNAL ECU MIL warning The error is detected if Carry out a Faults If the fault
– – – – –
again the ECU.
0x060A INTERNAL ECU MIL warning The error is detected if Carry out a Faults If the fault
– – – – –
again the ECU.
0x060B LAMBDA The error could be Check the con-
out condi- detected
tions
0x060C LAMBDA The error could be Check: - wiring
(1548) SENSOR: due to: - short circuit in efficiency, eliminating
INTERNAL wiring; - Faulty lambda any short circuits;
RESISTANCE sensor; - faulty sensor - efficiency of the
PROBLEMS inside the Lambda Lambda sensor,
– – – – – – –
sensor. replace if necessary;
- efficiency of the
resistor inside the
Lambda sensor,
0x060D LAMBDA Faulty Lambda sensor Check gas exhaust
VALUE AT FULL injection system. meter accuracy.
– – – – – – –
LOAD OUT Check lambda sensor
OF NORMAL wiring and accuracy.
RANGE
0x060E LAMBDA Faulty Lambda sensor Check gas exhaust
VALUE AT injection system. meter accuracy.
– AVERAGE – – Check lambda sensor – – – –
LOAD OUT wiring and accuracy.
OF NORMAL
RANGE
0x060F LAMBDA Faulty Lambda sensor Check gas exhaust

VALUE OUT injection system. meter accuracy.
– – – – – – –
DURING
ENGINE
682 - Engine
OVERSPEED
DIAGNOSTICS
0x069E TORQUE LIM- Power reduction due No action required; if This is an
(1694) ITATION FROM to insufficient fuel power loss continues, information
INCORRECT quantity. find other possible system failure
– – – – – –
INJECTED FUEL faults in control unit (InfoFailure).
QUANTITY memory that might
cause it.
547
548
out condi- detected

DIAGNOSTICS
682 - Engine
tions
(1936) FEELER: or problems in the system. Check flow
– MONITORING – – injection system. meter accuracy. – – – –
OF THE Check lambda sensor
CONTROLLER wiring and accuracy.
0x07F0 TOO LONG Regeneration of par- Carry out the re-
(2032) SPENT IN RE- ticulate filter failed, or generation of the
GENERATION filter or other part of particulate filter via
– – – – – – –
tem.
DTC control unit EDC17 CV44 (Cursor 13)
DTC FMI Faulty component Error type Visible fault Possible Repair oper- Controls to Measuring Values Notes
Cause ation be carried conditions to be
out detected
0x002D SRC HIGH FOR BATTERY P0563
– – – – – – – –
(45) VOLTAGE SENSOR
0x002E SRC LOW FOR BATTERY P0562
– – – – – – – –
(46) VOLTAGE SENSOR
0x002F BRAKE PLAUSIBILITY CHECK P0504
– – – – – – – –
(47)
0x0031 ERROR PASSIVE CAN A U0073
– – – – – – – –
(49)
0x0032 CAN B PASSIVE ERROR U0073
– – – – – – – –
(50)
0x0033 ERROR PASSIVE CAN C U0073
– – – – – – – –
(51)
0x0034 ERROR PASSIVE CAN D U0073
– – – – – – – –
(52)
0x0035 ERROR CAN A BUS OFF U0073
– – – – – – – –
(53)
0x0036 ERROR CAN B BUS OFF U0073
– – – – – – – –
(54)
0x0037 ERROR CAN C BUS OFF U0073
– – – – – – – –
(55)
0x0038 ERROR CAN D BUS OFF U0073
– – – – – – – –
(56)
0x003C SCR HIGH FOR ENGINE P0118

(60) – COOLANT TEMPERATURE – – – – – – –
(DOWNSTREAM)
0x003D SCR LOW FOR ENGINE P0117
(61) – COOLANT TEMPERATURE – – – – – – –
(DOWNSTREAM)
0x003F CLUTCH PLAUSIBILITY CHECK P0704
682 - Engine
– – – – – – – –
(63)
DIAGNOSTICS
0x0041 TORQUE LIMIT CAUSED BY P1038
(65) – TURBOCHARGER PROTEC- – – – – – – –
TION
– – – – – – – –
(66) ENGINE PROTECTION
549
550
out detected

DIAGNOSTICS
682 - Engine
– – – – – – – –
(67) INJECTION SYSTEM
0x0044 WORK LIMIT INFORMATION P1006
– – – – – – – –
(68)
– – – – – – – –
(69) ENGINE BRAKE PROTECTION
0x0046 TORQUE LIMITATION DUE P1042
– – – – – – – –
(70) TO PARTICULATE FILTER
0x0047 TORQUE LIMIT DUE TO PER- P1043
– – – – – – – –
(71) FORMANCES LIMITATION
– – – – – – – –
(72) EXHAUST SMOKE LIMIT
0x0049 TIMEOUT ERROR OF THE U0100
(73) – CAN ACK TRANSMISSION – – – – – – –
STRUCTURE
0x004A TIMEOUT ERROR OF THE U0100
(74) – CAN AMBCON TRANSMIS- – – – – – – –
SION STRUCTURE
0x005B PATH CORRESPONDENCE P1400
(91) – SPN1 OF MESSAGE DM1DCU – – – – – – –
ERROR
0x005C PATH CORRESPONDENCE P1401
ERROR
0x005D PATH CORRESPONDENCE P1402
ERROR
0x005E PATH CORRESPONDENCE P1403

ERROR
0x005F PATH CORRESPONDENCE P1404
ERROR
(99) – CAN EEC1 TRANSMISSION – – – – – – –
STRUCTURE
out detected
STRUCTURE
STRUCTURE
0x006C TIMEOUT ERROR OF THE U0100
(108) – CAN FLECO TRANSMISSION – – – – – – –
STRUCTURE
0x006D TIMEOUT ERROR OF THE U0100
(109) – CAN ICON TRANSMISSION – – – – – – –
STRUCTURE
0x008C TIMEOUT ERROR OF THE U0100
(140) – CAN TCO1 RECEIVING – – – – – – –
STRUCTURE
0x0092 TIMEOUT DFC PASSIVE OF U0121
– – – – – – – –
(146) THE MESSAGE TSC1AR
0x00A2 TIMEOUT ERROR OF THE U0121
(162) – CAN TSC1AR RECEIVING – – – – – – –
STRUCTURE
0x00B9 FAULTY PATH THAT INDIC- P0575
(185) ATES INVALID COMBINATION
– – – – – – – –
OF CRUISE CONTROL BUT-
TONS PRESSED
0x00BA REPORTED ERRORS SPI AND P0607

– – – – – – – –
(186) COM OF CY146
0x00BB ERRORS SPI/COM OF CY320 P0607
– – – – – – – –
(187)
0x00BC THE POWER PHASE DIA- P0563
(188) GNOSIS MAY BE DISABLED
– – – – – – – –
682 - Engine
DUE TO HIGH BATTERY
DIAGNOSTICS
VOLTAGE
0x00BD POWER LEVEL DIAGNOSIS P0562
(189) – MAY BE DISABLED DUE TO – – – – – – –
LOW BATTERY VOLTAGE
0x00C5 EEP READ ERROR BASED ON P062F
– – – – – – – –
(197) MULTI-BLOCK ERROR
551
552
out detected

DIAGNOSTICS
682 - Engine
0x00C6 EEP READ ERROR BASED ON P062F
– – – – – – – –
(198) MULTI-BLOCK ERROR
0x00C7 EEP WRITE ERROR BASED ON P062F
– – – – – – – –
(199) SINGLE BLOCK ERROR
0x00DE INJECTION STOP REQUEST P1008
(222) – (ICO) FOR CUT-OUT CON- – – – – – – –
TROL UNIT
0x00DF OVER-SPEED READING IN P0219
(223) – ENGINE COMPONENT PRO- – – – – – – –
TECTION
0x00E6 HIGH SCR FOR AMBIENT P2229
– – – – – – – –
(230) PRESSURE
0x00E7 LOW SCR FOR AMBIENT P2228
– – – – – – – –
(231) PRESSURE
0x00E9 HIGH SCR FOR AMBIENT P0073
– – – – – – – –
(233) TEMPERATURE
0x00EA LOW SCR FOR AMBIENT P0072
– – – – – – – –
(234) TEMPERATURE
0x00EB FAULT CHECK FOR CAM- P0341
(235) – SHAFT SIGNAL DIAGNOSTICS – – – – – – –
ERROR - DISTURBED SIGNAL
0x00EC FAULT CHECK FOR CAM- P0340
ERROR - NO SIGNAL
0x00ED FAULT CHECK FOR CAM- P0340
(237) – SHAFT OFFSET ANGLE DEVI- – – – – – – –
ATION ERROR
0x00EE FAULT CHECK FOR CRANK- P0336

ERROR - DISTURBED SIGNAL
0x00EF FAULT CHECK FOR CRANK- P0335
ERROR - NO SIGNAL
0x0118 HIGH SCR FOR FUEL TEMPER- P0183
– – – – – – – –
(280) ATURE SENSOR
0x0119 LOW SCR FOR FUEL TEMPER- P0182
– – – – – – – –
(281) ATURE SENSOR
out detected
0x011A FAULT CHECK FOR FUEL P0181
(282) – TEMPERATURE PLAUSIBILITY – – – – – – –
CHECK FUNCTION ERROR
0x0124 NUMBER OF INJECTIONS LIM- P100E
(292) ITED BY LOAD BALANCING
– – – – – – – –
OF THE TURBOCHARGER CA-
PACITY
0x0125 NUMBER OF INJECTIONS LIM- P100F
(293) – ITED BY QUANTITY BALAN- – – – – – – –
CING OF THE HP PUMP
0x0126 NUMBER OF INJECTIONS P1010
– – – – – – – –
(294) LIMITED BY SYSTEM
0x0127 NUMBER OF INJECTIONS P1011
– – – – – – – –
(295) LIMITED BY OPERATING TIME
0x0129 MINIMUM RAIL PRESSURE P0087
– – – – – – – –
(297) CHECK
0x0132 CY33X IS FAULTY P062B
– – – – – – – –
(306)
0x014C INTERMITTENT CONTACT P0251
– – – – – – – –
(332) BETWEEN ECU AND MENU
0x014D OPEN LOAD OF METERING P0251
– – – – – – – –
(333) UNIT OUTPUT
0x014E MEASURING UNIT DEVICE P0252
– – – – – – – –
(334) DRIVER OVERTEMPERATURE
0x0153 AD DUCT METERING UNIT P0254

(339) – HIGH ERROR SIGNAL RANGE – – – – – – –
CHECK
0x0154 AD DUCT METERING UNIT P0253
(340) – LOW ERROR SIGNAL RANGE – – – – – – –
CHECK
682 - Engine
0x0175 DIAGNOSTIC ERROR CHECK P1045
DIAGNOSTICS
(373) TO REPORT POSITION ERROR
– – – – – – – –
OF REMOTE ACCELERATOR
PEDAL
0x017C BREAKER RELAY OPEN AD- P068A
– – – – – – – –
(380) VANCE FAULT
553
554
out detected

DIAGNOSTICS
682 - Engine
0x017D DFC FOR BREAKER RELAY P068B
– – – – – – – –
(381) STUCK
0x01C7 MINIMUM OIL PRESSURE ER- P0524
– – – – – – – –
(455) ROR IN PLAUSIBILITY CHECK
0x01C9 SRC HIGH FOR OIL PRESSURE P0523
– – – – – – – –
(457) SENSOR
0x01CA SRC LOW FOR OIL PRESSURE P0522
– – – – – – – –
(458) SENSOR
0x01CB HIGH OIL TEMPERATURE P0196
– – – – – – – –
(459) PLAUSIBILITY ERROR
0x01CD HIGH SCR FOR OIL TEMPER- P0198
– – – – – – – –
(461) ATURE
0x01CE LOW SCR FOR OIL TEMPER- P0197
– – – – – – – –
(462) ATURE
0x01D2 FAULT NOT PLAUSIBLE P1031
(466) PHYMOD_TRQ2QBAS_MAP
– – – – – – – –
CONTAINS Q CURVES NOT
RIGOROUSLY MONOTONE
0x01D3 PLAUSIBILITY CHECK FOR AIR P006D
(467) – PRESSURE UPSTREAM OF THE – – – – – – –
INTAKE VALVE SENSOR
0x01D4 PLAUSIBILITY CHECK FOR AIR P006D
(468) – PRESSURE UPSTREAM OF THE – – – – – – –
INTAKE VALVE SENSOR
0x01D5 DIAGNOSTIC ERROR CHECK P0238
(469) FOR HIGH SRC IN AIR PRES-
– – – – – – – –
SURE UPSTREAM OF THE
INTAKE VALVE SENSOR
0x01D6 DIAGNOSTIC ERROR CHECK P0237

(470) FOR LOW SRC IN AIR PRES-
– – – – – – – –
SURE UPSTREAM OF THE
INTAKE VALVE SENSOR
0x01DF THE PRESSURE RELIEF VALVE P0089
(479) HAS REACHED MAXIMUM
– – – – – – – –
NUMBER OF OPENING ACTU-
ATIONS CONSENTED
out detected
0x01E0 PRESSURE RELIEF VALVE P0089
(480) – STUCK OPEN: SUPPLY PRES- – – – – – – –
SURE
0x01E1 PRESSURE RELIEF VALVE P0089
(481) – STUCK OPEN: APPLY PRES- – – – – – – –
SURE SHOCK
0x01E2 PRESSURE RELIEF VALVE OPEN P0089
– – – – – – – –
(482)
0x01E4 AVERAGE RAIL PRESSURE P1037
– – – – – – – –
(484) OUT OF REQUIRED RANGE
0x01E5 THE PRESSURE RELIEF VALVE P0089
(485) – HAS REACHED MAXIMUM – – – – – – –
OPENING TIME CONSENTED
0x01E6 MSC ERRORS OF A R2S2 P060C
– – – – – – – –
(486) REPORTED
0x01E7 MAXIMUM POSITIVE DEVI- P0251
(487) – ATION OF DUCT OVERPRES- – – – – – – –
SURE
0x01E9 MAXIMUM NEGATIVE RAIL P0251
(489) PRESSURE DEVIATION WITH
– – – – – – – –
METERING UNIT ON LOWER
LIMIT IS EXCEEDED
0x01EB MINIMUM RAIL PRESSURE P0087
– – – – – – – –
(491) EXCEEDED
0x01F0 UNSTABLE RAIL PRESSURE P0194

– – – – – – – –
(496) APPROXIMATE VALUE
0x022B APP1 HIGH SIGNAL RANGE P0123
– – – – – – – –
(555) CHECK
0x022F APP1 LOW SIGNAL RANGE P0122
– – – – – – – –
(559) CHECK
682 - Engine
0x0235 SUPPLY SENSOR 1 ERROR P0643
– – – – – – – –
DIAGNOSTICS
(565)
– – – – – – – –
(566)
– – – – – – – –
(567)
555
556
out detected

DIAGNOSTICS
682 - Engine
0x0238 12V MONITORING SUPPLY P1602
– – – – – – – –
(568) SENSOR 1 SRC _HIGH ERROR
0x0239 12V MONITORING SUPPLY P1603
– – – – – – – –
(569) SENSOR 1 SRC _LOW ERROR
0x023C METER STOP TIMEOUT ERROR P060C
– – – – – – – –
(572)
0x0242 ERROR OF EXCESSIVE TEM- P0615
(578) PERATURE ON CONTROL
– – – – – – – –
UNIT POWER PHASE FOR
STARTER MOTOR
0x024C PLAUSIBILITY BETWEEN APP1 P2135
– – – – – – – –
(588) AND APP2 CHECK
0x024F T50 SWITCH FAULTY P2530
– – – – – – – –
(591)
0x0255 SRC HIGH FOR TEMPERATURE P0098
(597) – DOWNSTREAM OF THE AIR – – – – – – –
HEAT EXCHANGER
0x0256 SRC LOW FOR TEMPERATURE P0097
(598) – DOWNSTREAM OF THE AIR – – – – – – –
HEAT EXCHANGER
0x0258 HIGH SRC FOR CONTROL P0669
– – – – – – – –
(600) UNIT TEMPERATURE SENSOR
0x0259 LOW SCR FOR CONTROL P0668
– – – – – – – –
(601) UNIT TEMPERATURE SENSOR
0x02C3 CAN VEHICLE SPEED SIGNAL U1405
– – – – – – – –
(707) ERROR
0x02C4 VEHICLE SPEED MAXIMUM P0279
– – – – – – – –
(708) THRESHOLD ERROR
0x02C6 VEHICLE SPEED PLAUSIBILITY P0501

– – – – – – – –
(710) ERROR
0x02D3 TIMEOUT BAM-PACK FOR U0113
– – – – – – – –
(723) MESSAGE CAN DM19DS
0x02D4 TIMEOUT BAM FOR MESSAGE U0113
– – – – – – – –
(724) CAN DM19DS
0x02D5 TIMEOUT PACK-PACK FOR U0113
– – – – – – – –
(725) MESSAGE CAN DM19DS
out detected
0x02D6 TIMEOUT BAM-PACK FOR U0113
– – – – – – – –
(726) MESSAGE CAN DM19US
0x02D7 TIMEOUT BAM FOR MESSAGE U0113
– – – – – – – –
(727) CAN DM19US
0x02D8 TIMEOUT PACK - PACK FOR U0113
– – – – – – – –
(728) MESSAGE CAN DM19US
0x02E0 DFC ERROR FOR CAN TCO1 U0100
– – – – – – – –
(736) RECEIVING STRUCTURE
0x02ED DIAGNOSTIC ERROR CHECK P101A
(749) TO REPORT ERROR DUE
– – – – – – – –
TO OVERRUN COOLING
INJECTION
682 - Engine
DIAGNOSTICS
557
DTC Denox control unit (DCU)
558
DTC FMI Faulty compon- Error type Visible fault Possible Cause Repair opera- Controls to be Measuring Values Notes

DIAGNOSTICS
682 - Engine
ent tion carried out conditions to be
detected
0x0C9C NOX SENSOR POWER SUPPLY
– – – – – – – –
(3228) ERROR
0x0D21 SCR SYSTEM MINOR ERROR IN
– – – – – – – –
(3361) SCR SYSTEM
0x0FFA SCR SYSTEM SERIOUS ERROR
– – – – – – – –
(4090) IN SCR SYSTEM
0x110C NOX EMISSION HEAVY EXCESS
– – – – – – – –
(4364)
0x0106E1 ADBLUE TANK EMPTY ADBLUE
– – – – – – – –
(67297) LEVEL SENSOR TANK
0x0110EF PUMP LOW ADBLUE
– – – – – – – –
(69871) PRESSURE
0x020BD7 ADBLUE TEM- SIGNAL RELIABIL-
(134103) – PERATURE SIG- ITY ERROR – – – – – – –
NAL
0x020C9E NOX SENSOR SENSOR RELIABIL-
– – – – – – – –
(134302) ITY ERROR
0x021108 CATALYTIC SIGNAL RELIABIL-
(135432) CONVERTER ITY ERROR
– INLET TEMPER- – – – – – – –
ATURE SENSOR
SIGNAL
0x02110B CATALYTIC SIGNAL RELIABIL-
(135435) CONVERTER EX- ITY ERROR
– HAUST TEMPER- – – – – – – –
ATURE SENSOR
SIGNAL
0x0213AC NOX SENSOR SENSOR RELIABIL-

– – – – – – – –
(136108) ITY ERROR
0x0306E1 ADBLUE TANK VALUE
(198369) LEVEL SENSOR EXCEEDS MAX.
– – – – – – – –
THRESHOLD
ERROR
detected
0x030BD7 ADBLUE TANK VALUE
(199639) TEMPERATURE EXCEEDS MAX.
– – – – – – – –
SENSOR THRESHOLD
ERROR
0x030CA0 NOX SENSOR HEATER ABOVE
(199840) – MAXIMUM – – – – – – –
THRESHOLD
0x0310F0 PUMP VALUE
(200944) EXCEEDS MAX.
– – – – – – – –
THRESHOLD
ERROR
0x031108 CATALYTIC VALUE
(200968) CONVERTER EXCEEDS MAX.
– – – – – – – –
INLET TEMPER- THRESHOLD
ATURE SENSOR ERROR
0x03110B CATALYTIC VALUE
(200971) CONVERTER EX- EXCEEDS MAX.
– – – – – – – –
HAUST TEMPER- THRESHOLD
ATURE SENSOR ERROR
0x0406E1 ADBLUE TANK VALUE LOWER
(263905) LEVEL SENSOR THAN MIN.
– – – – – – – –
THRESHOLD ER-
ROR
0x040BD7 ADBLUE TANK VALUE LOWER
(265175) TEMPERATURE THAN MIN.
– – – – – – – –

SENSOR THRESHOLD ER-
ROR
0x040CA0 NOX SENSOR HEATER BE-
(265376) – LOW MINIMUM – – – – – – –
THRESHOLD
0x0410F0 PUMP VALUE LOWER
682 - Engine
(266480) THAN MIN.
DIAGNOSTICS
– – – – – – – –
THRESHOLD ER-
ROR
0x041108 CATALYTIC VALUE LOWER
(266504) CONVERTER THAN MIN.
– – – – – – – –
INLET TEMPER- THRESHOLD ER-
559
ATURE SENSOR ROR
560
detected

DIAGNOSTICS
682 - Engine
0x04110B CATALYTIC VALUE LOWER
(266507) CONVERTER EX- THAN MIN.
– – – – – – – –
HAUST TEMPER- THRESHOLD ER-
ATURE SENSOR ROR
0x071116 PUMP ERROR IN EN-
(463126) – GINE OR NOZZLE – – – – – – –
CLOGGED
0x0B0C9A NOX SENSOR NOX SENSOR
– – – – – – – –
(724122) ERROR
0x0B0D23 ADBLUE TANK INTERNAL
– – – – – – – –
(724259) HEATER ERROR
0x0B1101 PUMP INTERNAL
– – – – – – – –
(725249) HEATER ERROR
0x0B1102 ADBLUE PIPING INTERNAL
– – – – – – – –
(725250) HEATER HEATER ERROR
0x0D006C AMBIENT PRES- OUT OF RANGE
– – – – – – – –
(852076) SURE SIGNAL
0x0D006E COOLANT OUT OF RANGE
(852078) – TEMPERATURE – – – – – – –
SIGNAL
0x0D00AB AMBIENT TEM- OUT OF RANGE
(852139) – PERATURE SIG- – – – – – – –
NAL
0x0D00B7 FUEL FLOW OUT OF RANGE
– – – – – – – –
(852151) RATE SIGNAL
0x0D00BE ENGINE SPEED OUT OF RANGE
– – – – – – – –
(852158) SENSOR SIGNAL
0x0D0201 ENGINE OUT OF RANGE
(852481) – TORQUE – – – – – – –
SIGNAL
0x0D0658 VEHICLE SPEED OUT OF RANGE
– – – – – – – –
(853592) SIGNAL
0x0D0C9A NOX SIGNAL OUT OF RANGE
– – – – – – – –
(855194) (PPM)
0x0E0C9A NOX SENSOR SENSOR NOT
(920730) – SECURED ON – – – – – – –
EXHAUST PIPE
detected
0x0E1108 CATALYTIC SENSOR NOT
(921864) CONVERTER SECURED ON
– – – – – – – –
INLET TEMPER- EXHAUST PIPE
ATURE SENSOR
0x0E110B CATALYTIC SENSOR NOT
(921867) CONVERTER EX- SECURED ON
– – – – – – – –
HAUST TEMPER- EXHAUST PIPE
ATURE SENSOR
0x0F006C AMBIENT PRES- OVER THE WORK
– – – – – – – –
(983148) SURE SIGNAL LIMIT
0x0F006E COOLANT OVER THE WORK
(983150) – TEMPERATURE LIMIT – – – – – – –
SIGNAL
0x0F00AB AMBIENT TEM- OVER THE WORK
(983211) – PERATURE SIG- LIMIT – – – – – – –
NAL
0x0F00B7 FUEL FLOW OVER THE WORK
– – – – – – – –
(983223) RATE SIGNAL LIMIT
0x0F00BE ENGINE SPEED OVER THE WORK
– – – – – – – –
(983230) SENSOR SIGNAL LIMIT
0x0F0201 ENGINE OVER THE WORK
(983553) – TORQUE LIMIT – – – – – – –
SIGNAL
0x0F0658 VEHICLE SPEED OVER THE WORK
– – – – – – – –
(984664) SIGNAL LIMIT

0x0F06E1 ADBLUE LEVEL OVER THE WORK
– – – – – – – –
(984801) SIGNAL LIMIT
0x0F0BD7 ADBLUE TEM- OVER THE WORK
(986071) – PERATURE SIG- LIMIT – – – – – – –
NAL
682 - Engine
0x0F0C9A NOX SIGNAL OVER THE WORK
– – – – – – – –
DIAGNOSTICS
(986266) (PPM) LIMIT
0x0F1108 CATALYTIC OVER THE WORK
(987400) CONVERTER LIMIT
– INLET TEMPER- – – – – – – –
ATURE SENSOR
SIGNAL
561
562
detected

DIAGNOSTICS
682 - Engine
0x0F110B CATALYTIC OVER THE WORK
(987403) CONVERTER EX- LIMIT
– HAUST TEMPER- – – – – – – –
ATURE SENSOR
SIGNAL
0x10110C NOX EMISSION EXCESSIVELY
– – – – – – – –
(1052940) LOW
0x11006C AMBIENT PRES- BELOW THE
– – – – – – – –
(1114220) SURE SIGNAL WORK LIMIT
0x11006E COOLANT BELOW THE
(1114222) – TEMPERATURE WORK LIMIT – – – – – – –
SIGNAL
0x1100AB AMBIENT TEM- BELOW THE
(1114283) – PERATURE SIG- WORK LIMIT – – – – – – –
NAL
0x1100B7 FUEL FLOW BELOW THE
– – – – – – – –
(1114295) RATE SIGNAL WORK LIMIT
0x1100BE ENGINE SPEED BELOW THE
– – – – – – – –
(1114302) SENSOR SIGNAL WORK LIMIT
0x110201 ENGINE BELOW THE
(1114625) – TORQUE WORK LIMIT – – – – – – –
SIGNAL
0x110658 VEHICLE SPEED BELOW THE
– – – – – – – –
(1115736) SIGNAL WORK LIMIT
0x1106E1 ADBLUE LEVEL BELOW THE
– – – – – – – –
(1115873) SIGNAL WORK LIMIT
0x110BD7 ADBLUE TEM- BELOW THE
(1117143) – PERATURE SIG- WORK LIMIT – – – – – – –
NAL
0x110C9A NOX SIGNAL BELOW THE
– – – – – – – –
(1117338) (PPM) WORK LIMIT
0x111108 CATALYTIC BELOW THE
(1118472) CONVERTER WORK LIMIT
– INLET TEMPER- – – – – – – –
ATURE SENSOR
SIGNAL
detected
0x11110B CATALYTIC BELOW THE
(1118475) CONVERTER EX- WORK LIMIT
– HAUST TEMPER- – – – – – – –
ATURE SENSOR
SIGNAL
0x1206E1 ADBLUE TANK LEVEL BELOW
(1181409) – LEVEL SENSOR 10% OF MAX- – – – – – – –
IMUM LEVEL
0x130C9A CAN LINE NOX SENSOR
(1248410) – COMMUNICA- – – – – – – –
TION ERROR
0xE2F00B CAN LINE MESSAGE CAN
– – – – – – – –
(14872587) ET1 TIMEOUT
0xE2F00C CAN LINE TIMEOUT MES-
– – – – – – – –
(14872588) SAGE CAN AMB
0xE2F012 CAN LINE TIMEOUT MES-
– – – – – – – –
(14872594) SAGE LFE
0xE2F013 CAN LINE TIMEOUT TCO1
– – – – – – – –
(14872595) MESSAGE
0xE7F071 PUMP EEPROM ERROR
– – – – – – – –
(15200369)
0xE7F072 PUMP PILOT UNIT ER-
– – – – – – – –
(15200370) ROR
0xE7F074 PUMP RETURN LINE
– – – – – – – –
(15200372) BLOCKED

0xE7F0D1 CONTROL UNIT EEPROM ERROR
– – – – – – – –
(15200465)
0xE7F601 PUMP INTERNAL ERROR
– – – – – – – –
(15201793)
0xF3F008 CAN LINE DCU COMMU-
– – – – – – – –
682 - Engine
(15986696) NICATION ERROR
DIAGNOSTICS
0xF3F601 CAN LINE PUMP COMMU-
– – – – – – – –
(15988225) NICATION ERROR
563
682 - Engine
564 DIAGNOSTICS
682 ‒ Clutch
Contents 1
Contents
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

682 ‒ Clutch
2 Contents

682 ‒ Clutch
CLUTCH 3
Contents
Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARACTERISTICS AND DATA . . . . . . . . . . . . . . 7
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . 8
Pedal assembly tightening torques . . . . . . . . . . . . 9
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clutch removal and refitting . . . . . . . . . . . . . . . . . 10
Thrust bearing removal-refitting . . . . . . . . . . . . . . 13
Replacing the support bearing of the clutch shaft . . . . 14
Pedal assembly removal - refitting . . . . . . . . . . . . . 15
Checking and adjusting stops on clutch pedal . . . . . . 17
Specifications to replace the master cylinder . . . . . . . 18
Bleeding clutch circuit . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 20
Noise when the clutch is disengaged . . . . . . . . . 20
Noise when the clutch is engaged . . . . . . . . . . . 20
Clutch jerks . . . . . . . . . . . . . . . . . . . . . . . . . 20
The clutch does not release . . . . . . . . . . . . . . . 21
The clutch slips . . . . . . . . . . . . . . . . . . . . . . . 21
Abnormal wear of driven disc linings . . . . . . . . . 21

682 ‒ Clutch
4 CLUTCH

682 ‒ Clutch
CLUTCH 5
Description
CLUTCH
5052 Description
The clutch is the dry single-disc type, with pull engaging mechanism with diaphragm spring.
Actuation is hydropneumatic and involves the master cylinder, with incorporated oil tank, and clutch actuator.
5052 Hydraulic control

The hydraulic control is composed of :
1. Master cylinder with embedded oil tank;

2. clutch actuator with full recovery of driven disc wear.
Master cylinder
Master cylinder components
200117 Figure 1
1 Cylinder 2 Sensor

682 ‒ Clutch
6 CLUTCH
Hydraulic control
Clutch actuator without the clutch wear indicator
102607 Figure 2
1 Inlet (compressed air) 32 Purge screw
3 Exhaust (compressed air) * Valve control coupling
4 Drive (clutch liquid)
Note Clutch actuator can only be activated after mounting.
Technical data
Clutch fluid operating pressure (P₄) 40 bar
Air operating pressure (P₁) 7.5 bar
Clutch fluid maximum pressure (P₄) 120 bar
102608 Figure 3
1 Inlet (compressed air) 4 Drive (clutch liquid)
3 Exhaust (compressed * Valve control coupling
air)

682 ‒ Clutch
CLUTCH 7

Engine power > 280 HP
17" CLUTCH
FuDa/Valeo VALEO
type Dry single disc
Clutch mechanism Pull-type, with diaphragm spring
Driven disc With friction linings
Driven disc hub With double torsion springs
Lining external Ø [mm] 430
Lining internal Ø [mm] 240
Disc thickness (new) [mm] 10.5 + 0.5

- 0.3 10 + 0.3
- 0.3
Max. driven disc off centring [mm] ~0.7
Minimum load on pressure plate (new) [N] 25700 35000
Disengagement load [N] 6000 8300
Minimum pressure plate rise [mm]

1.6 1.7
mm
Stroke at disengagement [mm] 12 + 2
Max. depression stroke [mm] 16.5

682 ‒ Clutch
8 CLUTCH
TIGHTENING TORQUES
Engine power > 280 HP

17" CLUTCH
FuDa/Valeo VALEO
Master cylinder with embedded oil tank, clutch

Clutch control
actuator and driven disc.
Oil type Tutela TRUCK DOT SPECIAL
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
Flanged hex screw fixing pressure plate to flywheel 46.5 ± 4.5 (4.65 ± 0.45)
Nut for stud bolt fixing clutch housing to crankcase 46 ± 5 (4.6 ± 5)
Stud bolt fixing clutch housing to crankcase 19 ± 2 (2 ± 0.2)
Stud bolt fixing clutch housing to crankcase (with PWO Multipower) 19 ± 2 (2 ± 0.2)
Hex nut to lock cylinder push rod adjustment for clutch and servo-clutch 37.5 ± 3.5 (3.7 ± 0.3)
Hex nut securing servo-clutch to clutch housing 23.5 ±2.5 (2.3 ± 0.2)

682 ‒ Clutch
CLUTCH 9
TOOLS
502601 Pedal assembly tightening torques
222103 Figure 4
TORQUE
DETAIL
Nm kgm
1 Coupling 12 ± 1 1.2 ± 0.1
2 Master cylinder fastenings 22 ± 2 2 ± 0.2
3 Plate fastenings 35 + 5 3.5 + 0.5
TOOLS
Universal extraction tool for interiors from 5 to 70 mm (99348004)

682 ‒ Clutch
10 CLUTCH
Clutch removal and refitting
Guide pin for centring clutch plate (99370264)
Guide pin for centring clutch plate (99370280)
Support for clutch assemblies removal and refitting (apply to hydraulic jack) (99370547)
.505210. Clutch removal and refitting
Consumables
Molykote molybdenum disulphide grease
Work material
Guide pin for centring clutch plate 99370264
Support for clutch assemblies removal and refitting (apply 99370547
to hydraulic jack)
Abrasive paper
Fork wrench
Magnetic dial gauge
Guide pin
Technical data
Maximum eccentricity of the driven disc 0.20 mm

682 ‒ Clutch
CLUTCH 11
Main action
1. Remove and refit as in the procedure PROPELLER SHAFT REMOVAL AND REFITTING .
2. Remove and refit as in the procedure "Gearbox removal - refitting".
3. Insert the clutch centring pin (1) into the bearing for the gear
input shaft.
code
38438 Figure 5
4. Mount on the hydraulic jack the support (1) and apply it to the
pressure plate (3). Unscrew the screws (2) and remove the
clutch body with the pressure plate from the engine flywheel.
code
Support for clutch assemblies removal and refitting (apply 99370547
to hydraulic jack)
40194 Figure 6
.505211. Driven disc removal

5. Remove the clutch disk (2) together with the centring pin (1).
code
40195 Figure 7
.505211. Checks
6. Check that the contact surface of the driven disc on the flywheel is not excessively worn or scored.
7. Check that the teeth of the flywheel ring gear are not worn or broken.

682 ‒ Clutch
12 CLUTCH
Note If so, remove the engine flywheel.

8. In addition, check there is not even the slightest leakage of lubricant from the seal of the crankshaft rear cover: if there are,
remove the flywheel as described in the relevant paragraph.
9. Remove the rear cover with the sealing ring and replace as described in the chapter of the “Engine” section.
10. Check bearing or bush supporting the Transmission input shaft mounted on the crankshaft for wear or deterioration; In this
case, replace it.
11. Check the condition of the pressure plate: the supporting surface of the driven disc must have no deformation, wear or sign
of overheating and its spring or diaphragm must be sound.
12. Check the condition of the driven disc: The wear gaskets must be neither very worn, nor with signs of overheating or traces
of oil or grease.
13. Check that play between driven disc hub and transmission input shaft is restricted.
14. Check that the flexible coupling springs of the hub do not rotate in their seats and are not broken.
Note When any defects are found, replace the part in question.
Note The clutch assembly is supplied as a spare in kit form. The following are supplied individually: the driven disc and thrust
bearing. In this case it will be necessary to assemble the new parts of the same supply as the pressure plate spring that
is to be reused.
15. Before fitting a new driven disc check that it is centred as fol-
lows:
16. Place the disc (1) on a lathe, then using a magnetic-stand gauge
(2), check that the plate surface is not out of line at any point.
Technical data
Maximum eccentricity of the driven disc 0.20 mm
Tool / Material
Magnetic dial gauge
178204 Figure 8
Conditions
● Uncentered disc
▶ Use a fork wrench (1) as shown in the figure.

Tool / Material
Fork wrench
178205 Figure 9

682 ‒ Clutch
CLUTCH 13
Thrust bearing removal-refitting
.505211. Driven disc refitting

17. To install the clutch assembly, carry out the operations described in the removal process in reverse order, observing the fol-
lowing instructions.
18. Carefully clean the contact surface of the flywheel using alcohol and petrol; if any slight scratches are noted on the surface,
remove with an abrasive cloth.
Tool / Material
Abrasive paper
19. Position the driven disc, always using the guide pin for perfect centring and to prevent harmful stresses on the hub when refit-
ting the gearbox.
Tool / Material
Guide pin
20. Position the clutch body with pressure plate matching the holes for the retaining screws with the ones on the engine flywheel.
21. Assemble and lock the clutch body retaining screws to the specified torque.
22. Refit the gearbox back on after overspreading the splined shaft with specified grease.
Tool / Material
Molykote molybdenum disulphide grease
23. Adjust the push rod of the slave cylinder as described in the relevant chapter (operation 505277).
.505254. Thrust bearing removal-refitting
Main action
.505254. Clutch thrust bearing removal-refitting
1. Remove and refit as described in the procedure PROPELLER SHAFT REMOVAL AND REFITTING (see relative section for
operation 505601).
2. Remove the transmission (see operation 530210).
3. By using the appropriate pliers open the split pin (1) and ex-
tract the thrust bearing (2) from the pressure plate.
4. Reverse these steps when refitting.
Note The new part must be from the same supply as the
pressure plate that is to be reused.
36800 Figure 10
.505254. Push clutch thrust bearing removal - refitting

Note With push clutches you need to pay more attention when assembling the gear on the engine.
In this case the thrust bearing is not constrained to the clutch disengagement lever as for the pull clutches.

682 ‒ Clutch
14 CLUTCH
Replacing the support bearing of the clutch shaft
5. It is necessary to assemble the thrust bearing when connecting

the gearbox/engine as shown in the figure.
◁ A: Wrong assembly
◁ B: Correct assembly
161288 Figure 11
.540852. Replacing the support bearing of the clutch shaft

Work material
Universal extraction tool for interiors from 5 to 70 mm 99348004
Drift
Preliminary actions
1. Remove and refit the propeller shaft.
2. Remove the transmission (see operation 530210).
3. Remove and refit the clutch. ( ➠ Page 10)
Main action
1. Using the appropriate pliers remove the split ring (3).
2. Using the universal extractor (1 )remove the bearing (2).
code
3. For refitting, use the appropriate drift.

Tool / Material
Drift
4. Refit the circlip.
40196 Figure 12

682 ‒ Clutch
CLUTCH 15
Pedal assembly removal - refitting
.502601. Pedal assembly removal - refitting
Main action
.502601. Removal
1. Remove the kickplate (2) by undoing the fixing screws (1) and
removing the mat (3). 3
171946 Figure 13
2. Remove the trim of the steering column on the bottom (2) by

removing the retainers (1-3). 1
2
2
171947 Figure 14
3. Disconnect the pipe (2).

4. Take out the screws (3) and remove the steering gear mount-
ing (1) from the pedal assembly (4).
72834 Figure 15

682 ‒ Clutch
16 CLUTCH
Pedal assembly removal - refitting
5. From outside the cabin, slide out the cable tray (1) and the
pedal cables (6).
6. Disconnect the pipe (4) from the union (5).
7. Disconnect the sensor electrical connection (2) of the distrib-
utor (3).
99142 Figure 16
8. Remove the screws (4) securing the cover (5) of the control
valve (6).
9. Gradually lift the cover (5) to bleed pressurized air in the sys-
tem.
10. Remove the screws (1, 3) fixing the cable retaining straps (2)
and pedal assembly to the cab.
99143 Figure 17

682 ‒ Clutch
CLUTCH 17
Checking and adjusting stops on clutch pedal
11. Remove the screw (2) securing the bracket (1 ) supporting

piping and wiring and disconnect the pedal assembly from the
cab.
72837 Figure 18
.502601. Refitting
12. To refit, carry out the operations described in the removal
process in reverse order.
13. Then adjust the pedal stroke as described in the relevant
chapter.
Note Upon each removal, replace the seals (1) of the control
valve cover (2) coupling by new ones.
14. Tighten the screws and nuts to the specific torque.
15. After refitting, check and if necessary adjust the stroke of the
pedal as described in the relevant chapter.
72838 Figure 19
.505250. Checking and adjusting stops on clutch pedal
Main action
.505250. Clutch pedal adjustment
Note In the clutch pedal rest position, when this is fixed on the upper stop, held by the reaction spring, there must be clearance
0.5 - 1 mm between the end of the tappet and the cap of the master cylinder piston .

682 ‒ Clutch
18 CLUTCH
Specifications to replace the master cylinder
222104 Figure 20
1. This is obtained by setting the adjustment screw of the upper stop of the clutch pedal in such a way that after one stroke of 1
– 2 mm between the clutch pedal and the adjustment screw, the tappet positions itself exactly on the cap (this is noticeable).
When this position has been reached, fasten the adjustment screw with a lock nut.
2. To adjust the lower stop, secure the nut at a distance of 6.5 mm shown in the drawing.
.505250. Brake pedal adjustment

Note With the brake pedal in the rest position when it is firm against the upper stop retained by the reaction spring, the brake
pedal cam must also be firm against the brake control pedal unit rod with a clearance of 0.05 – 0.10 mm (without pres-
sure) .
3. To obtain the prescribed clearance, the adjustment screw of the upper stop of the brake must be adjusted in the same way as
the clutch pedal. When this position has been reached, fasten the adjustment screw with a lock nut.
Note The brake control pedal unit is required for the lower stop. In this case, no adjustment is required.
.505271. Specifications to replace the master cylinder

Main action
Caution!
Clutch liquid Warnings in case of accidental contact
▶ In the event of accidental contact immediately wash with water and neutral soap.
▶ Should you detect any oil leaks from the main cylinder, replace the component and bleed the hydraulic system.

682 ‒ Clutch
CLUTCH 19
Bleeding clutch circuit
.505260. Bleeding clutch circuit
Consumables
Tutela TRUCK DOT SPECIAL oil
Work material
Device for bleeding brake and clutch system air 99306010
Deaerator
Technical data
Bleeding pressure 1 bar to1.2 bar
Main action
1. Bleed air from clutch control hydraulic circuit after repairing
control clutch assembly or following periodic oil changes.
2. Use a deaerator to introduce compressed air into the tank(5).
Tool / Material
Deaerator
3. Fill the oil tank (4).

Tool / Material
4. Replace the cover (→) of the clutch fluid reservoir with one of
the caps supplied with specific tool and connect the pipe to the
cover. 176959 Figure 21
code
Device for bleeding brake and clutch system air 99306010
5. Apply a plastic tube (1) to the slave cylinder bleed screw (2).
6. Immerse the opposite end of the tube into a container with the
specified liquid.
7. Undo the bleed screw one rotation.
8. Open the tap (2) until the pressure gauge (3) reads a pressure
of:
Technical data
Bleeding pressure 1 bar to1.2 bar
Tool / Material
40355 Figure 22

682 ‒ Clutch
20 CLUTCH
DIAGNOSTICS
9. When clutch fluid emerging from circuit is free of bubbles,

tighten bleed screw and drain air from device reservoir (5)
through valve (6).
Note When clutch fluid is changed, bleed master cylinder
before bleeding the servo clutch.
176959 Figure 23
DIAGNOSTICS
Noise when the clutch is disengaged

1 Thrust bearing excessively worn, damaged or Cause confirmed ▶ Replace the thrust bearing.
not properly lubricated. Cause not confirmed Check: 2
2 Excessive play between the splined grooves Cause confirmed ▶ Replace the shaft and, if necessary, the
on the Transmission input shaft and the rel- driven disc.
evant housing on the hub of the driven disc. Cause not confirmed ▶ Contact the Service Network.
Noise when the clutch is engaged

1 Driven disc springs are broken or weakened. Cause confirmed ▶ Replace the driven disc.
2 Transmission input shaft worn. Cause confirmed ▶ Replace the shaft and, if necessary, the
driven disc also.
3 Thrust bearing has excessive play in the joint. Cause confirmed ▶ Replace the thrust bearing.
Cause not confirmed ▶ Contact the Service Network.
Clutch jerks

1 Oil or grease on the flywheel, or on the Cause confirmed ▶ Repair the oil or grease leaks; Thor-
linings of the driven disc. oughly clean the flywheel and replace
the driven disc.
2 Pressure plate deformed. Cause confirmed ▶ Replace the clutch.
3 Lining worn due to driven disc run out. Cause confirmed ▶ Replace the driven disc.
4 Clutch diaphragm spring weak or broken. Cause confirmed ▶ Replace the driven disc.

682 ‒ Clutch
CLUTCH 21
DIAGNOSTICS
The clutch does not release

1 Grooves on the Transmission input shaft are Cause confirmed ▶ Replace the shaft and, if necessary, the
worn and prevent the driven disc movement. driven disc.
2 Slave cylinder free play excessive. Cause confirmed ▶ Check and adjust the slave cylinder
free play.
3 Air in the hydraulic circuit. Cause confirmed ▶ Bleed the circuit.
The clutch slips

1 Driven disc linings worn or burnt. Cause confirmed ▶ Replace the driven disc.
2 Clutch diaphragm spring weak or broken. Cause confirmed ▶ Replace the clutch.
3 Oil or grease on the seals of the driven disc. Cause confirmed ▶ Repair the oil or grease leaks and
replace the driven disc.
Abnormal wear of driven disc linings

1 The driver keeps the clutch pedal pressed Cause confirmed ▶ The driver must break this habit and
while driving. use the clutch pedal only when neces-
sary.
2 Pressure plate deformed. Cause confirmed ▶ Replace pressure plate.
3 Clutch diaphragm spring blades weakened or Cause confirmed ▶ Replace the clutch.
broken. Cause not confirmed Check: 4
4 Insufficient operating cylinder free play. Cause confirmed ▶ Check and adjust the slave cylinder
free play.

682 ‒ Clutch
22 CLUTCH

682 ‒ Gearbox
Contents 1
Contents
9JS GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12JS GEARBOX . . . . . . . . . . . . . . . . . . . . . . . 127

682 ‒ Gearbox
2 Contents

682 ‒ Gearbox
9JS GEARBOX 3
Contents
Contents BOWDEN CABLES ADJUSTMENT DIAGRAM . . . . . 43
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 5 GEARBOX OVERHAULING . . . . . . . . . . . . . . . . 43
LONGITUDINAL CROSS SECTION . . . . . . . . . . . . 9 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 113
GEARBOX DESIGNATION . . . . . . . . . . . . . . . . . . 9 Main mechanical malfunctions . . . . . . . . . . . . . . . 118

The fast and low gears of the splitter are
GEAR CONTROL LEVER . . . . . . . . . . . . . . . . . . 10 disengaged . . . . . . . . . . . . . . . . . . . . . . . . . 118
Gears of main shaft disengaged or crossed . . . . . 118
Operation and troubleshooting the gearbox pneumatic
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Gear shifting is difficult or impossible for fast or
low gears . . . . . . . . . . . . . . . . . . . . . . . . . 119
GEARBOX COMPONENTS . . . . . . . . . . . . . . . . 13 Gear shifting is difficult or impossible on main
Main components of the gearbox housing . . . . . . 13 transmission . . . . . . . . . . . . . . . . . . . . . . . 120
Main components of the main shaft . . . . . . . . . . 16 Interlocking not possible . . . . . . . . . . . . . . . . 120
Main components of the layshafts . . . . . . . . . . . 18 Rattling sound when shifting . . . . . . . . . . . . . . 120
Main components of the direct drive input Cannot shift to neutral . . . . . . . . . . . . . . . . . 121
shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Excessive noise . . . . . . . . . . . . . . . . . . . . . . 121
Main components of the reverse gear transmission Noisy gears with engine running at idle
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Main components of the top cover of gearbox High vibrations . . . . . . . . . . . . . . . . . . . . . . 122
internal controls . . . . . . . . . . . . . . . . . . . . . . 21
The main shaft washer is burnt . . . . . . . . . . . . 122
Main components of gear control housing . . . . . . 24
The input groove is worn or damaged . . . . . . . 123
Main components of the air pressure regulator
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Clutch housing damaged . . . . . . . . . . . . . . . . 123
Main components of auxiliary transmission gear Synchronizer is damaged . . . . . . . . . . . . . . . . 123

assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Overheating . . . . . . . . . . . . . . . . . . . . . . . . 124
Main components of the auxiliary transmission Main shaft deformed . . . . . . . . . . . . . . . . . . 124
shaft reduction gear assembly . . . . . . . . . . . . . . 28
Bearing burnt . . . . . . . . . . . . . . . . . . . . . . . 125
Main components of left and right shafts of
auxiliary transmission . . . . . . . . . . . . . . . . . . . 29
Main components of gearbox reduction unit rear
housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main components of auxiliary transmission master
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Main components of power take-off (PTO: Power
Take Off ) . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CHARACTERISTICS AND DATA . . . . . . . . . . . . . 35
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 36
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL AND REFITTING MEASURES . . . . . . . . 42

Remove precautions . . . . . . . . . . . . . . . . . . . 42
Refitting precautions . . . . . . . . . . . . . . . . . . . 42

682 ‒ Gearbox
4 9JS GEARBOX

682 ‒ Gearbox
9JS GEARBOX 5
GENERAL INFORMATION
9JS GEARBOX
The main transmission and the splitter of the FAST twin countershaft transmission comprises two countershafts having the same
structure. They are offset 180 degrees one from the other. After having been transferred via the input shaft, the power is trans-
mitted to these two countershafts and then conveyed to the main shaft via splitter.
Each countershaft is able to withstand half of the overall torque. The twin countershaft structure makes it possible to reduce trans-
mission centre distance, reduce gearbox size and weight.
This floating gear structure does away with the typical roller bearing. This all makes the structure of the main shaft much more
simple. During operation, the radial forces transmitted by the two central gears to the gear of the primary shaft are equal but in
opposite directions, therefore, the main shaft must only support the torque. This improves the load capacity of the primary shaft
and the bearing, with an increase of the reliability and strength of the gearbox.
Tooth alignment and procedure

Transmission assembly gear teeth alignment diagram
174278 Figure 1
1 Left countershaft gear 3 Right countershaft gear
2 1st shaft gear
Aligning the gear teeth

Mark with paint two adjacent gears of a shaft, then in the same manner mark the opposite side at an angle of 180 degrees. The
gears between these two marks must be the same.
Mark with paint the upper part of the crest of the external tooth opposite to the slot of the groove of the inner hole of the gear
meshed with the two countershafts.
When mounting, be sure to fit the two marked gears of the constantly meshed gear of the two countershafts in the shaft gear
marked teeth. Free motion of the 1st shaft indicates correct assembly. Hindered or difficult rotation means that gear alignment
marks must be checked to see if they are correct.
Aligning the splitter gear teeth
Mark with paint two adjacent gears of the splitter gear reducer, then in the same manner mark the opposite side at an angle of 180
degrees. The gears between these two marks must be the same.
Mark the top portion of the tooth crest with the mark O of the splitter countershaft gear using paint.
When fitting, be sure to fit the two marked gears of the splitter countershaft gear marked into the splitter gear marked teeth.
When installing the splitter assembly on the main transmission, make sure that the gear marks are aligned. In this case, proceed with
installation

682 ‒ Gearbox
6 9JS GEARBOX
GENERAL INFORMATION
Gearboxes
Transmissions with twin countershaft do not feature synchronizers. The sleeve of the primary shaft is fixed to the main shaft via
the involute groove. Moving the sleeve causes the mating gear to mesh with the mating gear inside the main shaft gear to transfer
power.
There are two identical conical angles (α=35°) at the tips of the main shaft internal mating gear and sleeve. As the main shaft and its
gears are floating, these two conical surfaces play a self-centerring and timing role during gearshifting.
Thanks to the high number of gears and slight difference in gear ratios, the speed difference between the two adjacent gears is
limited and the gearbox shifts gear effortlessly.
Gearbox diagrams
174279 Figure 2
1 Sliding sleeve 4 Groove buffer
2 2nd shaft gear 5 Adjustment shim
3 Locking ring 6 Main shaft
Drive mechanism
174280 Figure 3
The drive mechanism of the twin countershaft transmission is direct (overlapping H).
Synchronizer structure and operating principle

The splitter of the twin countershaft transmission is equipped with an inertial synchronizer and locking pin. The synchronizer is
controlled by the splitter gear shift cylinder and functions only when down shifting gears. Its operation is coordinated and controlled
by the gearshift lever of the side transmission and by the double H valve.

682 ‒ Gearbox
9JS GEARBOX 7
GENERAL INFORMATION
The synchronizer structure is as in the figure. Three locking pins 4 and 7 are riveted on each of the two parts: synchronizer ring
for fast gears 2 and conical ring for low gears 6. The gearbox sleeve 3 is engaged with the output shaft via the groove. The material
forming the fast gears synchronizer ring and the low gears conical ring is a sintered iron powder.
The non-metallic materials with high friction properties are fixed on the inner cone of the fast gears synchronizer ring and outer
cone of the low gears synchronizer ring. The transmission gear and the reduction gear of the splitter, contain corresponding in-
ternal and external cones.
Splitter synchronizer assembly
174281 Figure 4
1 Fast gears belt 5 Low gears belt
2 Fast gear synchronizer ring 6 Low gears conical ring
3 Sliding sleeve 7 Low gears locking pins
4 Fast gears locking pins 8 Spring
Countershaft brake
The countershaft brake is also known as lay shaft brake or clutch, fixed on the right side of the main transmission seat. The coun-
tershaft brake is a pneumatically actuated braking system, whose control valve is fitted below the clutch pedal.
The countershaft brake circuit is connected when pressing the pedal during use. Therefore, the compressed air will push the brake
to the top portion of the friction gear of the lay shaft (countershaft) to decrease the speed of the countershaft, main shaft gear and
components controlled by the clutch.

682 ‒ Gearbox
8 9JS GEARBOX
GENERAL INFORMATION
Countershaft brake structural diagram
174282 Figure 5
1 Case PTO area 3 Brake piston
2 Friction gear external round interval 4 Compressed air inlet (0.7 - 0.8 Mpa)
The countershaft brake is used in the power train of the push or pull type clutch. The transmission is in neutral before starting the
vehicle. The clutch, input shaft and gear in the main transmission (except for the main shaft) will be actuated by the engine.
During gearshifting and start-up, release the clutch and press the clutch pedal to connect the central braking circuit. After decreas-
ing the speed of the clutch driven components and of its connected parts (transmission input shaft, countershaft gear and main
shaft gear), engage a gear to move the vehicle smoothly.
As regards vehicles not fitted with countershaft brakes, atypical noises will be heard when gearshifting. Smooth motion can be
achieved by waiting a moment after pressing the clutch pedal at vehicle start-up.
Note The countershaft brake is operative only at vehicle start-up.
Requirement and precautions of use

Appropriate use of the gearbox, accompanied by regular maintenance, it is of considerable importance for the safe driving of the
vehicle and for the life of the gearbox. Please note the following conditions of use.
No. of SAE lubricant
The gearbox must be topped-up with transmission oil Tutela Transmission W90/M-DA.
Correct oil level
Remove the conical plug of the oil level inspection window located at the side of the gearbox and add oil until it seeps out of the
hole. For the specific amount refer to the technical specifications.
Working temperatures
In continuous operation, the transmission must maintain a temperature less than 120 ° C. If the working temperature is higher than
120 ° C, the lubricating oil will degrade and transmission life shortened.
Transmission working temperatures higher than 120 ° C, may be due to one of the following reasons:
1. Gear at speeds below 32 km / h for more than 1 hour continuously.

2. Engine at high speed.
3. High ambient temperature.
4. Transmission surrounded by air turbulence.
5. Exhaust system excessively near the transmission.
6. Excessive use at high speed.

682 ‒ Gearbox
9JS GEARBOX 9
LONGITUDINAL CROSS SECTION
If the operating temperature is very high, the lubricant should be changed more frequently. If the above conditions can not be
avoided, it is advisable to install a cooling system on the gearbox to reduce the operating temperature.
530210 LONGITUDINAL CROSS SECTION
200119 Figure 6
The PTO connecting shaft is on the right side (1) of the gearbox.
530210 GEARBOX DESIGNATION
9 Forward gears
J Mechanical type
S Twin countershaft
135 X10 = Input rated torque Nm
A (B) Ratio code

682 ‒ Gearbox
10 9JS GEARBOX
GEAR CONTROL LEVER
530210 GEAR CONTROL LEVER
200124 Figure 7
H Fast gears L Low gears
1 Power Supply (red) 2 Output for low gears (black)
When engaging gears with super H, it is possible to change range using the lever switch on the gear selector.
If the lever switch is on "Low" the 1st to 4th gears have been selected. If it is set to "High" gears 5th to 8th are selected.
The neutral position is at the centre of ¾ path.
530210 Operation and troubleshooting the gearbox pneumatic system

The splitter of the twin countershaft transmission is used to up or down shift gears via the pneumatic system.
The pneumatic system comprises an air filter regulator, double-H valve, splitter gear change cylinder and connection pipes.
Identify and repair any damage if there are any issues with the operation of the pneumatic circuit after carrying out standard inspec-
tions.
Operating principle
The air (7.5 bar) from the compression cylinder is adjusted to a lower pressure (6.5 bar) through the air filter-regulator. Air is
drawn into the inlet of the dual-H valve.
When shifting down a gear, the contact of the double-H valve will be expelled through the air line to the lower gears. The piston of
the gearbox air cylinder is pushed back by the compressed air sucked into the inlet of the gearbox air cylinder from the air tube of
the double H valve for the low gears.

682 ‒ Gearbox
9JS GEARBOX 11
Operation and troubleshooting the gearbox pneumatic system
The shift drive fork of the gear air cylinder pushes the sliding sleeve of the splitter synchronizer until it engages with the teeth of
the internal gear to release the splitter, allowing the transmission to shift from fast to low gears.
When shifting up a gear, the contact of the double-H valve will be pressed through the air line to the faster gears. Air is drawn
through the inlet of the double H valve and comes into contact with the teeth of the internal gear of the splitter transmission, al-
lowing the transmission to shift from to high gears.
When changing gears from high to low, and vice versa, the air remaining in the air cylinder is discharged through the outlet of the
double H through the air hose.
Diagram of pneumatic transmission for gearshift mechanisms with double H valve.
N档阀
200120 Figure 8
1 Double H valve 3 Air filter regulator
2 Auxiliary gear cylinder 4 Compressed air intake
H Fast gear L Reduced gear
Transmission pneumatic system fault inspection
1. Inspection of the pneumatic transmission system must be performed with engine off and with rated air pressure at maximum
value.
2. Check that the air pipes are installed correctly and free of interferences.
3. Make sure that there are no leaks from the air pipe couplings.
4. Make sure that the air pipes have no fractures or are bottlenecked by other parts that may impeded air flow.
Inspecting the air filter regulator:
1. Make sure that there are no leaks or defects in the components of the air filter regulator.
2. When the vehicle air pressure is 7.5 bar, install a pressure gauge at the outlet, then check the air pressure is set at 6.5 bar.
Replace it if the measure does not comply with the specifications.
Inspecting the double H valve:
1. Check for any faults.

2. Make sure that the roll pin moves freely and shows no sign of wear.

682 ‒ Gearbox
12 9JS GEARBOX
3. With the roll pin to its original position, make sure that the compressed air exits outlet 4 only it is supplied air; when the roll
pin is forced to its lowest position, check that the compressed air exits outlet 2 only when air is supplied. The double H valve is
normal when having the above results. Otherwise, replace it.
Inspecting the splitter gear gearbox cylinder:

If after the above inspections should continue to experience problems, check that there are no defects on the O-rings or other
seals of the piston of the cylinder. See the following diagram.
Cylinder structural diagram (neutral)
174285 Figure 9
H Fast L Low
Troubleshooting
1. Air hole for low gears: reverse, low gears (gears 1 - 4).
2. Air hole for fast gears: gears 5 - 8
3. Piston.
4. O-ring failure. May cause a fault that impedes low gear change and results in pressure increase of the transmission.
5. Shift drive fork.
6. O-ring failure. It may cause a malfunction that prevents fast/slow gear change or a steady leak from the double H valve bleed
plug.
7. Leaks from the gaskets of slippage may cause slow gear shifting to high gears.

682 ‒ Gearbox
9JS GEARBOX 13
GEARBOX COMPONENTS
GEARBOX COMPONENTS
Main components of the gearbox housing
223340 Figure 10
1 Bolts, with holes on the hex head 2 Spring washer

682 ‒ Gearbox
14 9JS GEARBOX
GEARBOX COMPONENTS
223340 Figure 10
3 Direct drive input shaft cover 8 Hexagon head screw
4 Hexagon head screw 9 Spring washer
5 Spring washer 10 Stud
6 Oil seal 11 Washer
7 Gasket 12 Hex nut with nylon lock insert

682 ‒ Gearbox
9JS GEARBOX 15
GEARBOX COMPONENTS
13 Circlips for shafts 28 Sealing washer

14 Antidust cover 29 Clutch housing
15 Circlips 30 Sealing gasket for clutch housing
16 Bushing 31 Conical screw plug with square head
17 Ball bearings 32 Transmission case
18 Hexagon head screw 33 Hexagon head screw
19 Spring washer 34 Lower power take-off window opening cover
20 Fork bracket isolation 35 Gasket for power take-off window opening
21 Moving fork 36 Gearbox oil drain plug
22 Fork shaft isolation 37 Gearbox oil filler plug
23 Bearing lubrication pipe 38 circular magnet
24 Coupling connection 39 Screw
25 Grease nipple cup mount 40 Positioning pin
26 Grease nipple cup cover 41 Clutch inspection hole cover
27 Spring washer 42 Hexagon head screw

682 ‒ Gearbox
16 9JS GEARBOX
GEARBOX COMPONENTS
Main components of the main shaft
223341 Figure 11
1 Gearing for input shaft 4 Grooved spacer for main shaft
2 Snap circlip 5 Gearing for main shaft third gear
3 Synchronization assembly for third and fourth gears 6 Grooved spacer for main shaft

682 ‒ Gearbox
9JS GEARBOX 17
GEARBOX COMPONENTS
7 Gearing for main shaft second gear 13 Main shaft

8 Gear for main shaft first gear 14 Elastic pin
9 Low speed gear for main shaft 15 Hex key for main shaft
10 Crawler gear and reverse gear sliding sleeve 16 Main ring for main shaft gear
11 Reverse gear for main shaft 17 Snap circlip for reverse gear
12 Reverse gear metal toothed gasket for main shaft

682 ‒ Gearbox
18 9JS GEARBOX
GEARBOX COMPONENTS
Main components of the layshafts
223342 Figure 12
1 Hexagon head bolt 4 Radial ball bearing
2 Cover 5 Snap circlip
3 Flexible cylindrical pin 6 Circlip for layshaft

682 ‒ Gearbox
9JS GEARBOX 19
GEARBOX COMPONENTS
7 Transmission drive gear to layshaft 12 Layshaft square key

8 Spacer bushing 13 Disc tab
9 Gear for layshaft third gear 14 Layshaft
10 Gear for layshaft second gear 15 Straight roller bearing
11 Gear for layshaft first gear 15 Snap circlip
Main components of the direct drive input shaft
223343 Figure 13
1 Ring 4 Spacer
2 Snap circlip 5 Snap circlip
3 Radial ball bearing with circlip groove and dust boot on 6 Direct drive input shaft
one side 7 Output shaft sleeve guide

682 ‒ Gearbox
20 9JS GEARBOX
GEARBOX COMPONENTS
Main components of the reverse gear transmission assembly
223344 Figure 14
1 Hex lock nut 5 Reverse transmission gear
2 Washer 6 Cup washer
3 Thrust washer 7 Reverse gear transmission shaft
4 Roller bearings 8 Slotted screw with flat tip

682 ‒ Gearbox
9JS GEARBOX 21
GEARBOX COMPONENTS
Main components of the top cover of gearbox internal controls
223345 Figure 15
1 Top cover 4 Conical screw plug with square head
2 Gasket for top cover 5 Steel ball
3 M10 × 38 hex head screw with spring washer 6 Compression spring

682 ‒ Gearbox
22 9JS GEARBOX
GEARBOX COMPONENTS
223345 Figure 15
7 Compression springs 12 Hexagon nut
8 Stud 13 Spring washer
9 Hexagon nut 14 Locking pin
10 Thin hex nut 15 Piston lock
11 Metal gasket for inspection window 16 Locking spring

682 ‒ Gearbox
9JS GEARBOX 23
GEARBOX COMPONENTS
17 Screw securing gear selection fork 25 Guide block for the gears: third - fourth and seventh
18 Locking spring -eighth
19 Reverse gear fork low shaft 26 Fork shaft for third and fourth gears
20 Guide block for the gears: first - second and fifth -sixth 27 Fork for third and fourth gears
21 Steel ball 28 Gearbox lifting hook
22 Fork shaft locking pin 29 Hex head screw with spring washer and flat washer
23 Fork shaft for first and second gears 30 Hexagon head screw with spring washer
24 Fork for first and second gears

682 ‒ Gearbox
24 9JS GEARBOX
GEARBOX COMPONENTS
Main components of gear control housing
223346 Figure 16
1 Hexagon head screw 4 Seal ring
2 Hexagon nut 5 Side movement lever bushing
3 Sleeve 6 Compression spring

682 ‒ Gearbox
9JS GEARBOX 25
GEARBOX COMPONENTS
7 Ring with spring contact plate 21 Hex screw

8 Positioning ring 22 Double H valve with gasket
9 Spacer ring with two holes to allow entry of the 23 Hexagon head screws
hardened pistons 24 Vent valves
10 Ring with spring contact plate 25 Mushroom vent valve
11 Compression spring 26 Gear control housing
12 Square headed selection lever 27 Side shaft
13 Switch control block for low gear reversing 28 Pressure switch
14 Hex head screw with washer 29 Support plate
15 Hex head screw with washer 30 Support bar
16 Hardener piston 31 Hexagon head screw
17 Gasket 32 Cylindrical pin
18 Cover 33 Hole for cylindrical pin seat
19 Side cover with flange gasket; 34 Swinging arm
20 Lightened spring washer 35 Outer swinging arm

682 ‒ Gearbox
26 9JS GEARBOX
GEARBOX COMPONENTS
Main components of the air pressure regulator valve
223347 Figure 17
1 Pressure regulator with filter 4 Hex head screw with washer
2 90° elbow connector 5 Air pipe
3 Air filter connector 6 Hex head pins

682 ‒ Gearbox
9JS GEARBOX 27
GEARBOX COMPONENTS
Main components of auxiliary transmission gear assembly
223348 Figure 18
1 Lock bearing 5 Auxiliary transmission positioning disc
2 Grooved radial ball bearing 6 Snap ring
3 Snap ring 7 Capstan hex head screws
4 Auxiliary transmission driving gear 8 Wire

682 ‒ Gearbox
28 9JS GEARBOX
GEARBOX COMPONENTS
Main components of the auxiliary transmission shaft reduction gear assembly
223349 Figure 19
1 Auxiliary transmission main shaft 5 Reduction gear to auxiliary transmission main shaft
2 High and low gear synchronizer 6 Snap circlip
3 Washer 7 Reduction gear washer
4 Main grooved washer for shaft gearing 8 Flange nut

682 ‒ Gearbox
9JS GEARBOX 29
GEARBOX COMPONENTS
Main components of left and right shafts of auxiliary transmission
223350 Figure 20
1 Straight roller bearing 5 Snap circlip
2 Welded gear on auxiliary transmission long shaft 6 Snap circlip
3 Welded gear on auxiliary transmission short shaft 7 Bearing washer
4 Straight roller bearing

682 ‒ Gearbox
30 9JS GEARBOX
GEARBOX COMPONENTS
Main components of gearbox reduction unit rear housing
223358 Figure 21
1 Gasket for rear cover 4 Layshaft bearing cover
2 Rear cover housing 5 Hexagon head screw
3 Gasket for auxiliary transmission bearing cover 6 Hex head screw with spring washer

682 ‒ Gearbox
9JS GEARBOX 31
GEARBOX COMPONENTS
7 Conical roller bearing 16 Output flange

8 Main shaft rear bearing cap 17 Dust protection covering ring
9 Gasket 18 Oil seal for main shaft rear bearing cover
10 M10 x 75 hex head screw 19 Oil seal
11 Bushing for odometer driven gear shaft 20 Odometer driving gear
12 Screws with washers 21 Odometer driven gear
13 Joint for odometer driven gear 22 O-ring
14 Rear cover positioning pin 23 Gasket
15 Odometer protective sleeve 24 Hexagon head screw

682 ‒ Gearbox
32 9JS GEARBOX
GEARBOX COMPONENTS
Main components of auxiliary transmission master cylinder
223359 Figure 22
1 Capstan hex head screws 4 Gasket
2 Wire 5 Cylinder case
3 Auxiliary transmission gearbox fork 6 Washer

682 ‒ Gearbox
9JS GEARBOX 33
GEARBOX COMPONENTS
7 Hexagon head screw 15 Auxiliary transmission head

8 O-ring 16 Coupling T pipe
9 Auxiliary transmission fork master cylinder 17 Conical screw plug with square head
10 Rubber piston 18 45° elbow connector
11 O-ring 19 Copper washer
12 O-ring 20 Hex head screw for central assembly position of pneu-
13 Hex lock nut matic cylinder with round head rivets
14 Gasket for cylinder head
Main components of power take-off (PTO: Power Take Off )
223360 Figure 23
1 PTO housing case 9 Side cover gasket
2 Hollow shaft 10 Side cover
3 Bearing spacer ring 11 Label
4 Sleeve 12 Output gear shaft
5 Input gear 13 Deflector ring
6 Locking ring 14 Adjusting shim
7 End cover 15 Flange
8 End cover gasket 16 Bearing cover plug

682 ‒ Gearbox
34 9JS GEARBOX
GEARBOX COMPONENTS
223360 Figure 23
17 Gasket 36 Licence plate rivets
18 Fork 37 Oil seal
19 Clutch gear toothed sleeve 38 Hexagon head screw
20 Cylinder head gasket 39 Hexagon head screw
21 Cylinder head 40 Hexagon head screw
22 Fork piston stem 41 Hex head screw for cover of PTO housing case
23 Cylinder case 42 Conical pin ( 12 × 35 )
24 Cylinder gasket 43 Magnetic plug with tapered square grooving
25 Gasket 44 Hex head screw ( M16 × 1.5 × 30 ) with washer
26 Covering ring 45 Hex head screw with washer
27 Stop collar 46 Hex head screw for cylinder case cover
28 Rubber piston 47 Countersunk head screw
29 O-ring 48 Lock nut for hex insert ( M12 )
30 Fourth gear spacer bearing 49 Expansion dowel plug
31 Gasket 50 Conical roller bearing
32 O-ring 51 Flexible cylindrical pin
33 Wire 52 Reversing indicator switch
34 Set screw 53 Steel ball bearing ( Φ55 × Φ90 × 18 )
35 O-ring

682 ‒ Gearbox
9JS GEARBOX 35
54 Roller bearings 55 Hexagon head screw

GEARBOX 9JS135T-B
type Mechanical
Input torque 1350 Nm
Crawler gear 1
Forward gears 8
Reverse 1
Mechanical
Main four gears control E.R.G.* command
Pneumatic
Power take-off Optional
Gear engagement:
Forward gears and splitter Synchronised
Crawler gear and reverse Rapid engagement
Gears Straight teeth
Gear ratio
Crawler gear 12.11
1st 8.08
2nd
5.93
3rd 4.42
4 th
3.36
5 th
2.41
6th 1.76
7 th
1.32
8 th
1.00
Reverse gear 12.66
Oil type Tutela Transmission W90/M - DA
11.5 kg
Quantity
12.5 litres
Main shaft and lay shaft bearings ball bearings

682 ‒ Gearbox
36 9JS GEARBOX
TIGHTENING TORQUES
TIGHTENING TORQUES
TORQUE
DETAIL QUANTITY
Nm (kgm)
Clutch housing 6 M16×1.5 244 - 271 (24.4 - 27.1)
Clutch housing 4 M12 108 - 135 (10.8 - 13.5)
Shaft bearing 1st cap 6 M10 47.5 - 61 (4.75 - 6.1)
Shaft 1st gear M54×1.5 Left 338 - 406 (33.8 - 40.6)
Double H control unit 8 M10×1 47.5 - 61 (4.75 - 6.1)
Top cover 16 M10 47.5 - 61 (4.75 - 6.1)
Fork locking screws 5 M12~1.2S 67.5 - 88 (6.75 - 8.8)
Splitter fork 2 M12×1.5 67.5 - 88 (6.75 - 8.8)
Air filter bracket 2 M6 13.5 - 20.3 (1.35 - 2.03)
Output shaft M50×1.5 609 - 677 (60.9 – 67.7)
Splitter rear cover 19 M10 47.5 - 61 (4.75 - 6.1)
Oil drain plug Z3/4" 61 - 74.5 (6.1 - 7.45)
Oil filler 21 81 - 101.5 (8.1 - 10.15)
Splitter transmission gear positioning disc 6 6M10 47.5 - 61 (4.75 - 6.1)
Reverse spindle 2 M16×1.5 67.5 - 81 (6.75 - 8.1)
Splitter countershaft rear cover. 8 M10 47.5 - 61 (4.75 - 6.1)
Power take-off bottom cover 8 M12 67.5 - 81 (6.75 - 8.1)
Countershaft brake 8 M10 47.5 - 61 (4.75 - 6.1)
Transmission side door cover 6 M10 24.5 - 31 (2.45 - 3.1)
Main shaft rear bearing cap 6 M10 47.5 - 61 (4.75 - 6.1)
Gear shift cylinder seat 4 M10 47.5 - 61 (4.75 - 6.1)
Cylinder head (Splitter) 4 M10 47.5 - 61 (4.75 - 6.1)
Clutch housing bottom cover 4 M8 20 - 27 (2.0 - 2.7)
Countershaft front face 2 M16×1.5 122 - 162 (12.2 - 16.2)
TOOLS
Hot air device (99305121)

682 ‒ Gearbox
9JS GEARBOX 37
TOOLS
Assembly rotating stand for overhaul (load bearing capacity 1000 daN, torque 120 daNm)
(99322205)
Assembly supports (to apply to stand 99322205) (99322225)
Percussion extractor (99340205)
Simple bridge (99341003)

682 ‒ Gearbox
38 9JS GEARBOX
TOOLS
Clamp (99341015)
Pair of brackets with hole (99341017)
Grappling rope set (99341019)
Grips (99341024)

682 ‒ Gearbox
9JS GEARBOX 39
TOOLS
Grips (99341025)
Reaction block for extractors (99345058)
Pin to extract reverse gear shaft (use with 99340205) (99347092)
Key (70mm) for damper flywheel locking nut. (99355039)

682 ‒ Gearbox
40 9JS GEARBOX
TOOLS
Tool for removing and refitting the gearbox auxiliary housing (use at the bench with a
hoist) (99360523)
Grip for inter-changeable drifts (99370006)
Reaction lever with flange retainer extension (99370317)

682 ‒ Gearbox
9JS GEARBOX 41
TOOLS
Gearbox support during removal and refitting from vehicle. (99370629)
Brackets for supporting Transmission during overhaul (use with 99322205 -99322225)
(99371049)
Drift to fit bearing external races (91 -134 mm) (use with 99370007) (99374093)
Tool for fitting gasket on gearbox front cover (use with 99370006) (99374469)
Drift for fitting gasket on gearbox rear cover (99374470)

682 ‒ Gearbox
42 9JS GEARBOX
REMOVAL AND REFITTING MEASURES
Pliers to extract gearbox piston rings (99381125)
530210 REMOVAL AND REFITTING MEASURES

Remove precautions
When removing all assemblies, place all components on a clean workbench in the order in which they were removed. This makes
refitting much easier and reduces the risk of losing parts.
Repairs must be made in a clean area. Make sure that dust or other objects do not enter the gearbox. Thoroughly clean the outside
of the gearbox before removing it.
Check each component carefully before installation. To prevent damage, do not install parts that may be damaged.
Check the wear of all the grooves. Replace parts if the sliding sleeve and the outlet flange are thinned on one side of the groove
due to wear.
Check the surface conditions of all thrust washers. Replace scratched or worn washers.
Check that the grey cast iron components do not show fractures or damage. For very large parts, fusion welding, brazing or are
acceptable. However fractures heat must not extend up to the hole of the bearing or to the contact surface of the bolt.
Make sure that the O-rings are not fractured or deformed. Replace if worn.
Refitting precautions
● Sealings: Use new seals when fitting the transmission.
● Screws: To avoid loss, apply sealant thread lock on all screws. Regarding the corresponding torques, see the summary table.
● O-rings: Lubricate all O-rings with silicone grease.
● Screw the output shaft flange fastening nut. Tighten the nut using a torque of 610-680Nm. Failure to do so may lead to severe
consequences.

682 ‒ Gearbox
9JS GEARBOX 43
BOWDEN CABLES ADJUSTMENT DIAGRAM
530210 BOWDEN CABLES ADJUSTMENT DIAGRAM
222097 Figure 24
A Cab side C Selection Bowden cable
B Gearbox side D Bowden engagement cable
This diagram shows the dimensions for adjustment of the gear control Bowden cables.
.530210. GEARBOX OVERHAULING
Consumables
Silicone grease
Oil
TUTELA MR3 grease
Work material
Hot air device 99305121
Assembly rotating stand for overhaul (load bearing capa- 99322205
city 1000 daN, torque 120 daNm)
Assembly supports (to apply to stand 99322205) 99322225
Percussion extractor 99340205
Simple bridge 99341003
Clamp 99341015
Pair of brackets with hole 99341017
Grappling rope set 99341019
Grips 99341024
Grips 99341025
Reaction block for extractors 99345058
Pin to extract reverse gear shaft (use with 99340205) 99347092

682 ‒ Gearbox
44 9JS GEARBOX
GEARBOX OVERHAULING
Key (70mm) for damper flywheel locking nut. 99355039

Tool for removing and refitting the gearbox auxiliary 99360523
housing (use at the bench with a hoist)
Grip for inter-changeable drifts 99370006
Reaction lever with flange retainer extension 99370317
Brackets for supporting Transmission during overhaul 99371049
(use with 99322205 -99322225)
Tool for fitting gasket on gearbox front cover (use with 99374469
99370006)
Drift for fitting gasket on gearbox rear cover 99374470
Pliers to extract gearbox piston rings 99381125
Rope
Hooks
Tightening torques
M10 screw securing top cover 47.5 N⋅m to61 N⋅m
M12x1.5 screws securing the top cover 67.5 N⋅m to88 N⋅m
M10 nut for securing rear cover 47.5 N⋅m to61 N⋅m
M12x1.5 nut for securing fork 67.5 N⋅m to88 N⋅m
M10 screw for securing cylinder 47.5 N⋅m to61 N⋅m
Piston fastening nut 95 N⋅m to115 N⋅m
M10 screw for securing cover 47.5 N⋅m to61 N⋅m
M10 screw for securing layshafts cover 47.5 N⋅m to61 N⋅m
Main action
Caution!
Lubricants and detergents Disposal
▶ Follow the specific regulations to dispose of lubricants and detergents.
▶ Use protective gloves to hold heated parts.
1. Thoroughly wash the outside of the gearbox and drain the oil into an appropriate container.

682 ‒ Gearbox
9JS GEARBOX 45
GEARBOX OVERHAULING
.530510. Removal of clutch housing

2. Place the gearbox onto a suitable work bench.
3. Unscrew the grease nipple fastening plug (1).
4. Remove the screws (2) securing the clutch housing (3).
5. Then remove the clutch housing (3) from the gearbox.
223035 Figure 25
6. Fit the supporting brackets (1) shown below to the gearbox

support assembly.
code
Brackets for supporting Transmission during overhaul (use 99371049
with 99322205 -99322225)
7. Using ropes with hooks and a movable lifting device, position

the gearbox (4) assembly on the rotary stand (2) together with
the support (3), as shown below.
code
Rope
Hooks
Assembly rotating stand for overhaul (load bearing capacity 99322205
1000 daN, torque 120 daNm)
223036 Figure 26
Note Use the required specific tools for overhaul operations.
During removal it is recommended to place the parts in
the performed working order to facilitate subsequent
assembly operations.
All the sealing gaskets; rubber gaiters; o-ring; oil seal ring
and elastic pins; are always replaced with new ones.
.530520. Replacing gear control housing

.530520. Removal
Note Use the specified tools for the gearbox overhaul operations.
During removal, it is recommended that the parts are placed in the operating sequence carried out in order to make as-
sembly operations easier.
All the sealing gaskets; rubber gaiters; o-ring; oil seal ring and elastic pins; are always replaced with new ones.

682 ‒ Gearbox
46 9JS GEARBOX
GEARBOX OVERHAULING
8. Insert neutral by acting on the gear selection rod (6).

9. Remove the pipe clips (7) by acting on the retainers (2).
10. Remove the bracket (5) covering the gear control housing (3)
by acting on the retainers (4).
11. Remove the four bolts (1) securing the gear control housing
(3).
223037 Figure 27
12. Remove the air pipes (2) by unscrewing the retaining couplings
(1) using a suitable wrench.
223038 Figure 28
13. Remove the gear control housing (1) from the gearbox (2).
223039 Figure 29

682 ‒ Gearbox
9JS GEARBOX 47
GEARBOX OVERHAULING
.530520. Refitting
14. To refit the gear control housing, carry out the operations described in the removal process in the reverse order, tightening
the screws and nuts to the prescribed torque.
Note All the sealing gaskets; rubber gaiters; o-ring; oil seal ring and elastic pins; are always replaced with new ones.
.530520. Overhaul of the gear control housing

.530520. Removal of the gear control housing
15. Place the gear control housing (5) in the vice(4).
16. Using a suitable wrench (1), remove the reverse gear switch
(2) with black plastic on the inside.
17. Using a suitable wrench (1), remove the neutral gear safety
switch (3) with green plastic on the inside.
223040 Figure 30
18. Remove the splitter control pneumatic valve (2) retainers (1).
223041 Figure 31

682 ‒ Gearbox
48 9JS GEARBOX
GEARBOX OVERHAULING
19. Remove the splitter control pneumatic selection valve (2) by

removing it from its seat on the gear control housing (3).
20. Using a suitable wrench, unscrew the vent valve (4) by acting on
the fastening nut (5).
21. Remove the sealing gasket (1) which will be replaced with a
new one during assembly.
Note All the sealing gaskets; rubber gaiters; o-ring; oil seal ring
223042 Figure 32
22. Remove the wire (2) securing the control lever (1) retaining
pin (3).
23. Remove the control lever (1) retaining pin (3).
223043 Figure 33
24. Remove the gear selection lever (3) by acting on the retainer
(2).
25. Remove the rubber gaiter (1) protecting the gear control rod.
26. Remove the vent valve (4) which was loosened previously.
223044 Figure 34

682 ‒ Gearbox
9JS GEARBOX 49
GEARBOX OVERHAULING
27. Working from the opposite side of the gear control housing
(1), remove the hardener piston cover (2) retainers (3).
223045 Figure 35
28. Remove the hardener piston (1) cover (3).

29. Remove the hardener piston (1) thrust spring (2).
223046 Figure 36
30. Remove the hardener piston (1) by extracting it from its seat.
223047 Figure 37

682 ‒ Gearbox
50 9JS GEARBOX
GEARBOX OVERHAULING
31. Repeat the removal operations for the parts below on the
opposite side from the gear control housing (4): cover (1)
hardener piston (3) and spring (2) in the same removal se-
quence as described in the previous operation.
32. Remove the four plate (6) retainers (5).
223048 Figure 38
33. Extract the control rod (1) slightly together with the spring (2)
but do not remove it completely from its seat until the seal ring
(3) secured with an elastic pin (4) to the control rod (1) has
been released.
223049 Figure 39
34. Remove the elastic pin (3) from the seal ring (2) using a suit-
able drift; thus releasing the control rod (1).
223050 Figure 40

682 ‒ Gearbox
9JS GEARBOX 51
GEARBOX OVERHAULING
35. Remove the control rod (1) from the gear control housing (2)
making sure not to drop the parts (seal ring and control lever)
which are no longer secured by the pin and the elastic pin which
were removed previously.
223051 Figure 41
36. Proceed to remove the last parts of the gear control rod (6).
37. Remove the gear selection lever (1) by acting on the retainer
(2).
38. Remove the rubber gaiter (3).
39. Remove the clip with the plate (9).
40. Remove the spring (8).
41. Remove the spring (8) seal ring(4).
42. Use a suitable drift to remove the elastic pin (7).
43. Remove the seal ring (5) from the control rod (6).
223052 Figure 42
44. After having removed the control rod from the gear control
housing (2), continue on the other side by removing the oil seal
ring (1) (this will destroy the oil seal ring).
Note During assembly, replace the oil seal ring (1) with a
new one.
223053 Figure 43

682 ‒ Gearbox
52 9JS GEARBOX
GEARBOX OVERHAULING
45. Act on the threaded dowel (1) using a suitable Allen wrench
(2).
223054 Figure 44
46. Using a suitable Allen wrench (4), unscrew the threaded dowel
(3) securing the holed ring (1) and the shoulder ring (7)
through the hole (5) on the ring itself (1) inside the gear
control housing (2); the ring (1) can be removed from its seat
as well as the shoulder ring (7) followed by the spring (6).
Note Be very careful when removing the rings (1) and (7)
and the spring (6) as they are released by the threaded
dowel (3) which secures them; pushed by the spring
(6), the rings (1) and (7) are thrust out of their seat
with great force, therefore it is recommended that you
move away from the trajectory of the rings (1) and
(7) and the spring (6) placing a guard in front of the
trajectory to prevent them from falling and becoming
damaged.
223055 Figure 45
47. Them remove the parts listed below in a linear order.
48. Remove the holed ring (1) from its seat in the gear control
housing (2).
223056 Figure 46

682 ‒ Gearbox
9JS GEARBOX 53
GEARBOX OVERHAULING
49. Remove the shoulder ring (1) from its seat in the gear control
housing (2).
223057 Figure 47
50. Remove the thrust spring (1) from its seat in the gear control
housing (2).
51. With this last operation, removal of the gear control housing
(2) is completed.
.530520. Installing gear control housing

52. For assembly, place the gear control housing (2) in the vice
and carry out the operations described below, tightening all the
screws and nuts to the prescribed torque.
53. Insert the thrust spring (1) into its seat in the gear control hous-
ing (2).
223058 Figure 48
54. Insert the shoulder ring (1) into its seat on the gear control
housing (2).
223057 Figure 49

682 ‒ Gearbox
54 9JS GEARBOX
GEARBOX OVERHAULING
55. Insert the holed ring (1) into its seat on the gear control hous-
ing (2).
223056 Figure 50
56. Secure the parts listed previously acting on the threaded dowel
(1) with a suitable Allen wrench (2) and following the opera-
tions described below.
223054 Figure 51
57. Insert the spring (6), the shoulder ring (7) and the ring (1) into
their seat; then while applying pressure onto the inserted parts,
use a suitable Allen wrench (4) to screw the threaded dowel
(3) onto the holed ring (1); through the hole (5) and in this
way, blocking all the parts inside the gear control housing (2).
Note Pay attention to the rings (1 - 7) and the spring (6)
during this assembly operation.
When they are blocked by the threaded dowel (3); the
rings (1 - 7), pushed by the spring (6),must remain in
tension in their seat and the threaded dowel (3) must
remain fixed in the correct position to block the holed
ring (1) and subsequently all the other parts.
223055 Figure 52

682 ‒ Gearbox
9JS GEARBOX 55
GEARBOX OVERHAULING
58. Proceed to fit the parts of the control rod (6).

59. Fit the sealing ring (5) onto the control rod (6) then insert a
new elastic ring (7).
60. Fit the spring (8) seal ring (4).
61. Fit the spring (8).
62. Fit the shank with the plate (9) replacing the sealing gasket with
a new one.
63. Fit the new rubber gaiter (3).
64. Fit the gear selection lever (1) by acting on the retainer (2) and
tightening it to the prescribed torque.
223052 Figure 53
65. Insert the control rod (1) into the gear control housing (2).
223051 Figure 54
66. Fit a new elastic pin (3) onto the seal ring (2) using a suitable
drift; thus securing the control rod (1).
223050 Figure 55

682 ‒ Gearbox
56 9JS GEARBOX
GEARBOX OVERHAULING
67. Fir the hardener piston (1) into its seat.
223047 Figure 56
68. Fit the thrust spring (2) of the hardener piston (1).
69. Fit the hardener piston (1) cover (3).
223046 Figure 57
70. Fit the hardener piston cover (2) retainers (3) of the gear
control housing (1) tightening them to the prescribed torque.
223045 Figure 58

682 ‒ Gearbox
9JS GEARBOX 57
GEARBOX OVERHAULING
71. Repeat the assembly operations for the parts below on the
opposite side from the gear control housing (4): cover (1)
hardener piston (3) and spring (2) in the same assembly se-
quence as described in the previous operation.
72. Tighten the four plate (6) retainers (5) to the prescribed
torque.
223048 Figure 59
73. Working from the opposite side of the gear control housing,
use a suitable keying device to fit the new oil seal ring(1).
223053 Figure 60
74. Fit the gear selection lever (3) tightening the retainer (2) to the
prescribed torque.
75. Fit the new rubber gaiter (1) protecting the gear control rod.
76. Insert the vent valve (4) into its seat.
223044 Figure 61

682 ‒ Gearbox
58 9JS GEARBOX
GEARBOX OVERHAULING
77. Fit the control lever (1) retaining pin (3).

78. Insert the wire (2) securing the control lever (1) retaining pin
(3).
223043 Figure 62
79. Fit a new sealing gasket (1).

Note All the sealing gaskets; o-ring; oil seal ring and elastic
pins; are always replaced with new ones.
80. Fit the splitter control pneumatic valve (2) fitting it into its seat
on the gear control housing (3).
81. Tighten the vent valve (4) to the prescribed torque (previously
placed on the gear control housing (3)); acting on the fastening
nut(5) with a suitable wrench.
223042 Figure 63
82. Tighten the four splitter control pneumatic valve (2) retainers
(1) to the prescribed torque.
223041 Figure 64

682 ‒ Gearbox
9JS GEARBOX 59
GEARBOX OVERHAULING
83. Place the gear control housing (5) in the vice(4) as shown in
the figure.
84. Using a suitable wrench (1), tighten the reverse gear switch (2)
with black plastic on the inside to the prescribed torque.
85. Using a suitable wrench (1), tighten the neutral gear switch (3)
with green plastic on the inside to the prescribed torque.
86. At this point the gear control housing (5) is ready to be as-
sembled on the gearbox.
223040 Figure 65
.530517. Replacing top cover

.530517. Removal
87. Remove the housing as described in Removal of clutch housing ( ➠ Page 45).
88. Remove the gear control housing as described in Removal ( ➠ Page 46).
89. Turn the gearbox so that it is horizontal.

90. Remove the metal gasket (1) paying attention to the springs and
balls used for positioning the fork control rods which are below
the gasket (1) and which could come out.
91. Loosen all the screws (2) securing the top cover (3) of the
internal controls of the gearbox housing (4).
223068 Figure 66
92. Remove the springs (1) used for positioning the fork control
rods from their seat (2).
223069 Figure 67

682 ‒ Gearbox
60 9JS GEARBOX
GEARBOX OVERHAULING
93. Remove the three balls (3) from their seat (2) using a magnetic
tool (4).
94. Remove all the screws (1) which were loosened previously
from the gearbox housing cover (5).
223070 Figure 68
95. Remove the top cover (3) of the gearbox internal controls
together with the fork control (1) rods (2) from the gearbox
housing (4).
96. Remove the sealing gasket (5) which will be replaced with a
new one during assembly.
223071 Figure 69
.530517. Refitting
97. Refitting requires carrying out the operations for removal in reverse order, while taking the following precautions.
98. Fit a new gasket between the cover and the gearbox housing.
99. Tighten the screws(1) securing the top cover (2) to the gear-
box (3) to the prescribed torque.
Tightening torque
100. Refit the gear control housing as described in Refitting

( ➠ Page 47).
101. Refit the housing as described in Refitting the clutch housing
( ➠ Page 113).
226448 Figure 70

682 ‒ Gearbox
9JS GEARBOX 61
GEARBOX OVERHAULING
.5321. Overhaul of internal gearbox controls

.5321. Disassembly
103. Remove the top cover as described in Removal ( ➠ Page 60).
104. Place the top cover (2) in a vice with the reverse gear fork.
105. Remove the safety wire (1).
226608 Figure 71
106. Unscrew the screws (1) securing the drive bushing (4) and the
3rd and 4th gear control fork (2).
107. Extract the rod (3) recovering the drive bushing (4) and the 3rd
and 4th gear control fork (2).
226609 Figure 72
108. Using a magnet (1), recover the steel ball (2).
226610 Figure 73

682 ‒ Gearbox
62 9JS GEARBOX
GEARBOX OVERHAULING
109. Unscrew the screws (3) securing the drive bushing (5) and the
1st and 2nd gear control fork (1).
110. Extract the rod (2) recovering the safety pin (4), the drive
bushing (5) and the fork (1).
226611 Figure 74
111. Using a magnet (5), recover the steel ball (4).

112. Unscrew the screw (3), extract the rod (2) and recover the
reverse gear fork (1).
226612 Figure 75
113. The reverse gear fork (1) has a pin (4) which, due to the spring
below (2),determines the hardening of the gear lever when
reverse gear is selected.
114. If removing, proceed as follows.
115. Fit the pin (4) into the specific seat and insert the spring (2).
116. Screw the plug (3) on fully, and then unscrew it by 2.5 turns in
order to adjust the preloading of the spring (2).
117. Using the fork (5), compress the thread of the plug so that the
plug cannot unscrew.
226613 Figure 76
.5321. assembly
118. Reverse the sequence of operations described for removal following the precautions indicated below.

682 ‒ Gearbox
9JS GEARBOX 63
GEARBOX OVERHAULING
119. Lubricate the rods (2) before inserting them into their seat and
fit them with the ball seats (1) facing the cover.
226459 Figure 77
120. Insert the pins (1) into the fork control rod seats.
121. Tighten the fork fastening screws to the prescribed torque.
Tightening torque
M12x1.5 screws securing the top 67.5 N⋅m to88 N⋅m
cover
226460 Figure 78
122. Refit the top cover as described in Refitting ( ➠ Page 60).

123. Refit the gear control housing as described in Refitting ( ➠ Page 167).
.533010. Replacing the reduction gear

.533010. Removal of the GRE rear housing
124. To unscrew the flange (2) retaining nut (3), place the specific
reaction tool (1) on the flange (2) securing it to the flange
(2)with the screws (4).
code
223059 Figure 79

682 ‒ Gearbox
64 9JS GEARBOX
GEARBOX OVERHAULING
125. Working from the side opposite the direct drive input shaft (1),
remove the screws (2) fastening the layshafts and the washers
(3).
223060 Figure 80
126. Working on the flange side (1), unscrew the flange fastening
nut (1) using the specific tool (2) and the wench (3).
code
127. After having removed the flange fastening nut (1), remove all
the specific tools (2 - 3 - 4) from the gearbox (5).
128. Unscrew the cover (6) of the tachograph gear.
223061 Figure 81
129. Turning the flange slightly (2), extract and remove the tacho-
graph gear (3).
130. Remove the flange (2) from the gearbox (4) and then remove
the threaded disc (1) from the flange (2).
223062 Figure 82

682 ‒ Gearbox
9JS GEARBOX 65
GEARBOX OVERHAULING
131. Remove the layshaft cover (2) by acting on the retainers (1).
132. Remove the output shaft cover (3) by acting on the retainers
(4).
133. Remove the layshaft cover (5) by acting on the retainers (6).
223063 Figure 83
134. Remove the sealing gasket (1) of the layshaft cover.

135. Remove the sealing gasket (2) of the flange fastening body.
136. Remove the sealing gasket (3) of the layshaft cover.
137. Remove the screws (7) securing the normal and low gear mas-
ter cylinder body (5).
138. Remove the cover (4) from the normal and low gear master
cylinder body (5) by acting on the retainers (6).
139. Remove all the screws (9) retaining the GRE rear housing cover
(8).
140. Using a suitable drift, remove the two pins (10) centring the
cover (8) on the GRE rear housing.
141. To remove the cover (8) from the GRE rear housing, if neces- 223064 Figure 84
sary, apply two screws into the threaded holes (11) in order to
set the GRE rear housing away from the cover (8) and there-
fore be able to remove the GRE rear housing more easily.
142. Remove the gasket (3) retaining the cover (4) from the normal
and low gear master cylinder body (1).
143. Remove the gear master cylinder piston (5) retaining nut (2).
223065 Figure 85

682 ‒ Gearbox
66 9JS GEARBOX
GEARBOX OVERHAULING
144. Remove the rubber piston (3) from its seat (2) in the gear
master cylinder body (1).
145. During assembly, replace the O-ring (4).
223066 Figure 86
146. Fit the flange (2) which was removed previously.

147. Release the GRE rear housing (1) slightly from the gearbox
housing and apply the specific tool (3).
code
Tool for removing and refitting the gearbox auxiliary hous- 99360523
ing (use at the bench with a hoist)
148. Using ropes, remove the reduction unit (1) and the gasket
below.
Tool / Material
Rope
226600 Figure 87
.533010. Refitting the GRE rear housing

149. For refitting the GRE rear housing, repeat the removal operations but in the reverse order, tightening the screws and nuts to
.533010. Overhaul of the GRE rear housing

.533010. GRE rear housing removal
150. Unscrew the screws (1), (5) and remove the covers (2), (4 )
on the layshafts.
151. Unscrew the nut (3) securing the flange (6) which was
loosened previously.
226601 Figure 88

682 ‒ Gearbox
9JS GEARBOX 67
GEARBOX OVERHAULING
152. Remove the flange (1) and the odometer (2).
226602 Figure 89
153. Unscrew the screws (3) and remove the cover (2) from the
normal and low gear control cylinder (1).
226469 Figure 90
154. Unscrew the self-locking nut (2) securing the normal and low
gear control shaft and the screws (1) securing the cylinder (3)
to the reduction unit.
226470 Figure 91

682 ‒ Gearbox
68 9JS GEARBOX
GEARBOX OVERHAULING
155. Remove the safety wire (1) and unscrew the screws (3) secur-
ing the fork (4) to the control rod (2).
156. Remove the shaft (2) and the piston from the other side, the
fork (4) and the cylinder (5) .
226603 Figure 92
157. Using specific pliers, remove the bearing (1) retaining circlip (2)
on the lower layshaft (3).
code
226464 Figure 93
on the upper layshaft (3).
code
226465 Figure 94

682 ‒ Gearbox
9JS GEARBOX 69
GEARBOX OVERHAULING
159. With the jack (3) and the brackets (2), remove the upper lay-
shaft (1) and the bearing (4).
code
226466 Figure 95
160. With the jack (2) and the brackets (1), remove the lower lay-
code
226467 Figure 96
161. With the rear axle (1) brackets (2) hand-grips (3) and clamp
(6), remove the inner tracks (4) from the layshafts (5).
code
Grips 99341024
Clamp 99341015
226468 Figure 97

682 ‒ Gearbox
70 9JS GEARBOX
GEARBOX OVERHAULING
162. Remove the complete synchronizer (2) from the reduction unit
(1) paying careful attention to the springs inside.
226473 Figure 98
163. With the jack (3) and the brackets(2), remove the drive output
shaft (1).
code
164. Unscrew the screws (5), remove the rear cover (4) and re-
cover the rear bearing of the shaft (1).
226474 Figure 99
165. Unscrew the nut (1) and remove the odometer gear (2).
166. Remove the dust seal ring (5) and the oil seal ring (3) from the
rear housing (4).
226475 Figure 100

682 ‒ Gearbox
9JS GEARBOX 71
GEARBOX OVERHAULING
167. With the jack (1) and the brackets (2), extract the gear (6)
together with the spacer ring (5)and the front bearing (4) from
the drive output shaft(3).
code
226476 Figure 101
168. Remove the toothed washer (2) from the drive output
shaft(1).
226477 Figure 102
169. Remove the outer tracks (2) and (3) of the drive output shaft
bearings together with the corresponding external spacer (4)
from the auxiliary casing(1).
.533010. GRE rear housing assembly

170. Position the outer tracks (2) and (3) and the drive output shaft
into the auxiliary casing(1).
171. Note the position of the outer track (4) with the end of stroke
contact.
226478 Figure 103

682 ‒ Gearbox
72 9JS GEARBOX
GEARBOX OVERHAULING
172. Place the toothed washer (2) onto the drive output shaft(1).
226477 Figure 104
173. Place the gear (4) and the spacer ring (3) with the step facing
the gear (4) onto the drive output shaft(1).
174. Using a hot air blower, heat the bearing (2) to 80°C- 100°C
and insert it into the drive output shaft.
code
226479 Figure 105

682 ‒ Gearbox
9JS GEARBOX 73
GEARBOX OVERHAULING
175. Position the drive output shaft (1) in the reduction unit housing
(1).
226480 Figure 106
176. Using a hot air blower, heat the bearing (1) to a temperature of
80°C÷ 100°C and insert it into the drive output shaft (2).
code
226604 Figure 107
177. Using the keying device (1), fit the oil seal ring and the dust seal
ring into the rear cover (2).
code
226483 Figure 108

682 ‒ Gearbox
74 9JS GEARBOX
GEARBOX OVERHAULING
178. Insert the pin (6) and the odometer gear (2) into the rear
cover (5) and tighten the nut (1).
179. Grease the dust seal ring (3) and the oil seal ring (4).
Tool / Material
TUTELA MR3 grease
226484 Figure 109
180. Replace the gasket between the rear cover (2) and the reduc-
tion unit housing (4).
181. Place the rear cover (2) on the drive output shaft, tighten the
screws (3), the screw with the hole (1) and the screw with the
plastic washer (5) in the position indicated and tighten to the
prescribed torque.
Tightening torque
226485 Figure 110
182. Use paint to mark the two teeth diametrically opposed to the
gear so that there are the same number of teeth on the two
lower and upper semi circle perimeters.
226486 Figure 111

682 ‒ Gearbox
9JS GEARBOX 75
GEARBOX OVERHAULING
183. Insert the sleeve (3) onto the outer cone synchronizer (4) and
fit the synchronizer (1) with the springs (2) positioned in the
designated holes.
226487 Figure 112
184. Use oil to lubricate the contact surface of the gear (2) and fit
the synchronizer ring (1) of the normal and low gears.
Tool / Material
Oil
226488 Figure 113
185. Using a hot air blower on both auxiliary shafts, heat the inner
track (1) to a temperature of 80°C-100°C and fit it onto the
auxiliary shaft (2).
code
226605 Figure 114

682 ‒ Gearbox
76 9JS GEARBOX
GEARBOX OVERHAULING
186. Using paint, mark the tooth which corresponds to zero (1) on
both auxiliary shafts(2).
226606 Figure 115
187. Fit the layshafts (2) aligning the reference marks on the teeth
of these shafts with the marks on the centre gear of the drive
output shaft (1).
226491 Figure 116
188. After having made sure that the marks coincide, heat the bear-
ing (1) to a temperature of 80°C-100°C and key it onto the
189. Use pliers to fit the circlip (3).
code
226464 Figure 117

682 ‒ Gearbox
9JS GEARBOX 77
GEARBOX OVERHAULING
code
226465 Figure 118
192. Replace and grease the sealing rings (1) of the normal and low
gear control unit with silicone grease.
Tool / Material
Silicone grease
226607 Figure 119
193. Fit the cylinder (5).

194. Place the fork (4) on the synchronizer.
195. Fit the shaft (2) together with the piston.
196. Tighten the screws (3) to the prescribed torque and insert the
safety wire (1) into the specific holes.
Tightening torque
226603 Figure 120

682 ‒ Gearbox
78 9JS GEARBOX
GEARBOX OVERHAULING
197. Tighten the cylinder fastening screws (1) to the reduction unit
housing.
Tightening torque
198. Replace the piston fastening nut (2) with a new one and tighten
it to the prescribed torque.
Tightening torque
226470 Figure 121
199. Position the cover (2) on the cylinder (1) and tighten the
Tightening torque
226469 Figure 122
200. Fit the odometer (2) and the flange (1) onto the drive output
shaft.
226602 Figure 123

682 ‒ Gearbox
9JS GEARBOX 79
GEARBOX OVERHAULING
201. Screw in the flange (6) fastening nut (4).

202. Fit the covers (2), (4) and tighten to the screws (1) and (5) to
Tightening torque
M10 screw for securing layshafts 47.5 N⋅m to61 N⋅m
cover
226601 Figure 124
.530510. Removal of the gearbox housing

205. Remove the GRE rear housing as described in Removal of the GRE rear housing ( ➠ Page 66).
206. Remove the wire (1) from all the screws (3) securing the disc
(2).
207. Remove all the screws (3) retaining the disc(2).
223072 Figure 125
208. Unscrew the nut (3) securing the shaft and upper reverse
transmission gear (1). Recover the washer (2).
209. Do not remove the upper reverse transmission gear (1) from
the gearbox housing.
223076 Figure 126

682 ‒ Gearbox
80 9JS GEARBOX
GEARBOX OVERHAULING
210. Using the designated knockout extraction tool (2) and the des-
ignated extension tool (1); remove the upper reverse gear
transmission shaft together with the inner track of the gear
bearing and the relative shoulder washer.
code
211. Using specific pliers, remove the two circlips (3) retaining the
rear bearings of the layshafts.
code
223077 Figure 127
212. Working from inside the gearbox housing (3) and using a suit-
able drift (1), extract the outer track of the rear bearings of the
layshafts (4).
223078 Figure 128
213. Using a double-acting jack (2), a pair of tie rods (1) and a reac-
tion block (3) placed at the end of the upper layshaft, extract
the bearing (4) from its seat.
214. Repeat the same operation for the bearing of the lower lay-
shaft.
code
215. Remove the direct drive input shaft as described in operation

531010 Removal of the direct drive input shaft ( ➠ Page 83).
226499 Figure 129

682 ‒ Gearbox
9JS GEARBOX 81
GEARBOX OVERHAULING
216. Place a specific lifting rope (2) on the main shaft (1).
Tool / Material
Rope
217. After having slung the main shaft (1) with the rope (2), secure
the rope using a suitable lifting device (3).
218. Then tension the main shaft (1) without lifting it.
223086 Figure 130
219. Remove the circlip (1) from its seat in the main shaft (2) using
a specific tool.
code
220. Remove the sun gear (3) from the main shaft (2).
221. Remove the disc (4) from its seat.
223073 Figure 131
222. To remove the bearing (1), use a suitable universal bearing

extraction tool.
223. Secure the tool into the threaded holes (2) on the grooved
bushing (3).
224. Then by acting on the shaft (5) centring hole (4), extract the
bearing (1) from its seat.
225. Remove the two screw plugs (6) on the reverse transmission
gear shafts (7); unscrewing them using the specific tool (Philips
screwdriver).
223074 Figure 132

682 ‒ Gearbox
82 9JS GEARBOX
GEARBOX OVERHAULING
226. Remove the circlip (2) from the bearing (1) using the specific
tool.
code
227. Remove the grooved bushing (3) from the bearing (1) using a
universal bushing extraction tool.
223075 Figure 133
228. Using the specific tool, remove the two circlips (1) and (2)
retaining the ring (4) and main shaft (3).
code
223087 Figure 134
229. Lift the layshaft (6) and secure it to the gearbox housing (7)
with wire.
230. Slightly lift the main shaft (1) so that the gear can be removed
(4) thus making it easier to remove the main shaft (1).
231. During assembly, carry out the timing procedure described
below.
232. Check if the gear (4) has the paint markings on the teeth (5)
for timing during assembly; if it does not, use paint to mark
the teeth (5). The marking position can be found by dividing
the number of teeth by two and marking the teeth which are
diametrically opposed (drive output shaft centre gear).
233. Marking on the teeth on the layshaft gears is already there and
is indicated with a punched symbol on the timing teeth for both
layshaft gears.
234. Therefore during assembly for the timing, make the teeth (5) 223088 Figure 135
marked on the main shaft gear coincide with the punched teeth
on the layshaft gears.
235. Remove the gear (3) from the synchronizer set (2) to make it
easier to remove the main shaft (1).

682 ‒ Gearbox
9JS GEARBOX 83
GEARBOX OVERHAULING
236. Then, acting on the ropes with the lifting device, remove the
main shaft (1) from the gearbox housing (7) and place it on the
work bench for the subsequent disassembly operations.
237. Remove the layshaft (1) from the gearbox housing (2) and
place it on the work bench.
238. The reference point (4) on the layshaft (1) gear indicates the
tooth marked with the punching (5) for the timing.
239. On assembly, this tooth (4) must coincide with the teeth
marked by the main shaft gear.
240. The same is valid for the other layshaft (3).
241. Remove the previously positioned wire from the layshaft (3).
242. Remove the layshaft (3) from the gearbox housing (2) and
place it on the work bench.
243. Remove the upper reverse transmission gear from the gearbox
housing (2) which was not removed previously.
244. Now that the gearbox housing (2) is free, the final operation is
to disassemble and remove the lower reverse transmission gear
as described previously for the removal of the upper reverse 223089 Figure 136
transmission gear.
.531010. Removal of the direct drive input shaft

245. Remove the retainers (1) and extract the front cover (3) from
the direct drive input shaft(2).
223081 Figure 137

682 ‒ Gearbox
84 9JS GEARBOX
GEARBOX OVERHAULING
246. Remove the oil seal ring (5) (to be disposed of) from the front
cover (1).
247. During assembly, use the specific tool to replace the oil seal ring
(5) and the sealing gasket (4) with new ones.
code
Note Be particularly careful when fitting the front cover

(1) as the recess (2) must be positioned correctly at
the lubrication oil outlet hole on the gearbox housing
between the two retainers (3).
223082 Figure 138
248. Using the specific tool, remove the circlip (2) fixing the bearing
(3) to the direct drive input shaft (4).
code
249. Strike the direct drive input shaft (4) a few times with a mallet
until it comes off the bearing (3).
250. Remove the bearing (3) from the gearbox housing (5) using
a suitable extractor, then use the specific tool to remove the
circlip (1).
code
Simple bridge 99341003 223083 Figure 139
Clamp 99341015
Grips 99341025
251. Extract the spacer (1) from the direct drive input shaft (2).
223084 Figure 140

682 ‒ Gearbox
9JS GEARBOX 85
GEARBOX OVERHAULING
252. Using the specific tool, remove the circlip (1) and extract the
direct drive input shaft (2).
code
223085 Figure 141
253. Using an extractor (1), press out the bushing (2) from the
drive input shaft (3).
code
226506 Figure 142
.531020. Removal of the main shaft

254. Place the main shaft (1) in the vice (2) inserting appropriate
protections in the jaws of the vice to prevent any damage to the
main shaft walls (1) as the jaws close then remove the rope (3)
from the main shaft (1).
223090 Figure 143

682 ‒ Gearbox
86 9JS GEARBOX
GEARBOX OVERHAULING
255. Remove the gear (2) from the main shaft (1) for the input
shaft.
223091 Figure 144
256. Remove the synchronisation assembly (2) gear (3) for the third
and fourth gear from the main shaft (1).
223092 Figure 145
257. Remove the toothed disc (3) and the synchronisation assembly
(2) ring (4) for the third and fourth gear from the main
shaft(1).
Note Pay attention to the plates (5) with the spring when the
toothed disc (3) is removed as they could come out of
their seat.
223093 Figure 146

682 ‒ Gearbox
9JS GEARBOX 87
GEARBOX OVERHAULING
258. Use the specific tool (1) to remove the circlip (2) retaining the
synchronizer (3) from its seat in the main shaft (4).
code
223094 Figure 147
259. Remove the synchroniser ring (1) from the main shaft (2).
260. Remove the ring set (3) from the main shaft (2).
223095 Figure 148
261. Use the specific tool to remove the circlip (2) retaining the
synchronizer gear (1) from its seat (3) in the main shaft (6).
code
262. Use a suitable tool to remove the elastic pin (5) and extract the
hex key (4) retaining the main shaft gear (6).
223096 Figure 149

682 ‒ Gearbox
88 9JS GEARBOX
GEARBOX OVERHAULING
263. Remove the last gear (1) from the synchronisation assembly for
the third and fourth gear from the main shaft (2).
223097 Figure 150
264. Remove the grooved spacer ring (2) from the main shaft (1).
223098 Figure 151

682 ‒ Gearbox
9JS GEARBOX 89
GEARBOX OVERHAULING
265. Remove the gear (2) for the third speed from the main shaft
(1).
223099 Figure 152
223100 Figure 153

682 ‒ Gearbox
90 9JS GEARBOX
GEARBOX OVERHAULING
267. Remove the gear (2) for the second speed from the main shaft
(1).
223301 Figure 154
269. Use the specific tool to remove the circlip.
code
223302 Figure 155

682 ‒ Gearbox
9JS GEARBOX 91
GEARBOX OVERHAULING
270. Remove the gear (3) of the second synchronisation assembly

(1) from the main shaft (2).
223303 Figure 156
271. Remove the synchronizer toothed disc (3) and the synchroniza-
tion assembly (1) ring (4) from the main shaft(5).
Note Pay attention to the plates (2) with the spring when the
toothed disc (3) is removed as they could come out of
their seat.
223304 Figure 157

682 ‒ Gearbox
92 9JS GEARBOX
GEARBOX OVERHAULING
272. After having removed the synchronizer toothed disc (4), use
the specific tool to remove the circlip (2) retaining the syn-
chronizer (1) from its seat in the main shaft (3).
code
223305 Figure 158
273. Remove the synchronisation assembly (3) from the main shaft
(1).
274. Remove the last gear (2) of the synchronisation assembly from
the main shaft (1).
223306 Figure 159

682 ‒ Gearbox
9JS GEARBOX 93
GEARBOX OVERHAULING
223307 Figure 160
276. Remove the gear (2) for the first speed from the main shaft
(1).
223308 Figure 161

682 ‒ Gearbox
94 9JS GEARBOX
GEARBOX OVERHAULING
223309 Figure 162
278. Remove the low speed gear (2) from the main shaft (1).
223310 Figure 163

682 ‒ Gearbox
9JS GEARBOX 95
GEARBOX OVERHAULING
223311 Figure 164
280. Remove the crawler gear and reverse gear engagement sliding
sleeve (1) from the main shaft (2).
223312 Figure 165

682 ‒ Gearbox
96 9JS GEARBOX
GEARBOX OVERHAULING
281. Remove the reverse gear (1) from the main shaft (2).
223313 Figure 166
282. Remove the grooved metal contact ring (1) for the reverse
gear from the main shaft (2); this will complete the disassembly
operations of the main shaft.
223314 Figure 167

682 ‒ Gearbox
9JS GEARBOX 97
GEARBOX OVERHAULING
.531020. Main shaft assembly

283. Place the main shaft (1) in the vice; inserting appropriate pro-
tections in the jaws of the vice to prevent any damage to the
main shaft walls (1) as the jaws close .
284. Fit the grooved metal contact ring (2) of the reverse gear onto
the main shaft (1).
223315 Figure 168
285. Fit the reverse gear (3) onto the main shaft (5).
286. Insert the hex key (1) into its seat (2) using the hole (4) of the
elastic pin which will be inserted next as reference.
Note Place a surface below the key (1) to prevent it from
falling during assembly of the gears on the main shaft
(5).
Let the key (1) move upwards and therefore lift the
stop surface each time a gear engages on the main shaft
(5).
223316 Figure 169

682 ‒ Gearbox
98 9JS GEARBOX
GEARBOX OVERHAULING
287. Fit the sliding sleeve (2) for the crawler gear and reverse gear
engagement on the main shaft (4); inserting it inside the reverse
gear (1).
288. Let the hex key (3) move up above the sliding sleeve (2) keep-
ing it fixed with the previously positioned stop surface.
223317 Figure 170
289. Fit the grooved spacer ring (2) onto the main shaft (4) placing
it at the correct height of the sliding sleeve (1) as shown in the
figure.
290. Let the hex key (3) move up above the grooved spacer ring
(2).
223318 Figure 171

682 ‒ Gearbox
9JS GEARBOX 99
GEARBOX OVERHAULING
291. Fit the low speed gear (1) onto the main shaft (2) placing it so
that makes contact with the grooved spacer ring which has been
inserted.
223319 Figure 172
292. Fit the grooved spacer ring (1) on to the main shaft (2).
223320 Figure 173

682 ‒ Gearbox
100 9JS GEARBOX
GEARBOX OVERHAULING
293. Fit the gear (1) for the first speed onto the main shaft (2).
223321 Figure 174
223322 Figure 175

682 ‒ Gearbox
9JS GEARBOX 101
GEARBOX OVERHAULING
295. Fit the synchronization assembly (2) together with the toothed
ring (1) and the rings (3) onto the main shaft (4).
296. Use the specific tool to fit the circlip (5) retaining the synchron-
ization assembly (2) in its seat on the main shaft (4).
code
223323 Figure 176
223324 Figure 177

682 ‒ Gearbox
102 9JS GEARBOX
GEARBOX OVERHAULING
298. Fit the gear (2) for the second speed onto the main shaft (3).
299. Let the hex key (1) move up above the gear (2) for the second
speed stopping it at the base with the stop surface.
223325 Figure 178
223326 Figure 179

682 ‒ Gearbox
9JS GEARBOX 103
GEARBOX OVERHAULING
301. Fit the gear (2) for the third speed onto the main shaft (5).
302. Fit the grooved spacer ring (3) onto the main shaft (5).
303. Let the hex key (1) move up above the grooved spacer ring (3)
stopping it at the base with the stop surface.
304. Insert a new elastic pin into the seat (4) pushing it as far as pos-
sible and cutting it appropriately with a suitable tool to allows
the last gears to engage.
305. Use the specific tool to fit the circlip after inserting the grooved
spacer ring (3).
code
223327 Figure 180
306. Fit the synchronization assembly (2) together with the toothed
ring (1) and the rings onto the main shaft (4).
307. Use the specific tool to fit the circlip (3) retaining the synchron-
ization assembly (2) in its seat on the main shaft (4).
code
223328 Figure 181

682 ‒ Gearbox
104 9JS GEARBOX
GEARBOX OVERHAULING
308. Fit the toothed ring (4) closing the synchronization assembly
(3) onto the main shaft (6).
309. Fit the gear (5) for the input shaft on the main shaft (6).
310. With the help of a tool (1), let the hex key move up until it
makes contact with the elastic pin inserted previously; with this
operation, assembly of the main shaft is completed (6).
311. Remove the main shaft (6) from the vice (2).
223329 Figure 182
.530510. Gearbox housing assembly

312. Insert the layshaft (4) into the gearbox housing (1) and secure
it with wire (2).
313. Insert the other layshaft (3) into the gearbox housing (1).
223330 Figure 183

682 ‒ Gearbox
9JS GEARBOX 105
GEARBOX OVERHAULING
314. Fit the upper reverse transmission gear (1) inserting the sup-
port spindle and the washer (2) without securing the gear (1)
with the nut (3).
315. Fit the other lower reverse transmission gear in same way; this
is to be tightened with the nut to the prescribed torque.
223076 Figure 184
316. Use the specific tool to fit the circlip (6) onto the bearing (1) of
the lower layshaft.
code
317. Using a suitable drift (4), insert the bearing (1) retaining the
layshaft, together with the circlip (6) inside its seat, driving it in
until it is in line with the gearbox housing wall (5).
318. Fit the bushing (2) securing it with the bolt (3) tightened to the
prescribed torque.
223332 Figure 185
319. Working from the opposite side and using a suitable drift, insert
the bearing (2) retaining the layshaft (1) in its seat on the gear-
box housing (3) securing it definitively to the layshaft (1) in the
gearbox housing (3).
320. Using a suitable drift, insert the bearing (4) into its seat.
223333 Figure 186

682 ‒ Gearbox
106 9JS GEARBOX
GEARBOX OVERHAULING
321. Temporarily remove the first gear near to the synchronization

assembly (3) toothed disc (2) from the main shaft (5) in order
to make it easier to insert the main shaft (5) into the gearbox
housing (1).
322. Use wire (6) to secure the main shaft (5) to prevent the gears
from falling when inserting the main shaft (5) into the gearbox
housing (1).
323. Sling the main shaft (5) with a specific rope (4), lift the main
shaft (5) with a suitable lifting device and place it above the
Tool / Material
Rope
324. Gently lower the main shaft (5) inside the gearbox housing (1)
without removing the rope from the main shaft (5).
223331 Figure 187
325. When the main shaft (5) is positioned halfway inside the gear-
box housing, insert the gear removed previously positioning it
near the toothed disc (2) of the synchronization assembly (3).
326. Remove the wire (6) around the main shaft (5).
327. Carry out the timing procedure as described below.

328. Lower the main shaft (5) into the gearbox housing (4) bringing
it towards the lower layshaft (3) and making the main shaft (5)
gear teeth (1) marked with paint coincide with the layshaft (3)
gear teeth (2) marked with punching.
223335 Figure 188
329. Using the specific tool, fit the two circlips (1) and (2) retaining
the ring (4) and main shaft (3).
code
223087 Figure 189

682 ‒ Gearbox
9JS GEARBOX 107
GEARBOX OVERHAULING
330. Fit the circlip (2) onto the bearing (1) using the specific tool.
code
331. Fit the grooved bushing (3) onto the bearing (1) using a suit-
able drift.
223075 Figure 190
332. Using a suitable drift, insert the bearing (1) into its seat together
with the bushing (3) securing the main shaft (2) in the gearbox
housing (4).
333. Tighten the screw plugs (6) on the reverse transmission gear
shafts (5) to the prescribed torque.
334. Using a suitable drift, insert the cylindrical roller bearing (7) into
its seat.
223339 Figure 191
335. Timing procedure: remove the wire from the upper lay-
shaft (2) and move it so the teeth of the layshaft (2) gear (1)
marked with punching coincide with the teeth of the main shaft
(3) gear (4) marked with paint.
336. Fit the direct drive input shaft as described in operation 531010
Direct drive input shaft assembly ( ➠ Page 111).
223338 Figure 192

682 ‒ Gearbox
108 9JS GEARBOX
GEARBOX OVERHAULING
337. Fit the circlip (5) onto the bearing (3) using the specific tool.
code
338. Using a suitable drift, insert the bearing (3) retaining the lay-
shaft, together with the circlip (5) inside its seat, driving it in
until it is in line with the gearbox housing (6) wall (4).
339. Fit the bushing (2) securing it with the bolt (1) tightened to the
prescribed torque.
223336 Figure 193
340. Working from the opposite side of the upper layshaft (1) and
using a suitable drift, insert the bearing retaining the layshaft (1)
in its seat (2) securing the layshaft (1) in the gearbox housing
(3).
223337 Figure 194
341. Secure the upper reverse transmission gear (1), the support
spindle and the washer (2) tightening the nut (3) to the pre-
scribed torque.
223076 Figure 195

682 ‒ Gearbox
9JS GEARBOX 109
GEARBOX OVERHAULING
342. Fit the sun gear (3) onto the main shaft (2).
343. Fit the disc (4) in its seat.
344. Insert the circlip (1) into its seat on the main shaft (2) using a
specific tool.
code
223073 Figure 196
345. Insert the screws (3) securing the disc (2) and tighten them to
346. Insert the wire (1) into all the screws (3) securing the disc (2).
223072 Figure 197
347. Replace the gasket (5)retaining the top cover (3) on the gear-
box housing (4) with a new one.
348. Fit the top cover (3) together with the fork control (1) rods
(2) on the gearbox housing (4).
223071 Figure 198

682 ‒ Gearbox
110 9JS GEARBOX
GEARBOX OVERHAULING
349. Insert the three balls (3) into their seat (2) using a magnetic
tool (4).
350. Position all the gearbox housing cover (5) screws (1) into their
seats.
223070 Figure 199
351. Insert the three springs (1) used for positioning the fork control
rods into their seat (2).
223069 Figure 200
352. Insert the new metal gasket (1).

353. Tighten the screws(2) securing the top cover (3) of the gear-
box housing (4) to the prescribed torque.
354. Fit the gear control housing as described in operation 530520
"Installing gear control housing ( ➠ Page 59).
223068 Figure 201

682 ‒ Gearbox
9JS GEARBOX 111
GEARBOX OVERHAULING
.531010. Direct drive input shaft assembly

355. Using a copper hammer, fit the new bushing (1) into the drive
input shaft (2).
226586 Figure 202
356. Insert the direct drive (2) input shaft into the main shaft; using
the specific tool, fit the circlip (1) into its seat on the direct
code
223334 Figure 203
357. Insert the spacer (1) onto the direct drive (2) input shaft.
223084 Figure 204

682 ‒ Gearbox
112 9JS GEARBOX
GEARBOX OVERHAULING
358. Using a suitable drift and mallet, insert the bearing (3) together
with the circlip (1) onto the direct drive input shaft (4) inside
its seat in the gearbox housing (5), then use the specific tool to
fit the sealing circlip (2).
code
223083 Figure 205
359. Using a drift (6) and keying device (1), fit the new oil seal ring
(2) onto the front cover(3).
code
99370006)
360. Replace the front cover sealing gasket (3) with a new one.
226618 Figure 206
361. Fit the front cover (3) of the direct drive input shaft (2) and
tighten the retainers (1) to the prescribed torque.
223081 Figure 207

682 ‒ Gearbox
9JS GEARBOX 113
DIAGNOSTICS
.530510. Refitting the clutch housing

362. To refit the clutch housing, repeat the operations described in the removal process in reverse order, tightening the screws
and nuts to the specified torques.
530210 DIAGNOSTICS
tions.
Operating principle
200120 Figure 208


682 ‒ Gearbox
114 9JS GEARBOX
DIAGNOSTICS
value.


174285 Figure 209

H Fast L Low
Troubleshooting
3. Piston.
plug.

682 ‒ Gearbox
9JS GEARBOX 115
DIAGNOSTICS
Noisy transmission
The transmission may generate noise during typical operation. Excessive or abnormal noise, for example, particularly acute or bom-
bastic sounds, indicates that there may be a fault in the transmission. It is possible that the noise is generated by other noisy parts
and is amplified by the transmission.
Internal transmission noise
1. Impact
1. The transmission gear teeth strike against each other. It can be identified by the obvious signs revealed after grinding the gear
teeth. In general, the noise issue is more noticeable when the gears are under load. If the noise only occurs when changing a
certain gear, it means that the gear teeth of said gear are defective. This type of impact problem can be solved using an abras-
ive stone or a portable grinder.
2. Damage or scoring of the races due to damaged bearing spheres or rollers may cause noise when gear shifting.
3. If during assembly the gear has been exposed to impact or fracture, it may impact when in low gear and generate screeching
noises at high speeds.
2. Screeching noise
1. It can be caused by normal wear of the gears. Scratches caused by prolonged operation can cause screeching noises before
the final damage of a gear.
2. This may be caused by an incorrect coupling of the gears, which can be identified by uneven wear of the gear surface.
3. A reduced axial and radial play can cause screeching noises after the pre-tightening of the bearing.
3. Bombastic noise
It can be caused by an error in the alignment of the teeth. Bombastic noises may be caused by misalignment of the teeth when
refitting the transmission or by a misalignment of the teeth caused by the rotation of the secondary shaft.
4. Popping
Turning the gear set generates a popping noise due to excessive axial play between lay shaft and main shaft. An excessive radial
play of the bearing on the lay shaft leads to an excessive distance between the lay shaft, possibly causing the gear may break due to
excessive load on the tips.
Transmission overheating
The transmission must work with a temperature not exceeding 120 ° C during prolonged operation. If the operating temperature
is higher than 120 ° C, the lubricant will deteriorate, and the life of the transmission will be reduced.
The transmission will generate heat due to friction of the moving parts. The normal operating temperature is about 38 ° C higher
than the ambient temperature. Poor heat dissipation can cause overheating of the transmission.
To ensure correct reading of the oil temperature indicator, check the oil temperature sensor and indicator before proceeding with
troubleshooting. Typically overheating is due to:
1. Incorrect lubrication. Too much or little lubricating fluid, the fluid has an incorrect SAE no. or transmission working angle ex-
ceeds 12°.
2. Vehicle speed generally below 32 km/h.
4. Air flow is prevented because the transmission is surrounded by the chassis of the vehicle, from the floor, from the fuel tank
and the bumper assembly.
5. Engine exhaust system excessively near the transmission.
6. Excessively high ambient temperature.
7. Overload drive conditions or excessive engine speed.

682 ‒ Gearbox
116 9JS GEARBOX
DIAGNOSTICS
Disengaging the transmission gear (gear slippage) or difficult gearshifting.

Main transmission gear disengagement
When the seat of the mesh wheel gear (sliding sleeve on lay shaft) and the main shaft gears move to mesh, the teeth of the gear to
engage must be parallel. If the teeth of the gear engaged are worn or consumed, these teeth will tend to slip out of mesh and thus
disengage gear under specific conditions.
Gear disengagement reasons:
1. The transmission input shaft and the pilot bearing of the motor flywheel are not concentric.
2. Violent impact of the gears during shifting causes wear of the tips of the meshing teeth.
3. The meshing teeth are worn until bevelled.
4. The pressure applied to the positioning ball of the shaft drive fork is insufficient due to a weakened or damaged check spring.
5. Positioning slot of the shaft drive fork extremely worn.
6. The connection to the control device of remote gearshifting is adjusted incorrectly, therefore meshing of the meshing teeth
and sliding sleeves is only partial.
7. When the vehicle is in full drive or while driving under load conditions, gear disengagement often occurs during sudden decel-
erations.
8. Driving on an uneven road, the gearshift lever may oscillate like a pendulum if it is extremely long and heavy, causing fractures
due to the pressure of the check spring and therefore disengaging the gear.
Gear splitter disengagement

Disengagement of splitter gears may be due to wear, erosion or partial meshing of meshing teeth between the splitter transmission
gear and the sliding sleeve of the synchronizer.
These faults are the result of impacts while gearshifting and of standard wear due to prolonged use.
Other factors that cause disengagement include vibrations due to incorrect transmission shaft installation and insufficient pressure
in the pneumatic transmission system.
Difficult gearshfting
While changing gears, various gears require different sorts os effort to engage. However, excessive force should not be exerted to
shift gears.
Difficult gearshifting often occur on remote control devices used for models with cabs mounted above the engine.
Therefore, while troubleshooting issues, check the linkage of the remote control device. In addition, the reasons for failure of the
linkage are various, such as wear and tear, incorrect connection and adjustment of the fork bushing or junction, poor lubrication of
the joints, limited movement of the rod due to mechanical barrier.
To check whether the problem is caused by the change difficult transmission itself is necessary to remove the gearshift lever or rod
from the transmission, drive gear guide block with a bar or screwdriver to be able to engage the single gears. The fault is not linked
to the transmission if the shaft drive fork slides smoothly. Otherwise, this means that the transmission is damaged.
If the transmission is damaged, the fault may be caused by:
1. The groove of the sliding sleeve of the lay shaft is locked on the main shaft, due to a distortion of the main shaft, the fork or
the groove of the main shaft.
2. The shaft drive fork is stuck in the transmission seat, which in turn may be due to impacts or bending of the shift drive fork
resulting from fractures of the seat or excessive tightening torque on the fixing screw of the gear shaft.
3. The shaft check screw is loose.
Damage to the gear

Engaged gear teeth damaged
This is a common fault for transmissions that mount synchronizer; gear impact may cause more damage to the teeth of the gear
engaged when gearshifting.
Minor impact may cause slight consequences whilst violent gearshifting before synchronization occurs will cause serious damage. In
this case, the ends of the meshed gear teeth may fracture and fall off.

682 ‒ Gearbox
9JS GEARBOX 117
DIAGNOSTICS
The causes leading to damage of the engaged gear are:
1. Incorrect gearbox operation. The driver lacks familiarity with the positions of the gearbox as well as with the engine speed
range for different gears.
2. When setting into motion in first or reverse gears, impact may occur due to inefficient clutch release clearance or only partial
release.
Damage to teeth
1. Standard wear
Due to relative stroke during gear engagement, gear tooth wear is normal. This type of wear is gradual and even.
Nevertheless, at times the surface of the teeth may be subjected to rapid wear and duration shortened when faced with harsh
conditions.
2. Gear tooth fracture
Gear tooth fracture is severe. The fragments of the teeth may damage other parts.
The cause of most of these fractures is attributed to a heavy impact. Gears that break after short periods of use during heavy loads
fall into the category of "impact fractures". If fracture occurs after numerous duty cycles, then this is "fatigue fracture".
3. Scoring
A gear will be scored after lengthy periods of use with overloads or also with soiled lubricant or with a SAE number that is not
suitable that can lead to tooth surface faults. Fatigue fracture may occur if these gears remain in use.
4. Scratching and sticking
Scratching and sticking occur after direct contact between metal surfaces of the gear teeth.
Relative motion of the metal surfaces may generate extremely high temperatures. This may lead to sticking of the softened metals
during these conditions of gear engagement.
The main cause of sticking and scratching is due to poor quality or lack of lubrication oil.
Gearbox deformation and breakage

Deformation or breakage of the gearbox may occur when the torsion motion applied to the shaft is higher than the rated value.
The possible causes of deformation or breakage of the gearbox are:
1. Incorrect gearshifting.
2. Putting into drive with high gears.
3. Towing in non-conform conditions.
4. Attempts to drive the vehicle while brake is engaged.
5. Gearbox service conditions not conform to design specifications.
6. Vehicle rear impact against obstacles.
7. Fatigue or impact fracture.
Bearings damage
Bearing wear is evident from the stripping of the bearing race or rough surface of the roller, which will generate loud noise and
vibrations. When the bearing is approaching the end of its life heavy and standard duty cycles, it shows signs of wear / fatigue.
When refitting the bushing into the bearing bore inside the transmission, it could be damaged if the hole is too small or out of
round. A deformation of the holes in the housing of the transmission can cause incorrect installation of the shaft, resulting in early
damage to the bearing due to fatigue.
Poor lubrication
Some features of the damage to bearings due to poor lubrication are fading components, stripping of the bearing race and the
damage to the bearing cage.
A poor level of lubrication is only one of the factors of damage of the bearings there are other causes, such as the presence of
impurities in the lubricant, different classifications of lubricant or mixture of lubricants with different SAE no.

682 ‒ Gearbox
118 9JS GEARBOX
Troubleshooting guide
1. Preliminary checks
● Visual inspection: Look for signs of damage and pay attention to key parts, such as brackets, connectors, connections and con-
trol the pneumatic circuit.
● Gather information relating to conditions of work and the historical failure rate.
● Create documentation that includes intervals for maintenance , lubrication and faults occurred in the past, mileage and days of
use.
2. Removing the gearbox
● Keep an oil sample to check the impurity content when necessary.

● Make sure components are mounted correctly, that there are no missing components or unoriginal parts during removal.
● Thoroughly clean and check the parts.
3. Identify type of fault

4. Determine cause of fault and resolve the problem

The fast and low gears of the splitter are disengaged

1 Faulty pressure control valve. Cause confirmed ▶ Replace parts.
2 Slackened air pipe or connector. Cause confirmed ▶ Tighten parts.
3 Crushed air pipe or connector. Cause confirmed ▶ Remove the parts subjected to
obstacles.
4 The gears disengage due to misalignment of Cause confirmed ▶ Replace parts.
teeth and shaft distortion. ▶ Identify cause of damage.
5 Worn meshing tooth Cause confirmed ▶ Replace parts.
Gears of main shaft disengaged or crossed

1 Worn fork. Cause confirmed ▶ Replace parts.
2 Weakened or missing check spring. Cause confirmed ▶ Replace parts.
▶ Install missing parts.
5 Sliding sleeve fork groove worn. Cause confirmed ▶ Replace parts.

682 ‒ Gearbox
9JS GEARBOX 119

5 Sliding sleeve fork groove worn. Cause not confirmed Check: 6
6 The sleeve does not move freely. Cause confirmed ▶ Remove the parts subjected to
obstacles.
7 Sleeve incorrect position. Cause confirmed ▶ Replace the part.
8 Damaged engine mount Cause confirmed ▶ Replace parts.
9 Engine and gearbox misaligned. Cause confirmed ▶ Replace parts.
▶ Make new adjustments based on re-
quirements.
Gear shifting is difficult or impossible for fast or low gears

3 Crushed air pipe. Cause confirmed ▶ Remove the parts subjected to
obstacles.
4 The plug of the double H valve is rigid. Cause confirmed ▶ Clean the parts.
5 Gearbox cylinder O-ring damaged. Cause confirmed ▶ Clean the parts.
▶ Replace parts.
6 Loose nut on the cylinder piston. Cause confirmed ▶ Tighten parts.
▶ Clean the parts.
7 Cracked cylinder piston. Cause confirmed ▶ Replace parts.
▶ Apply a thin layer of silicone grease.
8 Damaged synchronizer spring. Cause confirmed ▶ Replace parts.
▶ Identify cause of damage.
9 Synchronizer damaged. Cause confirmed ▶ Replace parts.
10 Too little lubricant of the cylinder O-ring Cause confirmed ▶ Apply a thin layer of silicone grease.
11 Too much lubricant of the cylinder O-ring Cause confirmed ▶ Clean the components

682 ‒ Gearbox
120 9JS GEARBOX
Gear shifting is difficult or impossible on main transmission

1 Shaft drive fork bent. Cause confirmed ▶ Replace parts.
▶ Loosen the fixing screw and tighten to
2 Shaft drive fork with burr Cause confirmed ▶ Grind the surface with sand.
3 Rigid check spring. Cause confirmed ▶ Replace parts.
4 Gearbox seat cracked. Cause confirmed ▶ Replace parts.
6 Main shaft deformed. Cause confirmed ▶ Replace parts.
7 Incorrect clutch use. Cause confirmed ▶ Instruct the driver on correct driving.
obstacles.
9 Incorrect clutch adjustment. Cause confirmed ▶ Make new adjustments based on re-
quirements.
Interlocking not possible

1 Missing interlock steel ball. Cause confirmed ▶ Replace parts.
2 Missing interlocking pin. Cause confirmed ▶ Replace parts.
Rattling sound when shifting

1 Damaged fork. Cause confirmed ▶ Replace parts.

682 ‒ Gearbox
9JS GEARBOX 121

3 Countershaft brake not operational. Cause confirmed ▶ Replace parts.
▶ Tighten parts.
▶ Check the air pipe.
obstacles.
5 Connecting rod incorrect adjustment. Cause confirmed ▶ Make new adjustments based on re-
quirements.
6 Worn gearbox housing sleeve Cause confirmed ▶ Replace parts.
quirements.
Cannot shift to neutral

obstacles.
quirements.
Excessive noise

2 Gear teeth cracked or with burr. Cause confirmed ▶ Grind the surface with sand.
▶ Replace parts.
3 Main shaft gear excessive difference. Cause confirmed ▶ Replace parts.
4 Slippage of race inside front bearing of the Cause confirmed ▶ Install missing parts.
splitter countershaft. Cause not confirmed Check: 5
5 Damaged bearing. Cause confirmed ▶ Replace parts.
6 Low oil level. Cause confirmed ▶ Identify cause of damage.
7 Lubricant too low. Cause confirmed ▶ Top-up lubricant

682 ‒ Gearbox
122 9JS GEARBOX

7 Lubricant too low. Cause not confirmed Check: 8
8 Oil change not performed on time. Cause confirmed ▶ Replace parts - Top-up oil level
9 Different oil mixtures. Cause confirmed ▶ Replace parts.
Noisy gears with engine running at idle speed:

2 Engine operation unstable. Cause confirmed ▶ Make new adjustments based on re-
quirements.
High vibrations

2 Output shaft nut tightening torque insuffi- Cause confirmed ▶ Make new adjustments based on re-
cient. quirements.
3 Incorrect propeller shaft assembly. Cause confirmed ▶ Make new adjustments based on re-
quirements.
4 Worn suspension. Cause confirmed ▶ Replace parts.
quirements.
The main shaft washer is burnt

2 Low vehicle tow or sliding. Cause confirmed ▶ Replace parts.
quirements.

682 ‒ Gearbox
9JS GEARBOX 123
The input groove is worn or damaged

1 Drive with too high gears. Cause confirmed ▶ Instruct the driver on correct driving.
▶ Replace parts.
2 Excessive load. Cause confirmed ▶ Instruct the driver on correct driving.
▶ Replace parts.
quirements.
4 Clutch damage. Cause confirmed ▶ Replace parts.
quirements.
5 Engine and transmission misaligned. Cause confirmed ▶ Make new adjustments based on re-
quirements.
▶ Replace parts.
quirements.
Clutch housing damaged

quirements.
▶ Replace parts.
3 Missing transmission auxiliary support. Cause confirmed ▶ Install missing parts.
Synchronizer is damaged

2 Reverse mounting of fork. Cause confirmed ▶ Replace parts.
▶ Refit.

682 ‒ Gearbox
124 9JS GEARBOX

6 Low functioning and use. Cause confirmed ▶ Instruct the driver on correct driving.
Overheating

3 Slippage of race inside front bearing of the Cause confirmed ▶ Replace parts.
splitter layshaft. Cause not confirmed Check: 4
5 Oil level too high. Cause confirmed ▶ Check correct oil quantity.
7 Excessive transmission work angle. Cause confirmed ▶ Replace damaged parts.
quirements.
Main shaft deformed

▶ Replace parts.
2 Excessive shock absorber load. Cause confirmed ▶ Instruct the driver on correct driving.
▶ Replace parts.

682 ‒ Gearbox
9JS GEARBOX 125
Bearing burnt

3 Faulty seat. Cause confirmed ▶ Replace parts.
quirements.
4 Damaged rear flange oil seal Cause confirmed ▶ Replace parts.
5 Loose or missing fixing screw. Cause confirmed ▶ Replace parts.
quirements.

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126 12JS GEARBOX

682 ‒ Gearbox
12JS GEARBOX 127
Contents
Contents GEARBOX OVERHAULING . . . . . . . . . . . . . . . 164
GENERAL INFORMATION . . . . . . . . . . . . . . . . 129 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 225
LOCATION OF GEARBOX DESCRIPTION Main mechanical malfunctions . . . . . . . . . . . . . . . 230

PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 The fast and low gears of the splitter are
disengaged . . . . . . . . . . . . . . . . . . . . . . . . . 230
GEARBOX VIEWS . . . . . . . . . . . . . . . . . . . . . 131
Gears of main shaft disengaged or crossed . . . . . 230
GEAR CONTROL LEVER . . . . . . . . . . . . . . . . . 133 Gear shifting is difficult or impossible for fast or
low gears . . . . . . . . . . . . . . . . . . . . . . . . . 231
Main components of the gearbox housing . . . . . . . 134 Gear shifting is difficult or impossible on main
transmission . . . . . . . . . . . . . . . . . . . . . . . 232
Main components of the main shaft . . . . . . . . . . . 136
Interlocking not possible . . . . . . . . . . . . . . . . 232
Main components of the layshafts . . . . . . . . . . . . 138 Rattling sound when shifting . . . . . . . . . . . . . . 232
Cannot shift to neutral . . . . . . . . . . . . . . . . . 233
Main components of the direct drive input shaft . . . . 139
Excessive noise . . . . . . . . . . . . . . . . . . . . . . 233
Main components of the reverse gear transmission Noisy gears with engine running at idle
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Main components of the top cover of gearbox High vibrations . . . . . . . . . . . . . . . . . . . . . . 234
internal controls . . . . . . . . . . . . . . . . . . . . . . . 141 The main shaft washer is burnt . . . . . . . . . . . . 234
The input groove is worn or damaged . . . . . . . 235
Main components of gear control housing . . . . . . . 142
Clutch housing damaged . . . . . . . . . . . . . . . . 235
Main components of the selection valve . . . . . . . . . 143 Synchronizer is damaged . . . . . . . . . . . . . . . . 235
Main components of auxiliary transmission gear Overheating . . . . . . . . . . . . . . . . . . . . . . . . 236

assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Main shaft deformed . . . . . . . . . . . . . . . . . . 236
Bearing burnt . . . . . . . . . . . . . . . . . . . . . . . 237
Main components of gearbox reduction unit rear
housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Main components of normal and low gear control

cylinder equipped with power take-off . . . . . . . . . 146
Man components of the rear cover . . . . . . . . . . . 147
Main components of the air pressure regulator

valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Main components of power take-off (PTO: Power

Take Off ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
GEARBOX REMOVAL-REFITTING . . . . . . . . . . . 158
BOWDEN CABLES ADJUSTMENT DIAGRAM . . . . 164

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12JS GEARBOX 129
GENERAL INFORMATION
12JS GEARBOX
Structural characteristics
● The design combines main and auxiliary cases that are compact, lightweight and offer high driving efficiency.
● Unique structure, power distribution and twin counter-shaft.

● Simple gearshifting that is flexible and fully synchronised. The main casing features a large capacity synchronizer with double
cone lock rings.
The auxiliary case implements an inertial synchronizer with an advanced locking pin and metal-free friction material for max-
imum reliability.
● Long first gear ratio (15.53), excellent load capacity, outstanding uphill drive.
● Rational gear layout, reduced gearing differences and better fuel economy.
● Thin tooth design, stable engagement and silent gearing.
● Various possibilities offered for power take-off, and can be installed in any point of the transmission.
● Gearshifting is single-H type for clear gear layout with simple and flexible gear engagement.
172604 Figure 210
Gearbox designation
Number (F) 12 J D S 160 T A (-B)
Description Fast Gear No. Mechanical Single body Twin coun- x10 = Input With syn- Gear ratio Modified
tershaft torque Nm chronizers type

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130 12JS GEARBOX
LOCATION OF GEARBOX DESCRIPTION PLATE
530210 LOCATION OF GEARBOX DESCRIPTION PLATE
A
E
D C
172605 Figure 211

A= Type of transmission
B = Nominal input torque
C = Drawing number
D = P.T.O. gear ratio
B = Nominal input power

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12JS GEARBOX 131
GEARBOX VIEWS
530210 GEARBOX VIEWS
200121 Figure 212

1. Air pipe for neutral gear with PTO engaged
2. Air pipe connected to tank

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132 12JS GEARBOX
GEARBOX VIEWS
200122 Figure 213

1. Cab tipping neutral safety switch
2. Reverse gear switch

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12JS GEARBOX 133
GEAR CONTROL LEVER
530210 GEAR CONTROL LEVER
200123 Figure 214

H Fast gears L Low gears
1 Power Supply (red) 2 Output for low gears (black)
When engaging gears with super H, it is possible to change range using the lever switch on the gear selector.
When the lever switch is on "Low", gears 1 to 6 are selected. If it is set to "High" gears 7th to 12th are selected.
The neutral position is at the centre of ¾ path.

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223340 Figure 215

1 Bolts, with holes on the hex head 4 Hexagon head screw
2 Spring washer 5 Spring washer
3 Direct drive input shaft cover 6 Oil seal

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12JS GEARBOX 135
7 Gasket 25 Grease nipple cup mount

8 Hexagon head screw 26 Grease nipple cup cover
9 Spring washer 27 Spring washer
10 Stud 28 Sealing washer
11 Washer 29 Clutch housing
12 Hex nut with nylon lock insert 30 Sealing gasket for clutch housing
13 Circlips for shafts 31 Conical screw plug with square head
14 Antidust cover 32 Transmission case
15 Circlips 33 Hexagon head screw
16 Bushing 34 Lower power take-off window opening cover
17 Ball bearings 35 Gasket for power take-off window opening
18 Hexagon head screw 36 Gearbox oil drain plug
19 Spring washer 37 Gearbox oil filler plug
20 Fork bracket isolation 38 circular magnet
21 Moving fork 39 Screw
22 Fork shaft isolation 40 Positioning pin
23 Bearing lubrication pipe 41 Clutch inspection hole cover
24 Coupling connection 42 Hexagon head screw

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222752 Figure 216

1 Fifth speed gear 4 Sixth speed gear
2 Snap circlip 5 Grooved ring for main shaft
3 Complete fifth and sixth gear synchronizer 6 Spacer for main shaft

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7 Fourth speed gear 13 Crawler gear and reverse gear sliding sleeve
8 Complete third and fourth gear synchronizer 14 Reverse gear
9 Third speed gear 15 Reverse gear metal toothed gasket
10 Second speed gear 16 Hex key for main shaft
11 Complete first and second gear synchronizer 17 Elastic pin
12 First speed gear 18 Main shaft

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138 12JS GEARBOX
223342 Figure 217

1 Hexagon head bolt 4 Radial ball bearing
2 Cover 5 Snap circlip
3 Flexible cylindrical pin 6 Circlip for layshaft

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12JS GEARBOX 139
7 Transmission drive gear to layshaft 12 Layshaft square key

8 Spacer bushing 13 Disc tab
9 Gear for layshaft third gear 14 Layshaft
10 Gear for layshaft second gear 15 Straight roller bearing
11 Gear for layshaft first gear 15 Snap circlip
223343 Figure 218

1 Nut with left handed pitch 4 Spacer
2 Snap circlip 5 Snap circlip
3 Radial ball bearing with circlip groove and dust boot on 6 Direct drive input shaft
one side 7 Bushing

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140 12JS GEARBOX
222753 Figure 219

1 Hex lock nut 5 Shoulder washer
2 Washer 6 Reverse transmission gear
3 Roller bearing 7 Cable washer
4 Reverse gear shaft 8 Screw plug

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222754 Figure 220

1 Steel ball 14 Reverse gear fork control rod drive
2 Stud 15 Elastic pin
3 Guide block for gears of third and fourth gear 16 Reverse gear fork control rod
4 Third and fourth gear transmission rod 17 Fork control rod for fifth, sixth, first, second gear
5 Guide block for gears of third and fourth gear 18 Reverse gear fork
6 Fork for third and fourth gears 19 Cover
7 Fork for first and second gears 20 Steel ball
8 Fork for fifth and sixth gears 21 Elastic pin
9 Fifth and sixth gear transmission pin 22 Hexagon nut
10 Fifth and sixth gear transmission 23 Washer
11 Washer 24 Washer
12 Hexagon nut 25 Hexagon nut
13 Reverse gear fork drive lock screw 26 Compression spring

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142 12JS GEARBOX
222755 Figure 221

1 Hexagon nut 16 Side lever
2 Washer 17 Square headed selection lever
3 External engagement lever 18 Spring seat
4 Hexagon head screw 19 Safety ring
5 Boot 20 Guide bushing
6 Seal ring 21 Side cover
7 Cylindrical pin 22 Hex head screw with washer
8 Gear control housing 23 Cylindrical head screw
9 Double H valve with gasket 24 Set screw
10 T coupling 25 Reaction bar coupling lever
11 Coupling 26 Wrench
12 Hexagon head screw 27 Dust cover
13 Actuator valve 28 Cylindrical head screw
14 Hex head screw with washer 29 Cylindrical head screw
15 Plug 30 Hex head bolt with washer

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Main components of the selection valve
31 Gasket 37 Support plate

32 Spring plate 38 Neutral switch
33 Spring 39 Reverse gear switch
34 Seal ring 40 Breather pipe
35 Cylindrical pin 41 Low gear switch control block
36 Hex head screw with washer 42 Side lever bushing
Main components of the selection valve
222756 Figure 222

1 Breather pipe 4 Coupling
2 Single H valve 5 Air pipe
3 Air pipe 6 Coupling

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222757 Figure 223

1 Circlip 5 Circlip
2 Circlip 6 Auxiliary transmission positioning disc
3 Bearing support 7 Hexagon head screw
4 Bearing - 8 Safety wire
9 Gearing for normal gears 10 Circlip

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222758 Figure 224

1 Auxiliary transmission main shaft gear 15 Screw securing transmission control cylinder
2 Bearing track 16 Transmission control cylinder
3 Lower layshaft gear 17 Seal
4 Straight roller bearing 18 Screw securing upper layshaft cover
5 Circlip 19 Upper layshaft cover
6 Circlip 20 Gasket for upper layshaft cover
7 Lower layshaft cover 21 Drive output shaft
8 Conical roller bearing 22 Reducer box
9 Seal 23 Upper layshaft gear
10 Rear cover 24 Grooved washer for shaft gear
11 Rear cover fastening screw 25 Normal and low gear synchronizer
12 Capstan hex head screw for rear cover 26 Synchronizer fork
13 Flange fastening nut 27 Capstan hex screws
14 Hex head screw securing rear cover

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Main components of normal and low gear control cylinder equipped with power take-off
Main components of normal and low gear control cylinder equipped with power take-off
222759 Figure 225

1 Cylinder case 15 Cylinder cover gasket
2 Seal ring 16 Cylinder
3 M10x32 hex nut 17 Piston
4 Seal ring 18 Seal ring
5 Piston 19 Seal ring
6 Seal ring 20 Seal ring
7 Circlip 21 Cylinder case gasket
8 T coupling 22 Piston
9 Screw 23 Seal ring
10 Washer 24 Fork control rod
11 Hexagon head screw 25 Seal ring
12 Air coupling 26 Steel ball
13 Breather plug 27 Spring
14 Cylinder cover 28 M12×1.25×50 hex head screw

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12JS GEARBOX 147
Man components of the rear cover
Man components of the rear cover
222760 Figure 226

1 Rear cover 3 Oil seal ring
2 Odometer gear bushing 4 Dust seal ring

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148 12JS GEARBOX
223347 Figure 227

1 Pressure regulator with filter 4 Hex head screw with washer
2 90° elbow connector 5 Air pipe
3 Air filter connector 6 Hex head pins

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12JS GEARBOX 149
223360 Figure 228

1 PTO housing case 18 Fork
2 Hollow shaft 19 Clutch gear toothed sleeve
3 Bearing spacer ring 20 Cylinder head gasket
4 Sleeve 21 Cylinder head
5 Input gear 22 Fork piston stem
6 Locking ring 23 Cylinder case
7 End cover 24 Cylinder gasket
8 End cover gasket 25 Gasket
9 Side cover gasket 26 Covering ring
10 Side cover 27 Stop collar
11 Label 28 Rubber piston
12 Output gear shaft 29 O-ring
13 Deflector ring 30 Fourth gear spacer bearing
14 Adjusting shim 31 Gasket
15 Flange 32 O-ring
16 Bearing cover plug 33 Wire
17 Gasket 34 Set screw

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150 12JS GEARBOX
223360 Figure 228

35 O-ring 46 Hex head screw for cylinder case cover
36 Licence plate rivets 47 Countersunk head screw
37 Oil seal 48 Lock nut for hex insert ( M12 )
38 Hexagon head screw 49 Expansion dowel plug
39 Hexagon head screw 50 Conical roller bearing
40 Hexagon head screw 51 Flexible cylindrical pin
41 Hex head screw for cover of PTO housing case 52 Reversing indicator switch
42 Conical pin ( 12 × 35 ) 53 Steel ball bearing ( Φ55 × Φ90 × 18 )
43 Magnetic plug with tapered square grooving 54 Roller bearings
44 Hex head screw ( M16 × 1.5 × 30 ) with washer 55 Hexagon head screw
45 Hex head screw with washer

12JSD180T 12JSD180TA
GEARBOX 12JSD160T 12JSD160TA
type Mechanical

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12JS GEARBOX 151
GEARBOX 12JSD160T 12JSD160TA
Gearboxes 12JSD160T / 12JSD160TA = 1600 Nm
Input torque Gearboxes 12JSD180T / 12JSD180TA = 1800 Nm
Gearboxes 12JSD220T / 12JSD220TA = 2200 Nm
Forward gears 12
Reverse 2
Main six gears control Mechanical
ERG control * Pneumatic
Power take-off Optional
Gear engagement:
1 - 2 - 3rd - 4th - 5th - 6th and
st nd
Free-ring synchronizer
E.R.G.*
Crawler gear and reverse Rapid engagement
Speed retention mechanism Sliding sleeves locked by rollers and springs
Gears Straight teeth
Gear ratio
1st 15.53 12.10 15.53 12.10
2 nd
12.08 9.41 12.08 9.41
3rd 9.39 7.31 9.39 7.31
4th 7.33 5.71 7.33 5.71
5 th
5.73 4.46 5.73 4.46
6th 4.46 3.48 4.46 3.48
7 th
3.48 2.71 3.48 2.71
8th 2.71 2.11 2.71 2.11
9 th
2.10 1.64 2.10 1.64
10 th
1.64 1.28 1.64 1.28
11th 1.28 1.00 1.28 1.00
12 th
1.00 0.78 1.00 0.78
1st
RG 14.86 11.56 14.86 11.56
2nd
RG 3.33 2.59 3.33 2.59
Oil type Tutela Transmission W90/M - DA
16 kg 16 kg 17.5 kg 17.5 kg
Quantity
17 litres 17 litres 18.5 litres 18.5 litres
E.R.G.* = Epicyclic Reduction Gear Unit

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152 12JS GEARBOX
TIGHTENING TORQUES
TIGHTENING TORQUES
TORQUE
DETAIL
Nm (kgm)
Gearbox retaining screws M10 51 ± 5 (5.1 ± 0.5)
Bowden cable fasteners M8 10 ± 1 (1 ± 0.5)
Bowden cable fasteners M10 12 ± 2 (1.2 ± 0.2)
Self-locking nut M12 83.5 ± 8.5 (8.35 ± 0.8)
Self-locking nut M14 162 ± 16 (16.2 ± 1.6)
Self-locking nut M16 221 ± 22 (22.1 ± 2.2)
TOOLS
(99322205)

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12JS GEARBOX 153
TOOLS
Percussion extractor (99340205)
Simple bridge (99341003)
Clamp (99341015)
Pair of brackets with hole (99341017)

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154 12JS GEARBOX
TOOLS
Grips (99341024)
Grips (99341025)

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12JS GEARBOX 155
TOOLS
Pin to extract reverse gear shaft (use with 99340205) (99347092)
Wrench (80mm) to remove and refit the nut of the gearbox direct drive shaft (99355053)

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156 12JS GEARBOX
TOOLS
Tool for removing and refitting the gearbox auxiliary housing (use at the bench with a
hoist) (99360523)

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12JS GEARBOX 157
TOOLS
Brackets for supporting Transmission during overhaul (use with 99322205 -99322225)
(99371049)
Tool for fitting gasket on gearbox front cover (use with 99370006) (99374469)
Drift for fitting gasket on gearbox rear cover (99374470)
Pliers to extract gearbox piston rings (99381125)

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158 12JS GEARBOX
GEARBOX REMOVAL-REFITTING
.530210. GEARBOX REMOVAL-REFITTING
Work material
Propeller shaft support during removal and refitting. 99370618
Gearbox support during removal and refitting from 99370629
vehicle.
Tightening torques
Gearbox housing fixing screws 50 N⋅m
Gearbox housing fixing screws 50 N⋅m
Main action
.530210. Gearbox removal from vehicle
1. In order to remove the Transmission, proceed as follows: Place the vehicle over a pit or a lifter.
2. Disconnect the battery leads via the battery isolator in order to avoid possible short circuits.

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12JS GEARBOX 159
8 1 2
10 3
4
9
5
6
14
7
171941 Figure 229

3. Disconnect the bowden cables (2, 7) acting on the fasteners (6).
4. Remove the plate (3) along with supports by acting on the fastener (1).
5. Disconnect the electrical connections of the gear engage and shift (10).
6. Cut away and remove the fasteners (4) that secure the cable bundles running from the chassis.
7. Disconnect the air pipes (5) (red and black pipes) connected to the Bowden cables.
8. Slacken the top fixing screws (8) that secure the gearbox housing to the engine.
9. Remove the retainer bracket (9) on the gearbox by acting on the retainers (11).

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160 12JS GEARBOX
.530210. Gearbox removal from under the vehicle
11
1
10 2
9 3
8 5
7
12
171942 Figure 230

10. Remove the drive shaft (1) using the specific support tool; see relative chapter on drive shaft.
11. Remove the fastenings (2) of the shaft to the gearbox.

12. Remove the fastenings of the shaft to the rear axle.
13. Release the spindle (3) of the PTO from the gearbox by acting on the fasteners (4) and marking the order of installation on
the spindle (gearbox).
14. Cut away and remove the various fastening clamps of the electrical cables (10) that route from the chassis to the gearbox.
15. Disconnect the ground cable (7) from the chassis to gearbox housing by acting on the retainers (8).
16. Disconnect the rpm sensor cable (11) from the rpm sensor (9) and the pneumatic actuations (5, 6, 12).
17. Check that there are no interferences with the cables.
18. Disconnect the PTO activation sensor (6).

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12JS GEARBOX 161
227433 Figure 231

19. Disconnect the clutch actuator (2) acting on the fasteners (1) and secure it to the chassis.
20. Place a hydraulic jack fitted with specific support (3) under the gearbox..
Gearbox support during removal and refitting from vehicle. 99370629
21. Remove the gearbox suspension (5) from the gearbox removing the central retainer (4).

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162 12JS GEARBOX
1 2
8
7
4
6 5
171944 Figure 232

22. Undo the last fasteners (6) of the gearbox housing and engine.
23. Remove the clutch inspection cover (8) and the pressure plate spring (2) by slipping a hand through the inspection window
(5).
24. Unscrew the cap and screw in the specific tool (4) to allow engine rotation to simplify removal of the pressure plate spring
(2).
25. Remove the fork retainer (1) that engages the pressure plate by acting on the retainers.
26. Remove the gearbox from the vehicle making sure that the specific support tool (3) and hydraulic jack are positioned cor-
rectly in order to support gearbox weight.

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12JS GEARBOX 163

.530210. Gearbox refitting under the vehicle

27. Refit the pressure plate engage fork and then the clutch inspection cover.
28. Position gearbox under the vehicle and bring it near to the connection on the engine on the clutch side.
29. Tighten the fixing screws of the gearbox housing on the bottom side and tighten to the specified torque.
Tightening torque
Gearbox housing fixing screws
50 N⋅m
30. Remove the specific tool for rotation of the engine and tighten cap.
31. Refit the gearbox to the gearbox "suspension" by tightening the side and centre screws.
32. Remove the specific gearbox support tool.
33. Refit the clutch actuator by acting on the fastenings.

34. Reconnect the bracket holding the chassis, lifting it and placing it with a special hydraulic jack under the gearbox, tighten the
eight screws.
35. Reconnect the PTO activation sensor.
36. Reconnect the rpm sensor cable and the various activations by checking that there are no interferences with the cables.
37. Reconnect ground that runs from the chassis to the gearbox case by tightening the fasteners.
38. Fit fasteners on the electrical cables that go from the chassis to gearbox.
39. Reconnect the PTO shaft to the transmission and tighten the fasteners paying attention to the correct position by the side
transmission shaft.
40. Replace the propeller shaft with the special tool in the seats on the gearbox side and rear axle side, tighten the fasteners on
the gearbox side and rear axle side on the rear, see the chapter on transmission shafts.
.530210. Gearbox refitting on vehicle

41. Tighten the retaining screws on top of the gearbox housing to the correct torque value.
Tightening torque
Gearbox housing fixing screws
50 N⋅m
42. Secure the cable bundle running from the chassis using fasteners.
43. Secure the cable bundle to the gearbox housing captive using the support bracket.
44. Reconnect the air pipes (red and black pipes) connected to the Bowden cables.
45. Reconnect the bowden cable plate along with supports by acting on the fastener.
46. Reconnect the electrical connections of the gear engage and shift to their seats on the gearbox.
47. Reconnect the bowden cables acting on the fasteners.
48. Top-up power steering oil level, coolant and R134A gas for the A/C system.
49. Reconnect the battery leads and remove vehicle from lifter.

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164 12JS GEARBOX
BOWDEN CABLES ADJUSTMENT DIAGRAM
530210 BOWDEN CABLES ADJUSTMENT DIAGRAM
177316 Figure 233

1 Bowden gear selection cable A Cab side
2 Gears engagement Bowden cable. B Gearbox side
This diagram shows the dimensions for adjustment of the gear control Bowden cables.
.530210. GEARBOX OVERHAULING
Consumables
Silicone grease
Oil
TUTELA MR3 grease
LOCTITE
Work material
Clamp 99341015
Grips 99341024
Grips 99341025

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12JS GEARBOX 165
GEARBOX OVERHAULING

Wrench (80mm) to remove and refit the nut of the 99355053
gearbox direct drive shaft
Tool for removing and refitting the gearbox auxiliary 99360523
housing (use at the bench with a hoist)
Brackets for supporting Transmission during overhaul 99371049
(use with 99322205 -99322225)
99370006)
Rope
Hooks
Lifter
Tightening torques
M12 screws securing housing 108 N⋅m to135 N⋅m
M16x1.5 self-locking nut for securing the housing 244 N⋅m to271 N⋅m
M12x1.5 screws securing the top cover 67.5 N⋅m to88 N⋅m
M50 nut for securing flange 609 N⋅m to677 N⋅m
M10 screw for securing layshafts cover 47.5 N⋅m to61 N⋅m
M16x1.5 self-locking nut securing reverse transmission gear 67.5 N⋅m to81 N⋅m
M10 screws securing disc to gearbox housing 47.5 N⋅m to61 N⋅m
M16x1.5 screws securing layshaft bearings 122 N⋅m to162 N⋅m
M50 nuts securing drive input shaft 609 N⋅m to677 N⋅m
M10 screws securing drive input shaft sleeve 47.5 N⋅m to61 N⋅m
Main action
Caution!
Lubricants and detergents Disposal
▶ Follow the specific regulations to dispose of lubricants and detergents.
▶ Use protective gloves to hold heated parts.
1. Thoroughly wash the outside of the gearbox and drain the oil into an appropriate container.

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166 12JS GEARBOX
GEARBOX OVERHAULING
Note Use the required specific tools for overhaul operations.

During removal it is recommended to place the parts in the performed working order to facilitate subsequent as-
sembly operations.
.530510. Removal and refitting of the clutch housing

.530510. Removal of clutch housing
2. Place the gearbox onto a suitable work bench.
3. Unscrew the screws (1) and the self-locking nuts (2) and re-
move the housing (3).
4. Remove the gasket.
222761 Figure 234
.530510. Refitting the clutch housing

6. Fit a new gasket between the housing and the gearbox housing.
7. Apply loctite and tighten the screws to the specified torque.
Tightening torque
M12 screws securing housing 108 N⋅m to135 N⋅m
M16x1.5 self-locking nut for securing the housing 244 N⋅m to271 N⋅m
Tool / Material
LOCTITE
.530520. Replacing gear control housing

.530520. Removal
Note Use the specified tools for the gearbox overhaul operations.
During removal, it is recommended that the parts are placed in the operating sequence carried out in order to make as-
sembly operations easier.
8. Remove the housing as described in Removal of clutch housing ( ➠ Page 166).

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12JS GEARBOX 167
GEARBOX OVERHAULING

support assembly.
code
with 99322205 -99322225)
the gearbox assembly (4) on the rotary stand (2) together with
code
222762 Figure 235
11. Disconnect the air couplings (6) from the gearbox.

12. Release the air pipes from the collars (1).
13. Unscrew the screws(3) securing the selection valve (2) to the
gearbox.
14. Unscrew the screws (4) securing the actuator valve (5) and
disconnect it from the gearbox lever.
15. Remove the air pipes together with the selection valve (2) and
the actuator valve (5).
222763 Figure 236
16. 9. Unscrew the nuts (1) and remove the gearbox control lever
(2) from the gearbox making sure that the springs below do
not come out.
222764 Figure 237
.530520. Refitting
17. To refit the gear control lever, carry out the removal operations in the reverse order, taking the following precautions.
18. Fit a new gasket between the gear control housing and the gearbox housing.
19. Remove the housing as described in Refitting the clutch housing ( ➠ Page 166).

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168 12JS GEARBOX
GEARBOX OVERHAULING
.530520. Overhaul of the gear control housing

21. Position the gearbox control lever (1) on the workbench.

22. Remove the reverse gear (2) and neutral (3) switch with the
pins below.
222765 Figure 238

24. Unscrew the screw (2) and remove the reaction bar coupling
lever (1).
222766 Figure 239
25. Remove the key (3).

26. Unscrew the screws (2) and remove the boot (1).
27. Unscrew the screws (4) securing the side cover(5).
222767 Figure 240

682 ‒ Gearbox
12JS GEARBOX 169
GEARBOX OVERHAULING
28. Remove the side cover (1) and the bushing below (2).
222768 Figure 241
29. Mark (3) the lever near the slot.

30. Unscrew the bolt (4) and remove the lever (2).
31. Remove the bolt (1).
222769 Figure 242
32. Unscrew the screws (1) and remove the support plate (2).
222770 Figure 243

682 ‒ Gearbox
170 12JS GEARBOX
GEARBOX OVERHAULING
33. Using the specific copper drift, remove the plug (1).
222771 Figure 244
35. Using a punch, remove the pin (1).
222772 Figure 245
36. Remove the circlip (1).
222773 Figure 246

682 ‒ Gearbox
12JS GEARBOX 171
GEARBOX OVERHAULING
37. Remove the spring (1) and the two washers (2).
222774 Figure 247
38. Let the lever (3) move until the control block (1) is visible.
39. Use a punch to remove the rubber pin from the switch control
(1).
40. Let the lever (3) move and remove the selection lever (2) and
the control block (1).
222775 Figure 248
41. Remove the oil seal ring (1).
222776 Figure 249
.530520. Installing gear control housing


682 ‒ Gearbox
172 12JS GEARBOX
GEARBOX OVERHAULING
43. Fit a new oil seal ring (1) with the lip facing outwards.
( ➠ Page 167).
222776 Figure 250
.530517. Replacing top cover

.530517. Removal
46. Remove the 4 springs (1) for positioning the fork control rods
from their seat.
226446 Figure 251
47. Using a magnet, remove the 4 balls (1).
226447 Figure 252

682 ‒ Gearbox
12JS GEARBOX 173
GEARBOX OVERHAULING
48. Unscrew the screws (1) securing the top cover (3) to the gear-
box (2).
226448 Figure 253
49. Remove the top cover (1) together with the fork control rods
(3) and the forks (2).
226449 Figure 254
.530517. Refitting
50. Refitting requires carrying out the operations for removal in reverse order, while taking the following precautions.
51. Fit a new gasket between the cover and the gearbox housing.
52. Tighten the screws(1) securing the top cover (2) to the gear-
box (3) to the prescribed torque.
Tightening torque

( ➠ Page 47).
( ➠ Page 113).
226448 Figure 255

682 ‒ Gearbox
174 12JS GEARBOX
GEARBOX OVERHAULING
.5321. Overhaul of internal gearbox controls

.5321. Disassembly
57. Place the top cover (1) in a vice with the reverse gear fork (2)
facing downwards.
58. Place the fork in the neutral position.
226450 Figure 256
59. Remove the safety wire (1) from the drive fastening screws
(3).
60. Unscrew the drive fastening screws (2).
226451 Figure 257
61. Using a copper drift, partially remove the 3rd and 4th gear (1)
control transmission rod and remove the drive units (2).
62. Completely remove the 3rd and 4th gear (1) control transmis-
sion rod.
226452 Figure 258

682 ‒ Gearbox
12JS GEARBOX 175
GEARBOX OVERHAULING
63. Using a magnet, recover the steel ball (1).
226453 Figure 259
64. Using a punch, remove the elastic pin (2) locking the 3rd and 4th
gear (1) control fork.
226454 Figure 260
65. Using a copper drift, partially remove the 3rd and 4th gear (1)
control rod and remove the fork (3).
66. Completely remove the 3rd and 4th gear (1), the drive (2) and
recover the pin.
67. Use a magnet to remove the steel ball from its seat.
226455 Figure 261

682 ‒ Gearbox
176 12JS GEARBOX
GEARBOX OVERHAULING
68. Using a punch, remove the elastic pin (4) locking the 1st and 2nd
gear (3) control fork.
69. Using a copper drift, partially remove the 1st, 2nd, 5th, 6th gear (2)
control rod and remove the fork (3).
70. Completely remove the 1st, 2nd, 5th, 6th gear (2) control rod,
remove the forks (1) and (3) and recover the pin.
71. Use a magnet to remove the steel ball from its seat.
226456 Figure 262
72. Remove the safety wire (4) from the fork and the bushing.
73. Unscrew the screws (3) securing the bushing (7) and reverse
gear fork (5).
74. Using a copper drift, remove the control rod (6), the reverse
gear fork (5) and the bushing (7).
75. Unscrew the screw (2) and remove the 5th and 6th gear trans-
mission.
226457 Figure 263
76. The bushing (1) from the fork has a pin (2) which, due to the
spring below (3), determines the hardening of the gear lever
when reverse gear is selected.
77. If removing, proceed as follows.
78. Fit the pin (2) in the designated seat; - Insert the spring (3).
79. Screw the plug (4) on fully, and then unscrew it by 5 turns in
order to adjust the preloading of the spring (3).
80. Using the fork (5), compress the thread of the plug so that the
plug cannot unscrew.
226458 Figure 264
.5321. assembly

682 ‒ Gearbox
12JS GEARBOX 177
GEARBOX OVERHAULING
82. Lubricate the rods (2) before inserting them into their seat and
fit them with the ball seats (1) facing the cover.
226459 Figure 265
83. Insert the pins (1) into the fork control rod seats.
84. Tighten the fork fastening screws to the prescribed torque.
Tightening torque
M12x1.5 screws securing the top 67.5 N⋅m to88 N⋅m
cover
226460 Figure 266

86. Refit the gear control housing as described in Refitting ( ➠ Page 167).
.533010. Replacing the reduction gear

.533010. Removal of the GRE rear housing
87. Remove the clutch housing as described in Removal of clutch housing ( ➠ Page 166).
support assembly.
code
with 99322205 -99322225)
the gearbox (4) assembly on the rotary stand (2) together with
code
Rope
Hooks
222762 Figure 267

682 ‒ Gearbox
178 12JS GEARBOX
GEARBOX OVERHAULING
90. Disconnect the air pipes (2) from the master cylinder (4).
91. Unscrew the screw (1) and release the air pipe from the re-
duction unit (3).
92. Move the air pipes (2) so they do not hinder removal opera-
tions of the reduction unit (3).
226594 Figure 268
93. Unscrew the flange fastening nut (4) using the bushing (1), the
wrench (3) and the reaction lever (2).
code
226461 Figure 269
94. Unscrew the screws (3) securing the reduction unit to the
gearbox housing.
95. Apply screws into the threaded holes (2) until the reduction
unit is set apart from the gearbox housing.
96. Apply the tool (1) at the level of the screws (3) and with the
help of the ropes, remove the gasket below.
code
Tool for removing and refitting the gearbox auxiliary hous- 99360523
ing (use at the bench with a hoist)
226462 Figure 270
.533010. Refitting the GRE rear housing

98. Fit a new gasket between the reduction unit and the gearbox housing.
99. Replace the flange fastening nut with a new one and tighten it to the prescribed torque.

682 ‒ Gearbox
12JS GEARBOX 179
GEARBOX OVERHAULING
Tightening torque
M50 nut for securing flange 609 N⋅m to677 N⋅m
100. Refit the clutch housing as described in Refitting the clutch housing ( ➠ Page 166).
.533010. Overhaul of the GRE rear housing

102. Unscrew the screws (1), (4) and remove the covers (2), (3)
on the layshafts.
226463 Figure 271
on the lower layshaft (3).
code
226464 Figure 272
on the upper layshaft (3).
code
226465 Figure 273

682 ‒ Gearbox
180 12JS GEARBOX
GEARBOX OVERHAULING
105. With the jack (3) and the brackets (2), remove the upper lay-
code
226466 Figure 274
106. With the jack (2) and the brackets (1), remove the lower lay-
code
226467 Figure 275
107. With the rear axle (1) brackets (2) hand-grips (3) and clamp
(6), remove the inner tracks (4) from the layshafts (5).
code
Grips 99341024
Clamp 99341015
226468 Figure 276

682 ‒ Gearbox
12JS GEARBOX 181
GEARBOX OVERHAULING
108. Unscrew the screws (3) and remove the cover (2) from the
normal and low gear control cylinder (1).
226469 Figure 277
109. Unscrew the self-locking nut (2) securing the normal and low
gear control shaft and the screws (1) securing the cylinder (3)
to the reduction unit.
226470 Figure 278
110. Remove the safety wire (2) and unscrew the screws (3) secur-
ing the fork (4) to the control rod.
111. Remove the shaft (4) together with the cylinder (1), the gasket
below and the fork (5).
226471 Figure 279

682 ‒ Gearbox
182 12JS GEARBOX
GEARBOX OVERHAULING
112. Lock the normal and low gear control assembly in a vice (2) and
remove the piston (1) from its seat.
113. Unscrew the screw (3), recover the spring (5), the ball (6) and
remove the shaft (4).
226472 Figure 280
114. Remove the complete synchronizer (2) from the reduction unit
(1) paying careful attention to the springs inside.
226473 Figure 281
115. With the jack (3) and the brackets(2), remove the drive output
shaft (1).
code
116. Unscrew the screws (5), remove the rear cover (4) and re-
cover the rear bearing of the shaft (1) with the relative internal
spacer and the odometer.
226474 Figure 282

682 ‒ Gearbox
12JS GEARBOX 183
GEARBOX OVERHAULING
117. Unscrew the nut (1) and remove the odometer gear (2).
118. Remove the dust seal ring (5) and the oil seal ring (3) from the
rear housing (4).
226475 Figure 283
119. With the jack (1) and the brackets (2), extract the gear (6)
together with the spacer ring (5)and the front bearing (4) from
the drive output shaft(3).
code
226476 Figure 284
120. Remove the toothed washer (2) from the drive output
shaft(1).
226477 Figure 285

682 ‒ Gearbox
184 12JS GEARBOX
GEARBOX OVERHAULING
121. Remove the outer tracks (2) and (3) of the drive output shaft
from the auxiliary casing(1).
.533010. Assembly
122. Position the outer tracks (2) and (3) and the drive output shaft
into the auxiliary casing(1).
123. Note the position of the outer track (4) with the end of stroke
contact.
226478 Figure 286
124. Place the toothed washer (2) onto the drive output shaft(1).
226477 Figure 287
125. Place the gear (4) and the spacer ring (3) with the step facing
the gear (4) onto the drive output shaft(1).
80°C÷ 100°C and insert it into the drive output shaft.
code
226479 Figure 288

682 ‒ Gearbox
12JS GEARBOX 185
GEARBOX OVERHAULING
127. Position the drive output shaft (1) in the reduction unit housing
(1).
226480 Figure 289
80°C÷ 100°C and insert it into the drive output shaft (2).
129. Place the gasket (3) onto the drive output shaft(2).
code
226481 Figure 290
130. Place the odometer (1) onto the drive output shaft (2).
226482 Figure 291

682 ‒ Gearbox
186 12JS GEARBOX
GEARBOX OVERHAULING
131. Using the keying device (1), fit the oil seal ring and the dust seal
ring into the rear cover (2).
code
226483 Figure 292
132. Insert the pin (6) and the odometer gear (2) into the rear
cover (5) and tighten the nut (1).
133. Grease the dust seal ring (3) and the oil seal ring (4).
Tool / Material
TUTELA MR3 grease
226484 Figure 293
134. Replace the gasket between the rear cover (2) and the reduc-
tion unit housing (4).
135. Place the rear cover (2) on the drive output shaft, tighten the
screws (3), the screw with the hole (1) and the screw with the
plastic washer (5) in the position indicated and tighten to the
prescribed torque.
Tightening torque
226485 Figure 294

682 ‒ Gearbox
12JS GEARBOX 187
GEARBOX OVERHAULING
136. Use paint to mark the two teeth diametrically opposed to the
gear so that there are the same number of teeth on the two
lower and upper semi circle perimeters.
226486 Figure 295
137. Insert the sleeve (3) onto the outer cone synchronizer (4) and
fit the synchronizer (1) with the springs (2) positioned in the
designated holes.
226487 Figure 296
138. Use oil to lubricate the contact surface of the gear (2) and fit
the synchronizer ring (1) of the normal and low gears.
Tool / Material
Oil
226488 Figure 297

682 ‒ Gearbox
188 12JS GEARBOX
GEARBOX OVERHAULING
139. Using a hot air blower on both auxiliary shafts, heat the inner
track (1) to a temperature of 80°C-100°C and fit it onto the
code
226489 Figure 298
140. Using paint, mark the tooth which corresponds to zero (1) on
both auxiliary shafts(2).
226490 Figure 299
141. Fit the layshafts (2) aligning the reference marks on the teeth
of these shafts with the marks on the centre gear of the drive
output shaft (1).
226491 Figure 300

682 ‒ Gearbox
12JS GEARBOX 189
GEARBOX OVERHAULING
code
226464 Figure 301
code
226465 Figure 302
146. Replace and grease the sealing rings (1) of the normal and low
gear control unit with silicone grease.
Tool / Material
Silicone grease
226492 Figure 303

682 ‒ Gearbox
190 12JS GEARBOX
GEARBOX OVERHAULING
147. Use silicone grease to lubricate the shaft (4) and insert it into
the cylinder (2).
Tool / Material
Silicone grease
148. Insert the ball (6) and the spring (5) into the cylinder(2) and
tighten the screw (3).
149. Fit the piston (1) onto the shaft (4).
226472 Figure 304
150. Place the fork (5) on the synchronizer.

151. Fit the shaft (4) together with the cylinder (1).
152. Tighten the screws (3) to the prescribed torque and insert the
safety wire (2) into the specific holes.
Tightening torque
226471 Figure 305
153. Tighten the cylinder fastening screws (1) to the reduction unit
housing.
Tightening torque
154. Replace the piston fastening nut (2) with a new one and tighten
it to the prescribed torque.
Tightening torque
226470 Figure 306

682 ‒ Gearbox
12JS GEARBOX 191
GEARBOX OVERHAULING
155. Position the cover (2) on the cylinder (1) and tighten the
Tightening torque
226469 Figure 307
156. Fit the covers (2) and (3) of the layshafts and tighten the
screws (1) and (4) to the prescribed torque.
Tightening torque
M10 screw for securing layshafts 47.5 N⋅m to61 N⋅m
cover
226463 Figure 308
157. Refit the GRE rear housing as described in Refitting the GRE rear housing ( ➠ Page 178).
.530510. Gearbox housing overhaul

.530510. Removal of the gearbox housing
158. Remove the clutch housing as described in Removal of clutch housing ( ➠ Page 166).
160. Remove the gear top cover as described in Removal ( ➠ Page 173).

682 ‒ Gearbox
192 12JS GEARBOX
GEARBOX OVERHAULING
162. Unscrew the nut (3) securing the shaft and upper reverse
transmission gear (1) and recover the washer (2)and (4) .
163. Do not remove the upper reverse transmission gear (1) of the
gearbox housing.
226596 Figure 309
164. Using the puller (2), remove the front bearings (1) and (3) of
the auxiliary housing of the layshafts.
165. Using a screw driver, remove the two screw plugs (3) on the
reverse transmission gear shafts.
code
226493 Figure 310
166. Using the designated knockout extraction tool (2) and the des-
ignated extension tool (1); remove the upper reverse gear
transmission shaft together with the inner track of the gear
bearing and the relative shoulder washer.
code
226595 Figure 311

682 ‒ Gearbox
12JS GEARBOX 193
GEARBOX OVERHAULING
167. Remove the retainers (1) and extract the sleeve (3) from the
direct drive input shaft(2).
223081 Figure 312
168. Remove the oil seal ring (1) from the thrust bearing sleeve (2).
226494 Figure 313
169. Working from inside the gearbox housing, insert the two gears.
170. Working from the side of the input drive shaft, unscrew the
screws (1) and (3) of the layshaft bearings and recover the
plates below.
Note The screws (1), (3) and the nut securing the bearing
to the drive input shaft will be hard as they are secured
with loctite
171. Using the specific wrench (2), unscrew the left-handed nut.
code
Wrench (80mm) to remove and refit the nut of the gear- 99355053
box direct drive shaft
226495 Figure 314

682 ‒ Gearbox
194 12JS GEARBOX
GEARBOX OVERHAULING
172. Sling the main shaft (1) using a rope (2).
226496 Figure 315
173. Remove the circlip (1) retaining the upper layshaft rear bearing.
226497 Figure 316
able drift (1), extract the outer track of the rear bearing of the
upper layshaft (4).
223078 Figure 317

682 ‒ Gearbox
12JS GEARBOX 195
GEARBOX OVERHAULING
175. Using a double-acting jack (2), a pair of tie rods (1) and a re-
action block (3) placed at the end of the layshaft, extract the
bearing (4) from its seat.
code
226499 Figure 318
176. Move the main shaft (2) from the layshaft (3) placing a copper
punch (1) in between.
226500 Figure 319
177. Remove the circlip (5) from its seat in the main shaft (4) using
a specific tool.
code
178. Remove the safety wire (1) from all the screws (3) securing
the disc (2).
179. Unscrew the screws (3) retaining the disc.
226501 Figure 320

682 ‒ Gearbox
196 12JS GEARBOX
GEARBOX OVERHAULING
180. Screw three screws (1) into the threaded holes until the gear
(2) is extracted from the main shaft.
181. Remove the disc (3).
226502 Figure 321
182. Remove the bearing (1) from the main shaft (2).
226503 Figure 322
183. using the specific tool, remove the two circlips (1) and (2)
retaining the ring (4) of the main shaft (3).
code
223087 Figure 323

682 ‒ Gearbox
12JS GEARBOX 197
GEARBOX OVERHAULING
184. With a plastic hammer, knock the drive input shaft (4) a couple
of times to make it retract.
185. Using hand-grips (1), brackets (2), jack (5) and clamp (6), re-
move the bearing (2) with the relative ring below.
code
Clamp 99341015
Grips 99341025
226504 Figure 324
186. Using screwdrivers, release the circlip (1) and remove the drive
input shaft (2).
226505 Figure 325
187. Using an extractor (1), press out the bushing (2) from the
code
226506 Figure 326

682 ‒ Gearbox
198 12JS GEARBOX
GEARBOX OVERHAULING
188. Using a suitable lifting device and ropes (2), extract the main
shaft (1) from the gearbox housing.
Tool / Material
Rope
Lifter
226507 Figure 327
189. Remove the upper reverse transmission gear (1) from the
gearbox housing.
226508 Figure 328
190. Using ropes (3), sling the upper layshaft (2) and remove it from
the gearbox housing (1).
Note If replacing the layshaft gears, it is recommended that
the gear set is replaced. This operation is to be carried
out in a press.
226509 Figure 329

682 ‒ Gearbox
12JS GEARBOX 199
GEARBOX OVERHAULING
191. Unscrew the nut (2) securing the shaft and lower reverse
transmission gear (1).
192. Remove the lower reverse transmission gear (1), the shaft and
the corresponding washers (3).
226510 Figure 330
193. Remove the circlip (1) retaining the lower layshaft rear bearing.
226511 Figure 331
able drift (3), extract the outer track (2) of the rear bearing of
the lower layshaft (4).
226512 Figure 332

682 ‒ Gearbox
200 12JS GEARBOX
GEARBOX OVERHAULING
195. Using the jack (4), brackets (1) and reaction block (3), remove
the bearing (2).
code
226513 Figure 333
196. Using ropes (1), sling the lower layshaft (2) and remove it from
the gearbox housing (3).
Tool / Material
Rope
Note If replacing the layshaft gears, it is recommended that

the gear set is replaced. This operation is to be carried
out in a press.
226514 Figure 334
.531020. Removal of the main shaft

197. Place the main shaft in a vice using the protection jaws.
198. Remove the gear from the 5th speed gear (1).
226515 Figure 335

682 ‒ Gearbox
12JS GEARBOX 201
GEARBOX OVERHAULING
199. Remove the toothed flange (1) from the 5th gear engagement
synchronizer set.
226516 Figure 336
200. Remove the toothed disc (1) of the 5th gear synchronizer set
226517 Figure 337
201. Remove the sliding sleeve (3), the springs (4), the pins (6) and
the plates (5) of the 5 th and 6 th gear synchronizer set from the
main shaft.
202. Using pliers, remove the circlip (2) and remove the fixed sleeve
(1) of the synchronizer set for the 5 th and 6 th gear.
code
226518 Figure 338

682 ‒ Gearbox
202 12JS GEARBOX
GEARBOX OVERHAULING
203. Using pliers, remove the circlip (3) and extract the toothed disc
(2) and the toothed flange (1) of the 6 th gear synchronizer set
code
226519 Figure 339
204. Push the key (1) downwards to free the grooved spacer ring
(2).
205. Using pincers, remove the pin (3).
226520 Figure 340
206. Remove the 6 th speed (1) gear and the grooved spacer ring
below (2).
226521 Figure 341

682 ‒ Gearbox
12JS GEARBOX 203
GEARBOX OVERHAULING
207. Remove the 4th speed (1) gear from the main shaft (2).
226522 Figure 342
208. The grooved spacer ring (1) and the toothed flange (2) of the
4(a) gear engagement synchronizer set.
226523 Figure 343
209. Using pliers, remove the circlip (2) from the main shaft (1).
code
210. Remove the toothed disc (1) of the 4 gear synchronizer set
th
226524 Figure 344

682 ‒ Gearbox
204 12JS GEARBOX
GEARBOX OVERHAULING
223100 Figure 345
212. Remove the sliding sleeve (1) and the fixed sleeve (2) of the
synchronizer set for the 3 rd and 4 th(a) gear ensuring that the
springs, pins and plates (3) do not come out .
226525 Figure 346
213. Using pliers, remove the circlip (1) and remove the toothed
disc (3) and the toothed flange (2) of the 3 rd gear synchronizer
set.
226526 Figure 347

682 ‒ Gearbox
12JS GEARBOX 205
GEARBOX OVERHAULING
214. Remove the grooved spacer ring (1) and the 3 rd speed gear
(2).
226527 Figure 348
215. (1)Remove the grooved spacer ring and the 2 nd speed gear
(2).
226528 Figure 349
216. The grooved spacer ring (1) and the toothed flange (2) of the
2 nd gear engagement synchronizer set.
226529 Figure 350

682 ‒ Gearbox
206 12JS GEARBOX
GEARBOX OVERHAULING
217. Remove the toothed disc (2) of the 2nd gear synchronizer set
218. Remove the last gear (2) of the synchronisation assembly from
the main shaft (1).
226530 Figure 351
219. Using pliers, remove the circlip (1).

code
220. Remove the sliding sleeve (2) and the fixed sleeve (4) of the
synchronizer set for the 1 st and 2 nd gear ensuring that the
springs, pins and plates (3) do not come out .
226531 Figure 352
221. Remove the toothed disc (2) of the 1 st gear engagement syn-
chronizer.
226532 Figure 353

682 ‒ Gearbox
12JS GEARBOX 207
GEARBOX OVERHAULING
222. Remove the toothed flange (1) of the 1st gear engagement
synchronizer set.
223. Using pliers, remove the circlip ((3)) and remove the 1 st speed
gear (2) with the grooved spacer ring (4).
code
226533 Figure 354
224. Extract the key (1) completely.

225. Remove the grooved spacer ring (3) and the reverse gear (2).
226534 Figure 355
226. Extract the grooved spacer ring (3), the reverse gear engage-
ment sliding sleeve (2) and the flange (1).
226535 Figure 356

682 ‒ Gearbox
208 12JS GEARBOX
GEARBOX OVERHAULING
.531020. Main shaft assembly

227. Fit the flange (2) onto the main shaft (1).
226536 Figure 357
228. Fit the reverse gear engagement sleeve (2) onto the main shaft
(1).
229. Insert the key (3) into the grooved seat at the hole of the
elastic pin.
230. Block the key (3)appropriately so that it doesn't fall during
assembly and push it upwards each time a gear engages.
226537 Figure 358
231. Fit the reverse gear (1) and the spacer ring (2) on the main
shaft (3).
226617 Figure 359

682 ‒ Gearbox
12JS GEARBOX 209
GEARBOX OVERHAULING
232. Fit the 1 st speed gear (3) with the relative spacer ring (5) onto
the main shaft (1).
233. Fit the circlip (2) into its seat with the opening in line with the
key (4) and let the key move up above the grooved ring (5).
226538 Figure 360
234. Fit the toothed flange (2) of the 1st gear engagement synchron-
izer set onto the main shaft (1).
226539 Figure 361
235. Fit the toothed disc (2) of the 1st gear engagement synchron-
226532 Figure 362

682 ‒ Gearbox
210 12JS GEARBOX
GEARBOX OVERHAULING
236. Fit the fixed sleeve (2) of the synchronizer set for the 1st and
2nd gear onto the main shaft (1), making the groove coincide
with the tab (3) of the toothed disc.
237. Fit the circlip (4) with the opening at the key.
226540 Figure 363
238. If the fixed sleeve has come out during removal operations,
insert the spring (2) into the hole of the fixed sleeve (3), press
it with a screwdriver and insert the plate together with the pin
(1).
226541 Figure 364
239. Fit the sliding sleeve (2) onto the fixed sleeve (1) of the syn-
chronizer set for the 1st and 2nd gear.
226542 Figure 365

682 ‒ Gearbox
12JS GEARBOX 211
GEARBOX OVERHAULING
240. Fit the toothed disc (1) of the 2nd gear engagement synchron-
izer set and the grooved spacer ring (2).
241. Let the key (3) move up.
226543 Figure 366
242. Fit the 2nd speed gear (2), the grooved spacer ring (1) and the
3 rd speed gear onto the main shaft ((3)).
226544 Figure 367
243. Fit the grooved spacer ring (1) onto the main shaft and let the
key (2)move upwards.
226545 Figure 368

682 ‒ Gearbox
212 12JS GEARBOX
GEARBOX OVERHAULING
244. Fit the toothed flange of the 4 (3) of the 3 rd gear engagement
synchronizer set onto the main shaft (4).
245. Fit the circlip (1) and let the key move upwards (3).
226546 Figure 369
246. Fit the toothed disc (1) of the 3rd gear engagement synchron-
226573 Figure 370
247. Fit the fixed sleeve (2) and the sliding sleeve (1) onto the main
shaft.
248. Fit the circlip (3) with the opening facing the key (4)and let the
key move upwards .
226574 Figure 371

682 ‒ Gearbox
12JS GEARBOX 213
GEARBOX OVERHAULING
249. Fit the toothed disc (3) of the 4th gear engagement synchron-
250. Fit the circlip (2) with the opening facing the key to allow the
key to move.
226524 Figure 372
251. Fit the grooved spacer ring (1) and the toothed flange (2) of
the 4th gear engagement synchronizer set onto the main shaft.
226523 Figure 373
252. Fit the 4th (1) gear onto the main shaft (2).
253. Let the wrench move up.
226522 Figure 374

682 ‒ Gearbox
214 12JS GEARBOX
GEARBOX OVERHAULING
254. Fit the grooved spacer ring (2) and the 6 th speed gear (1) onto
the main shaft.
255. Let the wrench move up.
226521 Figure 375
256. Fit the grooved spacer ring (2).

257. Fit the elastic pin(3) and bring it so that it makes contact with
the key (1).
226520 Figure 376
258. Fit the toothed flange (1) and the toothed disc (2) of the 6th
gear engagement synchronizer set onto the main shaft (4).
259. Fit the circlip (3) with the opening facing the key.
226519 Figure 377

682 ‒ Gearbox
12JS GEARBOX 215
GEARBOX OVERHAULING
260. Fit the fixed sleeve (1) and the sliding sleeve (2) of the 5 th and
6 th gear (2) synchronizer set onto the main shaft (4).
261. Fit the circlip (3).
226575 Figure 378
262. Fit the toothed disc (1) of the 5th gear engagement synchron-
226517 Figure 379
263. Fit the toothed flange (1)) of the 5th gear engagement syn-
chronizer set onto the main shaft (2).
226516 Figure 380

682 ‒ Gearbox
216 12JS GEARBOX
GEARBOX OVERHAULING
264. Fit the 5th speed gear(1) onto the main shaft .
226515 Figure 381
.530510. Gearbox housing assembly

265. If necessary, replace the magnetic pads (1) affixing the new
ones with cyanoacrylic adhesive.
226576 Figure 382
266. On both layshafts (1) use paint to mark the teeth aligned with
the zero (2) printed on the shaft.
226577 Figure 383

682 ‒ Gearbox
12JS GEARBOX 217
GEARBOX OVERHAULING
267. Using ropes (1), sling the lower layshaft (2) and place it in the
226514 Figure 384
268. Heat the front bearing track (1) to a temperature of 80°C-

100°C and fit it into the gearbox housing (2).
code
226578 Figure 385
269. Heat the rear bearing (2) to a temperature of 80°C-100°C, fit

it into the gearbox housing (1) and insert the circlip (3).
code
226579 Figure 386

682 ‒ Gearbox
218 12JS GEARBOX
GEARBOX OVERHAULING
270. Position the lower reverse transmission gear (4). Insert the
spindle (7) together with the eccentric washer (6), bearing (5),
shoulder washer (2) and (3) and screw in the new nut (1) to
Tightening torque
M16x1.5 self-locking nut securing 67.5 N⋅m to81 N⋅m
reverse transmission gear
226580 Figure 387
271. Place the upper layshaft (1) inside the gearbox housing(2).
226581 Figure 388
272. Bring the upper layshaft (1) into contact with the gearbox hous-
ing (2) using a shim.
226582 Figure 389

682 ‒ Gearbox
12JS GEARBOX 219
GEARBOX OVERHAULING
273. Place the upper reverse transmission gear (1) in the gearbox
housing (2).
226583 Figure 390
274. Before fitting the main shaft (4) in the gearbox housing (3),
lock the 5th speed gear so that it cannot fall during assembly
operations.
275. Use paint to mark the two teeth (2) diametrically opposed to
the gear (1) so that there are the same number of teeth on the
two lower and upper semi circle perimeters.
226584 Figure 391
276. Insert the main shaft (1) into the gearbox housing making the
references on the main shaft (1) coincide with the marks made
previously on the layshafts.
277. Release the gear of the 5th speed which was previously blocked.
226585 Figure 392

682 ‒ Gearbox
220 12JS GEARBOX
GEARBOX OVERHAULING
278. Using a copper hammer, fit the new bushing (1) into the drive
input shaft (2).
226586 Figure 393
279. Insert the drive input shaft (2) into the 5th gear and use a
screwdriver to insert the circlip (1).
226505 Figure 394
280. Fit the spacer ring (2) on to the drive input shaft (1).
226587 Figure 395

682 ‒ Gearbox
12JS GEARBOX 221
GEARBOX OVERHAULING
281. Using a specific drift, fit the thrust bearings (2) onto the drive
input shaft (1).
code
226588 Figure 396
282. Heat the inner track of the bearing (2) to a temperature of

80°C -100°C and using a drift, fit it onto the drive input shaft
(1) and the gearbox housing at the same time.
223087 Figure 397
283. Fit the bearing (1) onto the main shaft (2).
226503 Figure 398

682 ‒ Gearbox
222 12JS GEARBOX
GEARBOX OVERHAULING
284. Fit the disc (2) onto the gearbox housing and tighten the screws
(3) to the specified torque.
Tightening torque
M10 screws securing disc to gear- 47.5 N⋅m to61 N⋅m
box housing
285. Fit the new safety wire (1).

286. Fit the gear (4) and using the specific pliers, insert and block the
circlip (5).
code
226589 Figure 399

it into the gearbox housing and insert the circlip (2).
code
226590 Figure 400

it into the gearbox housing and insert the circlip (2).
code
226591 Figure 401

682 ‒ Gearbox
12JS GEARBOX 223
GEARBOX OVERHAULING
289. Insert the spindle (7) onto the previously positioned gear (4)
together with the eccentric washer (6), bearing (5), shoulder
washers (2) and (3) and screw in the new nut (1) to the pre-
scribed torque.
Tightening torque
M16x1.5 self-locking nut securing 67.5 N⋅m to81 N⋅m
reverse transmission gear
226592 Figure 402
290. Fit the two bearings (1) with the designated drift until they are
in line with the gearbox housing. When the reduction unit is
inserted they will be pushed into their working seat.
291. Use a screw driver to screw in the two plugs (2) on the reverse
gear shafts.
226593 Figure 403
292. Fit the plates (1) making the reference dowels coincide with the
hole on the shaft.
293. Apply loctite thread lock to the screws (2) and tighten them to
Tightening torque
M16x1.5 screws securing layshaft 122 N⋅m to162 N⋅m
bearings
Tool / Material
LOCTITE
294. Apply thread lock loctite on the new left handed nut securing
the drive input shaft and tighten it to torque using the specific
tool (3).
Tightening torque
226495 Figure 404
M50 nuts securing drive input shaft 609 N⋅m to677 N⋅m

code
Wrench (80mm) to remove and refit the nut of the gear- 99355053
box direct drive shaft
LOCTITE

682 ‒ Gearbox
224 12JS GEARBOX
GEARBOX OVERHAULING
295. Compress the drive input shaft fastening nut into the specific
seat.
226495 Figure 404
296. Using a drift (6) and keying device (1), fit the new oil seal ring
(2) onto the front cover(3).
code
99370006)
297. Replace the front cover sealing gasket (3) with a new one.
226618 Figure 405
298. Fit the sleeve (3) onto the shaft (2) and tighten the screws (1)
Tightening torque
M10 screws securing drive input 47.5 N⋅m to61 N⋅m
shaft sleeve
299. Refit the reduction unit as described in Refitting the GRE rear
housing ( ➠ Page 178).
( ➠ Page 167).
( ➠ Page 166).
223081 Figure 406

682 ‒ Gearbox
12JS GEARBOX 225
DIAGNOSTICS
530210 DIAGNOSTICS
tions.
Operating principle
200120 Figure 407

value.

682 ‒ Gearbox
226 12JS GEARBOX
DIAGNOSTICS


174285 Figure 408

H Fast L Low
Troubleshooting
3. Piston.
plug.
Noisy transmission
The transmission may generate noise during typical operation. Excessive or abnormal noise, for example, particularly acute or bom-
bastic sounds, indicates that there may be a fault in the transmission. It is possible that the noise is generated by other noisy parts
and is amplified by the transmission.

682 ‒ Gearbox
12JS GEARBOX 227
DIAGNOSTICS
Internal transmission noise

1. Impact
1. The transmission gear teeth strike against each other. It can be identified by the obvious signs revealed after grinding the gear
teeth. In general, the noise issue is more noticeable when the gears are under load. If the noise only occurs when changing a
certain gear, it means that the gear teeth of said gear are defective. This type of impact problem can be solved using an abras-
ive stone or a portable grinder.
2. Damage or scoring of the races due to damaged bearing spheres or rollers may cause noise when gear shifting.
3. If during assembly the gear has been exposed to impact or fracture, it may impact when in low gear and generate screeching
noises at high speeds.
2. Screeching noise
1. It can be caused by normal wear of the gears. Scratches caused by prolonged operation can cause screeching noises before
the final damage of a gear.
2. This may be caused by an incorrect coupling of the gears, which can be identified by uneven wear of the gear surface.
3. A reduced axial and radial play can cause screeching noises after the pre-tightening of the bearing.
3. Bombastic noise
It can be caused by an error in the alignment of the teeth. Bombastic noises may be caused by misalignment of the teeth when
refitting the transmission or by a misalignment of the teeth caused by the rotation of the secondary shaft.
4. Popping
Turning the gear set generates a popping noise due to excessive axial play between lay shaft and main shaft. An excessive radial
play of the bearing on the lay shaft leads to an excessive distance between the lay shaft, possibly causing the gear may break due to
excessive load on the tips.
Transmission overheating
The transmission must work with a temperature not exceeding 120 ° C during prolonged operation. If the operating temperature
is higher than 120 ° C, the lubricant will deteriorate, and the life of the transmission will be reduced.
The transmission will generate heat due to friction of the moving parts. The normal operating temperature is about 38 ° C higher
than the ambient temperature. Poor heat dissipation can cause overheating of the transmission.
To ensure correct reading of the oil temperature indicator, check the oil temperature sensor and indicator before proceeding with
troubleshooting. Typically overheating is due to:
1. Incorrect lubrication. Too much or little lubricating fluid, the fluid has an incorrect SAE no. or transmission working angle ex-
ceeds 12°.
2. Vehicle speed generally below 32 km/h.
4. Air flow is prevented because the transmission is surrounded by the chassis of the vehicle, from the floor, from the fuel tank
and the bumper assembly.
5. Engine exhaust system excessively near the transmission.
6. Excessively high ambient temperature.
7. Overload drive conditions or excessive engine speed.
Disengaging the transmission gear (gear slippage) or difficult gearshifting.

Main transmission gear disengagement
When the seat of the mesh wheel gear (sliding sleeve on lay shaft) and the main shaft gears move to mesh, the teeth of the gear to
engage must be parallel. If the teeth of the gear engaged are worn or consumed, these teeth will tend to slip out of mesh and thus
disengage gear under specific conditions.
Gear disengagement reasons:

682 ‒ Gearbox
228 12JS GEARBOX
DIAGNOSTICS
1. The transmission input shaft and the pilot bearing of the motor flywheel are not concentric.
2. Violent impact of the gears during shifting causes wear of the tips of the meshing teeth.
3. The meshing teeth are worn until bevelled.
4. The pressure applied to the positioning ball of the shaft drive fork is insufficient due to a weakened or damaged check spring.
5. Positioning slot of the shaft drive fork extremely worn.
6. The connection to the control device of remote gearshifting is adjusted incorrectly, therefore meshing of the meshing teeth
and sliding sleeves is only partial.
7. When the vehicle is in full drive or while driving under load conditions, gear disengagement often occurs during sudden decel-
erations.
8. Driving on an uneven road, the gearshift lever may oscillate like a pendulum if it is extremely long and heavy, causing fractures
due to the pressure of the check spring and therefore disengaging the gear.
Gear splitter disengagement

Disengagement of splitter gears may be due to wear, erosion or partial meshing of meshing teeth between the splitter transmission
gear and the sliding sleeve of the synchronizer.
These faults are the result of impacts while gearshifting and of standard wear due to prolonged use.
Other factors that cause disengagement include vibrations due to incorrect transmission shaft installation and insufficient pressure
in the pneumatic transmission system.
Difficult gearshfting
While changing gears, various gears require different sorts os effort to engage. However, excessive force should not be exerted to
shift gears.
Difficult gearshifting often occur on remote control devices used for models with cabs mounted above the engine.
Therefore, while troubleshooting issues, check the linkage of the remote control device. In addition, the reasons for failure of the
linkage are various, such as wear and tear, incorrect connection and adjustment of the fork bushing or junction, poor lubrication of
the joints, limited movement of the rod due to mechanical barrier.
To check whether the problem is caused by the change difficult transmission itself is necessary to remove the gearshift lever or rod
from the transmission, drive gear guide block with a bar or screwdriver to be able to engage the single gears. The fault is not linked
to the transmission if the shaft drive fork slides smoothly. Otherwise, this means that the transmission is damaged.
If the transmission is damaged, the fault may be caused by:
1. The groove of the sliding sleeve of the lay shaft is locked on the main shaft, due to a distortion of the main shaft, the fork or
the groove of the main shaft.
2. The shaft drive fork is stuck in the transmission seat, which in turn may be due to impacts or bending of the shift drive fork
resulting from fractures of the seat or excessive tightening torque on the fixing screw of the gear shaft.
3. The shaft check screw is loose.
Damage to the gear

Engaged gear teeth damaged
This is a common fault for transmissions that mount synchronizer; gear impact may cause more damage to the teeth of the gear
engaged when gearshifting.
Minor impact may cause slight consequences whilst violent gearshifting before synchronization occurs will cause serious damage. In
this case, the ends of the meshed gear teeth may fracture and fall off.
The causes leading to damage of the engaged gear are:
1. Incorrect gearbox operation. The driver lacks familiarity with the positions of the gearbox as well as with the engine speed
range for different gears.
2. When setting into motion in first or reverse gears, impact may occur due to inefficient clutch release clearance or only partial
release.

682 ‒ Gearbox
12JS GEARBOX 229
DIAGNOSTICS
Damage to teeth
1. Standard wear
Due to relative stroke during gear engagement, gear tooth wear is normal. This type of wear is gradual and even.
Nevertheless, at times the surface of the teeth may be subjected to rapid wear and duration shortened when faced with harsh
conditions.
2. Gear tooth fracture
Gear tooth fracture is severe. The fragments of the teeth may damage other parts.
The cause of most of these fractures is attributed to a heavy impact. Gears that break after short periods of use during heavy loads
fall into the category of "impact fractures". If fracture occurs after numerous duty cycles, then this is "fatigue fracture".
3. Scoring
A gear will be scored after lengthy periods of use with overloads or also with soiled lubricant or with a SAE number that is not
suitable that can lead to tooth surface faults. Fatigue fracture may occur if these gears remain in use.
4. Scratching and sticking
Scratching and sticking occur after direct contact between metal surfaces of the gear teeth.
Relative motion of the metal surfaces may generate extremely high temperatures. This may lead to sticking of the softened metals
during these conditions of gear engagement.
The main cause of sticking and scratching is due to poor quality or lack of lubrication oil.
Gearbox deformation and breakage

Deformation or breakage of the gearbox may occur when the torsion motion applied to the shaft is higher than the rated value.
The possible causes of deformation or breakage of the gearbox are:
1. Incorrect gearshifting.
2. Putting into drive with high gears.
3. Towing in non-conform conditions.
4. Attempts to drive the vehicle while brake is engaged.
5. Gearbox service conditions not conform to design specifications.
6. Vehicle rear impact against obstacles.
7. Fatigue or impact fracture.
Bearings damage
Bearing wear is evident from the stripping of the bearing race or rough surface of the roller, which will generate loud noise and
vibrations. When the bearing is approaching the end of its life heavy and standard duty cycles, it shows signs of wear / fatigue.
When refitting the bushing into the bearing bore inside the transmission, it could be damaged if the hole is too small or out of
round. A deformation of the holes in the housing of the transmission can cause incorrect installation of the shaft, resulting in early
damage to the bearing due to fatigue.
Poor lubrication
Some features of the damage to bearings due to poor lubrication are fading components, stripping of the bearing race and the
damage to the bearing cage.
A poor level of lubrication is only one of the factors of damage of the bearings there are other causes, such as the presence of
impurities in the lubricant, different classifications of lubricant or mixture of lubricants with different SAE no.
Troubleshooting guide
1. Preliminary checks
● Visual inspection: Look for signs of damage and pay attention to key parts, such as brackets, connectors, connections and con-
trol the pneumatic circuit.
● Gather information relating to conditions of work and the historical failure rate.

682 ‒ Gearbox
230 12JS GEARBOX
● Create documentation that includes intervals for maintenance , lubrication and faults occurred in the past, mileage and days of
use.
2. Removing the gearbox
● Keep an oil sample to check the impurity content when necessary.

● Make sure components are mounted correctly, that there are no missing components or unoriginal parts during removal.
● Thoroughly clean and check the parts.
3. Identify type of fault

4. Determine cause of fault and resolve the problem

The fast and low gears of the splitter are disengaged

3 Crushed air pipe or connector. Cause confirmed ▶ Remove the parts subjected to
obstacles.
Gears of main shaft disengaged or crossed

1 Worn fork. Cause confirmed ▶ Replace parts.
2 Weakened or missing check spring. Cause confirmed ▶ Replace parts.
▶ Install missing parts.
5 Sliding sleeve fork groove worn. Cause confirmed ▶ Replace parts.
obstacles.
7 Sleeve incorrect position. Cause confirmed ▶ Replace the part.

682 ‒ Gearbox
12JS GEARBOX 231

7 Sleeve incorrect position. Cause not confirmed Check: 8
9 Engine and gearbox misaligned. Cause confirmed ▶ Replace parts.
quirements.
Gear shifting is difficult or impossible for fast or low gears

3 Crushed air pipe. Cause confirmed ▶ Remove the parts subjected to
obstacles.
4 The plug of the double H valve is rigid. Cause confirmed ▶ Clean the parts.
5 Gearbox cylinder O-ring damaged. Cause confirmed ▶ Clean the parts.
▶ Replace parts.
6 Loose nut on the cylinder piston. Cause confirmed ▶ Tighten parts.
▶ Clean the parts.
7 Cracked cylinder piston. Cause confirmed ▶ Replace parts.
9 Synchronizer damaged. Cause confirmed ▶ Replace parts.
10 Too little lubricant of the cylinder O-ring Cause confirmed ▶ Apply a thin layer of silicone grease.
11 Too much lubricant of the cylinder O-ring Cause confirmed ▶ Clean the components

682 ‒ Gearbox
232 12JS GEARBOX
Gear shifting is difficult or impossible on main transmission

1 Shaft drive fork bent. Cause confirmed ▶ Replace parts.
▶ Loosen the fixing screw and tighten to
2 Shaft drive fork with burr Cause confirmed ▶ Grind the surface with sand.
3 Rigid check spring. Cause confirmed ▶ Replace parts.
4 Gearbox seat cracked. Cause confirmed ▶ Replace parts.
7 Incorrect clutch use. Cause confirmed ▶ Instruct the driver on correct driving.
obstacles.
quirements.
Interlocking not possible

1 Missing interlock steel ball. Cause confirmed ▶ Replace parts.
2 Missing interlocking pin. Cause confirmed ▶ Replace parts.
Rattling sound when shifting

1 Damaged fork. Cause confirmed ▶ Replace parts.

682 ‒ Gearbox
12JS GEARBOX 233

3 Countershaft brake not operational. Cause confirmed ▶ Replace parts.
▶ Tighten parts.
▶ Check the air pipe.
obstacles.
quirements.
6 Worn gearbox housing sleeve Cause confirmed ▶ Replace parts.
quirements.
Cannot shift to neutral

obstacles.
quirements.
Excessive noise

2 Gear teeth cracked or with burr. Cause confirmed ▶ Grind the surface with sand.
▶ Replace parts.
4 Slippage of race inside front bearing of the Cause confirmed ▶ Install missing parts.
splitter countershaft. Cause not confirmed Check: 5

682 ‒ Gearbox
234 12JS GEARBOX

Noisy gears with engine running at idle speed:

2 Engine operation unstable. Cause confirmed ▶ Make new adjustments based on re-
quirements.
High vibrations

2 Output shaft nut tightening torque insuffi- Cause confirmed ▶ Make new adjustments based on re-
cient. quirements.
quirements.
4 Worn suspension. Cause confirmed ▶ Replace parts.
quirements.
The main shaft washer is burnt

2 Low vehicle tow or sliding. Cause confirmed ▶ Replace parts.
quirements.

682 ‒ Gearbox
12JS GEARBOX 235
The input groove is worn or damaged

▶ Replace parts.
2 Excessive load. Cause confirmed ▶ Instruct the driver on correct driving.
▶ Replace parts.
quirements.
4 Clutch damage. Cause confirmed ▶ Replace parts.
quirements.
quirements.
▶ Replace parts.
quirements.
Clutch housing damaged

quirements.
▶ Replace parts.
3 Missing transmission auxiliary support. Cause confirmed ▶ Install missing parts.
Synchronizer is damaged

2 Reverse mounting of fork. Cause confirmed ▶ Replace parts.
▶ Refit.

682 ‒ Gearbox
236 12JS GEARBOX

6 Low functioning and use. Cause confirmed ▶ Instruct the driver on correct driving.
Overheating

7 Excessive transmission work angle. Cause confirmed ▶ Replace damaged parts.
quirements.
Main shaft deformed

▶ Replace parts.
2 Excessive shock absorber load. Cause confirmed ▶ Instruct the driver on correct driving.
▶ Replace parts.

682 ‒ Gearbox
12JS GEARBOX 237
Bearing burnt

3 Faulty seat. Cause confirmed ▶ Replace parts.
quirements.
4 Damaged rear flange oil seal Cause confirmed ▶ Replace parts.
5 Loose or missing fixing screw. Cause confirmed ▶ Replace parts.
quirements.

682 ‒ Gearbox
238 12JS GEARBOX

682 ‒ Propeller shafts
Contents 1
Contents
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . 3

2 Contents

PROPELLER SHAFTS 3
Contents
Contents

Sliding propeller shaft . . . . . . . . . . . . . . . . . . . . 5
Sliding propeller shaft . . . . . . . . . . . . . . . . . . . . 5
Propeller shaft for connection to elastic
support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVING - REASSEMBLING THE PROPELLER

SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check propeller shafts on vehicle . . . . . . . . . . . . 8
Dismounting and mounting the universal joints . . . . 9
Removing and reassembling the support . . . . . . . 11
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 12
Noisy and vibrating transmission . . . . . . . . . . . . 12

4 PROPELLER SHAFTS

PROPELLER SHAFTS 5
PROPELLER SHAFTS
Name mm
Assembly (radial) clearance of joint in seats on fork 0.05
Propeller shaft maximum runout
- measured at centre 0.4
- measured at the end 0.25
- measured on shank 0.15
Sliding propeller shaft
221527 Figure 1
Sliding propeller shaft
221528 Figure 2

6 PROPELLER SHAFTS
TIGHTENING TORQUES
Propeller shaft for connection to elastic support
221529 Figure 3
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
Ring nut to fasten the flange to the connection shaft:
M 40x1.5 350 + 50 35 + 5
M 55x1.5 380 + 70 38 + 7
Screw fastening the flange to the propeller shaft: M 20x160 450 ± 34 45 ± 3.4
Nut for screw fastening propeller shaft flanges 133.5 ± 13.5 13.3 ± 1.3
Nut for M12 screw fastening flexible support bracket to chassis 92 ± 9 9.2 ± 1
Nut for M14 screw fastening flexible support to bracket 146.5 ± 14.5 14.6 ± 1.4
TOOLS
Propeller shaft support during removal and refitting. (99370618)
.505620. REMOVING - REASSEMBLING THE PROPELLER SHAFT
Work material

PROPELLER SHAFTS 7
REMOVING - REASSEMBLING THE PROPELLER SHAFT
Main action
.505620. Propeller shaft removal
6 2
5 3
1
171977 Figure 4
1. Position the specific support (1) under the propeller shaft (2) and fix it.
2. Unscrew the 4 screws (3) securing the propeller shaft to the rear axle (4).
3. Unscrew the four screws (5) securing the propeller shaft to the gearbox (6).
4. Using the hydraulic jack (7) under the specific support (1) remove the propeller shaft (2).
.505620. Propeller shaft refitting

5. Position the propeller shaft (1) under the vehicle.
6. Align the two ends of the propeller shaft with the rear axle and gearbox sides.
7. Screw in the four fixing screws (3) on the rear axle (4) side.
8. Screw in the four fixing screws (5) on the gearbox (6) side.
9. Remove the specific support (1) from below the vehicle.

8 PROPELLER SHAFTS
.505601. Check propeller shafts on vehicle
Front propeller shaft components
38824 Figure 5
1 Front fork flange 6 Ring nut
2 Grease nipple 7 Washer
3 Circlip 8 Rear flange
4 Cross 9 Support
5 Shaft
Note The propeller shafts are supplied as assemblies ready to be installed.

They are statically and dynamically balanced.
The plates welded to the transmission shafts are balancing plates.
If there are no plates, it is necessary to balance the shaft again.

PROPELLER SHAFTS 9
Main action
1. By operating on the propeller shaft and simultaneously, in re-
verse direction, on the sliding sleeve (arrows), check that there
is no excessive clearance among splined parts.
2. Working on the forks of the sleeves (arrows) check that the
spiders are not worn; if they are, replace them as described
previously..
33808 Figure 6
.505694. Dismounting and mounting the universal joints

Work material
Punch
Main action
38825 Figure 7
1 Front fork flange 5 Front half shaft
2 Grease nipple 6 Sealing ring (only for KLEIN supply)
3 Circlip 7 Rear fork flange
4 Cross 8 Rear half-propeller shaft
1. Using callipers remove the safety ring (3).

10 PROPELLER SHAFTS
38825 Figure 7
2. Strike with a hammer on the flange of the fork (1) until the bearing partly comes out of its seat, that is until the spider joint
(4) does not interferes with the fork; turn the component upside down and repeat the operation.
3. Manually remove one of the two bearings, remove the fork (1) and use a punch to remove the other bearing.
Tool / Material
Punch
4. With the same procedure, extract the bearings from the other fork and free the joint (4).
5. To reassemble, repeat the above mentioned procedure backwards.

PROPELLER SHAFTS 11
.505697. Removing and reassembling the support

Main action
38824 Figure 8
1 Front fork flange 6 Ring nut
2 Grease nipple 7 Washer
3 Circlip 8 Rear flange
4 Cross 9 Support
5 Shaft
1. Using a suitable wrench remove the ring nut (6) and withdraw from the propeller shaft: the washer (7); the rear flange (8)
and the mount (9).
2. To reassemble, repeat the above mentioned procedure backwards.

12 PROPELLER SHAFTS
DIAGNOSTICS
DIAGNOSTICS
Noisy and vibrating transmission

1 Deformation of shaft. Cause confirmed ▶ Replace the shaft.
2 Shaft unbalanced. Cause confirmed ▶ Carry out balancing check and determ-
ine the points where balancing plates
must be welded.
3 Excessive play between splines. Cause confirmed ▶ Replace the shaft.
4 Screws and nuts loosening for shaft engage- Cause confirmed ▶ Carefully check parts, then fully tighten
ment to sleeves on transmission or on rear the loose screws and nuts; Replace any
axle. worn parts if necessary.
5 Propeller shaft universal joints seized or ex- Cause confirmed ▶ Overhaul or replace the universal
cessively worn. joints.
6 Flexible support securing screws loose. Cause confirmed ▶ Tighten the screws to the specified
torque.
7 Central support flexible insert worn. Cause confirmed ▶ Replace the support.
8 Mid flexible support bearing worn or with Cause confirmed ▶ Replace the support.
excessive play. Cause not confirmed Check: 9
9 Loose screws or ring nuts securing the flange Cause confirmed ▶ Tighten the screws or the ring nuts to
to the propeller shaft shank. the specified torque.

682 ‒ Rear axles
Contents 1
Contents
HR REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 3
HR INTERMEDIATE AXLE . . . . . . . . . . . . . . . . 41
SR REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . 123
SR INTERMEDIATE AXLE . . . . . . . . . . . . . . . . . 129
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 137

682 ‒ Rear axles
2 Contents

682 ‒ Rear axles
HR REAR AXLE 3
Contents
Contents
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section on differential . . . . . . . . . . . . . . . . . . . . 8
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL - REFITTING REAR AXLE . . . . . . . . . . 15
OVERHAULING THE HR REAR AXLE

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Epicyclic reduction gear assembly and
disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIFFERENTIAL REMOVAL . . . . . . . . . . . . . . . 19
DIFFERENTIAL OVERHAUL . . . . . . . . . . . . . . 20
REFITTING THE DIFFERENTIAL . . . . . . . . . . . 37

682 ‒ Rear axles
4 HR REAR AXLE

682 ‒ Rear axles
HR REAR AXLE 5
DESCRIPTION
HR REAR AXLE
525010 DESCRIPTION
The rear axle casing is comprised of a spot welded housing and a stainless steel housing, central and hub dual reduction, epicyclic
differential gearing, load bearing axle shaft and cam brake.
The rear axle is of the double reduction type: the first reduction is provided by the bevel pinion/ring bevel gear, whereas the
second reduction is by means of a planetary gear unit on the wheel hubs.
71549 Figure 1

682 ‒ Rear axles
6 HR REAR AXLE
DESCRIPTION
174555 Figure 2
1 Half shaft (right) 24 Planetary gear carrier assembly
2 Half shaft (left) 25 Planet washer
3 Planetary washer 26 Cylindrical pin
4 Planetary gear 27 Washer
5 Washer 28 Needle bearing
6 Spring washer with thrust bearing 29 Planet gear
7 Hexagon head bolt 30 Planetary gear shaft
8 Bevelled washer 31 Steel ball
9 Oil-repellent cover 32 Seal ring
10 Seal 33 Cross bevelled screw
11 Rear wheel hub external oil seal ring 34 Seal
12 Rear wheel hub internal oil seal ring 35 Hexagonal cylindrical recessed head bolt
13 Spacer assembly 36 Hexagon head bolt
14 Tapered roller bearing 37 Crest cover pin
15 Wheel bolt 38 Crest cover
16 Rear wheel bolt 40 Cross bevelled screw
17 Tapered roller bearing 41 Drum brake
18 Axial stop ring 42 Brake jaw unit
19 Crown 43 Roller
20 Crown assembly 44 Return spring
21 Rigid check device. 45 Camshaft brake
22 Bolt 46 Return spring pin
23 Planetary gear oil baffle 47 Return spring

682 ‒ Rear axles
HR REAR AXLE 7
48 Fulcrum pin 60 Hexagon head bolt

49 Cylindrical pin spring 61 Hexagon head bolt
50 Bolt 62 Metric threaded tapered grease nipple
51 Aux. washer 63 Camshaft support
52 O-ring 64 Seal ring
53 Bush 65 Adjustment shim
54 Metric threaded tapered grease nipple 66 Clearance adjustment arm assembly
55 Brake plate 67 Washer
56 Brake dust guard group 68 Adjustment shim
57 Bevelled washer 69 Spring collar with thrust bearing
58 Hexagon head bolt 70 Inner tube support
59 Spring collar with thrust bearing

Type of rear axle:
Load-bearing, double reduction with pneumatic differential locking and transfer case
Bevelled pinion bearings. 2 with tapered rollers
Reduction ratio 4.42 - 4.8 - 5.73 - 6.72 - 9.49
Pre-tightening torque bevelled pinion bearings Nm 1.0 ~ 2.0
Bevelled pinion bearing rolling torque adjustment using adjustment rings
Thickness of bevelled pinion to gear adjustment

– mm 0.05 - 0.10
shims
Clearance between pinion and crown wheel mm 0.20 0.48
Pinion to crown wheel clearance adjustment using adjustment shims
WHEEL HUBS
wheel hub bearings Two tapered rollers type
Pre-tightening torque tyre hub bearings: N 6~8
Rear axle oil Tutela Transmission W140/M-DA (1)

differential casing quantity Litres 6
wheel hubs Litres 2 (for each hub)
G.R.W. maximum load kg 16000
(1) Suitable for hot or temperate climates.

682 ‒ Rear axles
8 HR REAR AXLE
TIGHTENING TORQUES

Section on differential
174556 Figure 3
TORQUE
DETAIL
Nm (kgm)
1 Nut fixing bevelled pinion flange 750 ÷ 800 (75 ÷ 80)
2 Screw fixing bevelled pinion support to the box 120 ÷ 138 (12 ÷ 13.8)
3 Screw for securing differential housing to rear axle unit 83 ÷ 95 (8.3 ÷ 9.5)
4 Screws fastening ring bevelled gear to reduction box 290 ÷ 310 (29 ÷ 31)
5 Self-locking screw fixing safety plate 23 (2.3)
6 Differential housing coupling screw 175 ÷ 195 (17.5 ÷ 19.56)
7 Fixed sleeve locking nut 190 ÷ 210 (19.0 ÷ 21.0)

682 ‒ Rear axles
HR REAR AXLE 9
TIGHTENING TORQUES
174557 Figure 4
TORQUE
DETAIL
Nm (kgm)
1 Screws fixing cover to planet gear support 46 ÷ 52 (4.6 ÷ 5.2)
2 Rear axle housing fixing screws 120 ÷ 138 (55 ÷ 60)
3 Fixing screws for bottom plate and rear axle housing 315 ÷ 325 (31.5 ÷ 32.5)
4 Screws fixing the planet carrier to the reducer box 115 ÷ 125 (11.5 ÷ 12.5)

682 ‒ Rear axles
10 HR REAR AXLE
TOOLS
TOOLS
(99322205)
Rear axle and shaft overhaul stand (99322215)

682 ‒ Rear axles
HR REAR AXLE 11
TOOLS
Puller with locking device (99348001)
Wrench (94.5 mm) for wheel hub bearing adjusting nut (99354207)
Wrench for differential housing bearings adjustment ring nuts (99355025)
Wrench (60 mm) for differential bevel pinion nut (use with 99370317) (99355081)

682 ‒ Rear axles
12 HR REAR AXLE
TOOLS
Differential half box extracting hook (99370509)
Differential removal and refitting support (99370616)

682 ‒ Rear axles
HR REAR AXLE 13
TOOLS
Universal mounting to support axles during removal and refitting (99370617)
Differential support bracket pair for overhauling (use with 99322205-99322225) (99371022)
Differential removal and refitting support (99370616)

682 ‒ Rear axles
14 HR REAR AXLE
TOOLS
Key for differential bevel pinion gasket installation (use with 99370006) (99374013)
Drift for fitting bearing external races (134-215 mm) (use with 99370007) (99374094)
Tool for checking hub rolling torque (use with torque wrench) (99395026)

682 ‒ Rear axles
HR REAR AXLE 15
REMOVAL - REFITTING REAR AXLE
.525010. REMOVAL - REFITTING REAR AXLE
Work material
Universal mounting to support axles during removal and 99370617
refitting
Main action
.525010. Rear axle removal
1
2
3
5
4 2
13 14 15 6
12
19
11
18 10
17
16
9
8 7
171945 Figure 5
1. Set the vehicle on level ground and lock the front wheels using chocks.
2. Remove the wheel fastening nut guards (if present) and loosen the nuts.
3. Use a hydraulic jack to lift the rear of the vehicle and place it on two support stands.

682 ‒ Rear axles
16 HR REAR AXLE
2
3
5
4 2
13 14 15 6
19
12
11
18 10
17
16
9
8 7
171945 Figure 5
4. Position the hydraulic jack under the wheels. Remove the twin wheel fastening nuts and remove the wheels.
5. Remove the propeller shaft (1) from the rear differential lock, removing the ten fastening screws (3) and secure the pro-
peller shaft (1) to the vehicle chassis.
6. Release the brake cylinders (Rotochambers) by undoing the upper retainers (2).
7. Undo the fastening collars (12) and release the air hoses (11) of the brake cylinders (Rotochambers) from the electric cables.
8. Disconnect the air hoses (8) from the differential locking device and electric cable (14) from the differential locking indication
switch.
9. Remove the air hoses (7) from the brake cylinders (Rotochambers) by releasing them from the bracket (6).
10. Place a hydraulic jack fitted with specific support (16) under the rear axle.
Universal mounting to support axles during removal and refitting 99370617
11. Remove the stabiliser bar (18) from the retainers (17) on the two sealing sides of the rear axle and loosen the retainers (15)
that allow rotation inside so as not to interfere with the removal of the rear axle from the vehicle.
12. Remove the retainers (4) of the articulated joints of the lower side tie rods (5).

682 ‒ Rear axles
HR REAR AXLE 17
13. Remove the fastening retainers (9) of the articulated joint of the upper central tie rod (10).
14. Bring the axle backward so that the shoes (13) withdraw from the leaf springs(19).
15. Remove the axle from under the vehicle.
.525010. Refitting the rear axle

1
2
3
5
4 2
13 14 15 6
19
12
11
18 10
17
16
9
8 7
171945 Figure 6
16. Place the rear axle onto the tool (16) and secure it well to the tool from the differential flange side using the fixing screws
(3).
17. Place the rear axle beneath the vehicle by sliding in the ends of the leaf springs (19) into the shoes (13).
18. Secure the joint of the upper central longitudinal tie rod (10) using the securing elements (9).
19. Secure the joints of the suspension's lower side longitudinal tie rod (5) using the securing elements (4).
20. Put on the fastening collars (12) and connect the air hoses (12) of the brake cylinders (Rotochambers) to the electric cables.
21. Connect the hoses (8) of the differential lock actuator and its connection (14) of the differential lock engage sensor.

682 ‒ Rear axles
18 HR REAR AXLE
OVERHAULING THE HR REAR AXLE ASSEMBLY
2
3
5
4 2
13 14 15 6
19
12
11
18 10
17
16
9
8 7
171945 Figure 6
22. Connect the air delivery hoses (7) of the brake cylinders (Rotochambers) to the bracket (6).
23. Lift the vehicle and detach the tool (16) supporting the rear axle.
24. Reconnect the stabiliser bar (18) and unscrew the sealing retainers (17) from the two rear axle sides and tighten the retain-
ers (15) that allow the stabiliser bar to rotate.
25. Re-connect the propeller shaft (1) from the rear axle side by tightening the ten fixing screws (3).
.525040. Epicyclic reduction gear assembly and disassembly

26. The overhaul procedures for the epicyclic reduction gear and wheel hubs are the same as those for the HR intermediate axle
which should be taken as referenceOVERHAULING THE HR INTERMEDIATE AXLE ASSEMBLY ( ➠ Page 58).
.525010. OVERHAULING THE HR REAR AXLE ASSEMBLY

Work material
Rear axle and shaft overhaul stand 99322215

682 ‒ Rear axles
HR REAR AXLE 19
Main action
▶ Place rear axle (1) on specific stand (2) for assembly overhaul-
ing.
code
185317 Figure 7
.525040. Epicyclic reduction gear assembly and disassembly

Main action
▶ The overhaul procedures for the epicyclic reduction gear and wheel hubs are the same as those for the HR intermediate axle
which should be taken as referenceOVERHAULING THE HR INTERMEDIATE AXLE ASSEMBLY ( ➠ Page 58).
.526210. DIFFERENTIAL REMOVAL
Main action
1. Lift the rear axle from the stand using specific lifting belts to
simplify the removal of the differential gear housing (1).
185293 Figure 8

682 ‒ Rear axles
20 HR REAR AXLE
2. Remove the nuts (1) locking the differential (2) to the rear
axle(3).
185294 Figure 9
3. Extract the differential (1) using the specific cables.
185295 Figure 10
.526210. DIFFERENTIAL OVERHAUL
Work material
Puller with locking device 99348001
Wrench for differential housing bearings adjustment ring 99355025
nuts
Wrench (60 mm) for differential bevel pinion nut (use 99355081
with 99370317)
Differential half box extracting hook 99370509

682 ‒ Rear axles
HR REAR AXLE 21
Differential support bracket pair for overhauling (use 99371022

with 99322205-99322225)
Key for differential bevel pinion gasket installation (use 99374013
with 99370006)
Drift to fit bearing external races (91 -134 mm) (use 99374093
with 99370007)
Tightening torques
Hexagon head screws Tightening torque 450 N⋅m to520 N⋅m
Nut Tightening torque 900 N⋅m to1,100 N⋅m
Nuts - washers Tightening torque 630 N⋅m to670 N⋅m
Differential bearing Tightening torque 1.5 N⋅m to4 N⋅m
Bearing spring Tightening torque 8 N⋅m to20 N⋅m
Screw - torque wrench Tightening torque 180 N⋅m to207 N⋅m
torque wrench 280 ±15 N⋅m
Main action
.526210. Differential disassembly
1. Position the differential unit (1) on the rotating stand (2) to-
gether with support and a pair of brackets (3).
code
Differential support bracket pair for overhauling (use with 99371022
99322205-99322225)
185296 Figure 11
2. With the appropriate drift; remove the notch of the cotter pin
(1) and extract it, then loosen the retaining nut (2).
185297 Figure 12

682 ‒ Rear axles
22 HR REAR AXLE
.526220. gear housing disassembly

3. Place the complete differential case with the cover (1) of the
gear housing facing upwards, on a rotating stand (2) together
with support and a pair of brackets (3).
code
99322205-99322225)
4. Do not remove the bevelled pinion support (4).
39667 Figure 13
5. Unscrew the screws (1) and remove the safety plate (2).
6. Repeat the same operation on the opposite side.
39668 Figure 14
7. Heat the points indicated by the arrows with a hot air blower
and undo the screws (2) fixing the cover (secured with LOC-
TITE).
code
39669 Figure 15

682 ‒ Rear axles
HR REAR AXLE 23
8. Raise the gear housing cover (1).
39670 Figure 16
9. Put the differential casing (1) on the rotating stand (3) together
with the specified support and fasten it to the brackets (2).
code
99322205-99322225)
10. Remove the hexagonal head screws (5), the spring (6), the
washers (4) and the cover (7).
36312
36312 Figure 17
11. Extract the shaft from its seat (1), the fork (2) and the spring
(3).
185299 Figure 18

682 ‒ Rear axles
24 HR REAR AXLE
12. Remove the cotter pin (1) and the adjustment ring (2).
185308 Figure 19
13. Remove the screws (1) fastening the bush cover of the support
together with the washers (2), remove the cover of the differ-
ential bearing (3) and the adjustment ring (4).
Note Before disassembling the cover (3) mark it to dis-
tinguish the right from the left so as to simplify sub-
sequent re-fitting.
36314
36314 Figure 20

682 ‒ Rear axles
HR REAR AXLE 25
14. Using the specific hook (1), raise the gear housing (2) together
with the tapered roller bearings and bearing external rings.
code
19376
19376 Figure 21
15. Remove the screws and washers securing the bevelled pinion
support (1) to differential housing (3).
16. Fit the reaction screws (2) and extract the differential carrier
support.
39673 Figure 22
17. Remove the differential unit (2) using the specified hook (1)
and place it on the bench (3).
19379 Figure 23

682 ‒ Rear axles
26 HR REAR AXLE
18. Extract the tapered roller bearing (3, 4) from the differential
casing using the specified tool (1) and reaction block.
code
36317 Figure 24
19. Remove the nuts (1) connecting the half cap (2) and remove it,
then remove the planetary gear (3) inside.
185309 Figure 25
20. Remove the epicyclic gear reducer (1) together with the four
planetary gears (2) and the washer.
185310 Figure 26

682 ‒ Rear axles
HR REAR AXLE 27
.526249. Disassembly bevelled pinion support

21. Rotate the differential carrier 90º.
22. Apply reaction lever (2) to the drive coupling flange then, using
an Allen wrench (1) loosen the nut securing the flange (3).
code
Wrench (60 mm) for differential bevel pinion nut (use with 99355081
99370317)
185298 Figure 27
23. Remove the flange (1).

24. Extract the sealing ring (2) using the specific puller.
185311 Figure 28
25. Using a press, remove the bevelled gear (1) and the gear (2).
36318
36318 Figure 29

682 ‒ Rear axles
28 HR REAR AXLE
26. Insert the specified tool (2)and reaction block under the
tapered roller bearing (1), and extract it from the guide wheel
(3) with a press.
code
27. Disassemble the rear part of the bearing (4) from the bevelled
gear pair.
36319 Figure 30
28. Place the cover (1) in a vice and extract the lower bevelled
bearing rolling external ring (2) from the bearing block (3).
39689 Figure 31
29. Differential section RR 140E.
36321 Figure 32

682 ‒ Rear axles
HR REAR AXLE 29
30. Section of the differential assembly with differential lock.
36321a Figure 33
.526210. Checking the component parts of differential

31. Clean and carefully check the individual component parts of the differential, replacing any worn parts and all seals.
32. Lubricate the bearings and rotate the roller cage freely; rotation must be smooth and resistance-free.
33. Check the bearing surfaces of the ring bevelled gear and the thrust surface of the half-casing so that the crown wheel fits
perfectly. Any eventual deformation on these surfaces would cause screw vibration on the bevelled gear, leading to incorrect
assembly operation.
Note Carefully clean all the threads to ensure exact adjustments and precise tightening torque values.
34. Check that the grooved section for the shrink-fit flange on the pinion is not excessively worn. Replace the pinion if necessary.
Note If either the bevelled gear or pinion need to be replaced, both parts must be replaced as they are supplied as an as-
sembly.
.526220. gear housing assembly

35. Fit the epicyclic gear reducer (1) together with the four planet-
ary gears (2) with the washer.
36. Insert the planetary gear and its washer.
185310 Figure 34
.526220. Checking clearance between teeth.

37. Allow the head of the dial gauge to touch the surface of the planetary gear tooth, and turn the dial gauge from side to side.
The difference indicated by the dial gauge is the clearance.
38. Measure 4 - 6 symmetrical points of the planetary gear and make sure that the tolerance value is between +0.55 and - 0.23
mm.

682 ‒ Rear axles
30 HR REAR AXLE
39. Place the small differential shell (1) on the stand, then fix the
washers and the planetary gear (2) axle shaft which must not
be locked during rotation.
185300 Figure 35
40. Use the specified support tool (1) to fit the small differential
casing (2) on the bevelled gear (4) and align the holes of the
screws (3).
185312 Figure 36
41. Tighten the hexagonal head screws (2) to the specified torque
using torque wrench (1).
Tightening torque
Hexagon head screws Tightening torque
450 N⋅m to520 N⋅m
39695 Figure 37

682 ‒ Rear axles
HR REAR AXLE 31
42. Using the specific tool, heat the support bearing (2) to 80ºC for
about 15' and place it on the gear case cover using a drift (1).
43. Repeat the same operation on the other bearing.
39696 Figure 38
44. Spread oil on the shaft (1) of the tapered drive wheel. Insert
the internal ring (2) in the gear of the shaft.
185301 Figure 39
.526249. Assembly bevelled pinion support

45. Fit a new oil baffle on the pinion support (2).
46. Using the specified drift (1) and specific handle, fit the interme-
diate bearing external ring and the front bearing external ring in
their respective seats.
code
Drift to fit bearing external races (91 -134 mm) (use with 99374093
99370007)
39571 Figure 40

682 ‒ Rear axles
32 HR REAR AXLE
47. Mount and fasten the control gear (3) in the seat of the bearing
(4) and then the washers (2) and insert the internal ring (1) of
the tapered roller bearing.
185302 Figure 41
48. Use the spring balance (2) to measure the tangential force of
the bearing seat during rotation at constant speed.
49. The measurement is correct if the force is between 10 - 20
Nm.
185303 Figure 42
50. Remove the ring (3), spread LOCTITE sealing in correspond-

ence with the ring's surfaces, then insert it into the seat of the
bearing (2) with a specific keying device (2) and handle, and
eliminate the excess sealant.
code
Key for differential bevel pinion gasket installation (use with 99374013
99370006)
39579 Figure 43

682 ‒ Rear axles
HR REAR AXLE 33
51. Install the flange (1).
39705 Figure 44
52. Fix the nut (1) of the flange (2) on the main drive shaft (3),
verify the alignment of the nut with the drive wheel socket, then
attach the nut (1) and tighten it to the specified torque.
Tightening torque
Nut Tightening torque
900 N⋅m to1,100 N⋅m
185313 Figure 45
53. Insert the straight roller bearing in the differential shell (1).
185314 Figure 46

682 ‒ Rear axles
34 HR REAR AXLE
54. Spread oil on the differential bearing hole and use the specific
hook (1) to correctly position the differential (2) on the bear-
ing hole.
code
185304 Figure 47
55. Mount the bearing caps (3), and use the specified torque
wrench to tighten the nuts (1) and the washers (2) to the
specified torque.
Tightening torque
Nuts - washers Tightening torque
630 N⋅m to670 N⋅m
185307 Figure 48
56. Fix the adjustment nut (3) of the differential bearing and tighten
to the specified torque. Then carry out adjustment by tightening
or loosening the adjustment nut (2). On the external surface
of the cylinder, measure the tangential force using the spring
balance (1) during rotation of the bearing at constant speed.
The resulting force must be between 8 - 20 Nm.
Tightening torque
Differential bearing Tightening torque
1.5 N⋅m to4 N⋅m
Bearing spring Tightening torque
8 N⋅m to20 N⋅m
185305 Figure 49

682 ‒ Rear axles
HR REAR AXLE 35
.526210. Measurement and adjustment of drive gear teeth clearance

57. Adjust the end clearance between pinion-crown wheel teeth to
obtain 0.20 ÷ 0.48 mm.
58. Position the magnetic-based dial gauge (1) as illustrated.
59. Using wrench (2), tighten the bearing adjustment ring nut (3)
whilst loosening the ring nut on the opposite side by the same
amount, this prevents the previously measured rolling torque
from varying.
code
nuts
39586 Figure 50
60. Apply a thin layer of Prussian blue on the crown wheel teeth
with a brush(1).
61. Turn the pinion and examine the impression of the contact of
the pinion teeth on the crown wheel teeth.
39588 Figure 51
62. Carry out the clearance adjustment by turning the adjusting nut
(2) using the specific wrench (1).
39711 Figure 52

682 ‒ Rear axles
36 HR REAR AXLE
63. Measure the thickness of the adjusting ring (1) defined at disas-
sembly and record the value .
64. Heat the intermediate bearing to a temperature of 100 ºC for
approx. 15 minutes and shrink-fit it on the bevelled pinion. Fit
the adjusting ring (1) of the thickness defined previously.
185306 Figure 53
.526210. Reassembling the differential housing

65. Turn the differential shell (3), upside down, position the coup-
ling surface (2), and spread LOCTITE sealant on it.
66. Use the specified torque wrench (1) to tighten screws (4) to
the correct value.
Tightening torque
Screw - torque wrench Tightening torque
180 N⋅m to207 N⋅m
39707 Figure 54
67. Lock the adjustment ring (1) with the cotter pin in point (2)
and repeat the operation from the other side.
185315 Figure 55

682 ‒ Rear axles
HR REAR AXLE 37
68. Fit the gearbox fork (1) on the shaft (2) and insert the spring
on the pin (3) of the final reduction shell.
185316 Figure 56
69. Correctly fit the cover (3) matching marks made at disassembly;
tighten the screws (2) temporarily, then check that the adjusting
ring nuts (4) can be tightened freely.
70. Remove the screws (2) again, smear the threads with LOCTITE
AVX and then re-tighten with a torque wrench (1) to the spe-
cified torque.
Tightening torque
torque wrench 280 ±15 N⋅m
39709 Figure 57
.526210. REFITTING THE DIFFERENTIAL
Main action
1. Fit the sliding sleeve(1) on the drive shaft (2) with double
toothing.
39662 Figure 58

682 ‒ Rear axles
38 HR REAR AXLE
2. Apply sealant LOCTITE 573 (1) to the bearing surface.

Note At differential housing assembly, make sure that the
differential lock engagement fork is correctly seated in
the sliding sleeve.
39663 Figure 59
3. Position the seal ring and assemble the differential housing (1).
4. Apply sealant LOCTITE 573 to the threads of the external
screws (2).
5. Using the specified torque wrench, tighten the external screws
(2) and the internal screws (3) to the correct torque.
39664 Figure 60
6. Apply LOCTITE 573 (1) to the bearing surface.

Note Apply a bead of LOCTITE 510 around the oil flow
holes.
39665 Figure 61

682 ‒ Rear axles
HR REAR AXLE 39
7. Position the bevelled pinion support (1) on the differential

housing (2).
8. Use a torque wrench to tighten the screws (3) to the specified
torque:
Note The screw threads (3) screwed into the flow holes
must receive an application of LOCTITE 573.
39666 Figure 62

682 ‒ Rear axles
40 HR INTERMEDIATE AXLE

682 ‒ Rear axles
HR INTERMEDIATE AXLE 41
Contents
Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CHARACTERISTICS AND DATA . . . . . . . . . . . . . 45
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL-REFITTING OF THE INTERMEDIATE

AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
REPLACING THE DIFFERENTIAL TRANSFER BOX

ASSEMBLY ON THE VEHICLE . . . . . . . . . . . . . . . 56
OVERHAULING THE HR INTERMEDIATE AXLE

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Epicyclic reduction gear disassembly . . . . . . . . . . 60
Wheel hubs disassembly . . . . . . . . . . . . . . . . . 67
Checking the wheel hub components and the
epicycloid reduction gear . . . . . . . . . . . . . . . . 73
Wheel hub mounting . . . . . . . . . . . . . . . . . . . 73
REMOVAL OF TRANSFER BOX - DIFFERENTIAL

(with axle on stand 99322215) . . . . . . . . . . . . . . . 82
DIFFERENTIAL TRANSFER CASE UNIT

OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
REFITTING THE DIFFERENTIAL TRANSFER

BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Fitting the automatic adjustment device . . . . . . . . . 119

682 ‒ Rear axles

682 ‒ Rear axles
Description
HR INTERMEDIATE AXLE
525110 Description
174558 Figure 63
The intermediate axle is of the load-bearing, double reduction type. The first reduction is provided by the bevelled pinion/ring
bevelled gear, whereas the second reduction is by means of a epicyclic gearing on the wheel hubs.
The differential housing, with bevelled gear, is supported by two tapered roller bearings, which can be adjusted by means of two
threaded ring nuts.
The bevelled pinion is supported by two tapered roller bearings, which can be adjusted by means of adjustment shims. The inter-
mediate axle is fitted with a flow divider unit that distributes the torque between the two axles.
The axle is also provided with a differential locking pneumatic device and another distributor locking device. The brake is drum type
with cam control.

682 ‒ Rear axles
Description
HR intermediate axle
174559 Figure 64
1 Rear axle in tandem 27 Locking washer
2 Radial single crown ball bearing 28 Round nut
3 Bearing seat 29 Sliding coupling sleeve
5 Flange unit 30 Sliding fork
6 Flanged nut 31 Sliding fork moving section
7 Split pin 32 Bending plate
8 Plug 33 Hexagon nut
9 Sealing washer 34 Bevelled tip grooved grub screw
10 Magnetic plug assembly 35 Bevelled driving gear
11 Hexagon head bolt 36 Oil sealing plate
12 Bevelled washer 37 Roller bearing
13 Stop plate 38 Steel wire circlip
14 Differential bearing adjusting nut 39 Stud
15 Tapered roller bearing 40 Stud
16 Bolt 41 Type I hex nut
17 Differential casing 45 Driven spur gear
18 Tapered duct gear 46 Retainer
20 Adjustment shim 47 Stud
21 Axle shaft gear 48 Bearing seat
22 Differential spider 49 Radial single crown roller bearing
23 Planetary gear assembly 50 Adjustment shim
24 Planetary gasket 51 Bearing outer ring pressure plate
25 Hexagon head bolt 52 Bearing pressure plate
26 Fixed coupling sleeve 53 Hexagon head bolt

682 ‒ Rear axles
54 Hexagonal lock nut 80 Differential locking pin

55 Grooved round nut 81 Sliding fork
56 Flat steel wire circlip 82 Sliding fork moving section
57 Radial ball bearing with stop groove 83 Differential locking ring
58 Main retarder box 84 Interaxle differential gasket
59 Safety washer 85 Passenger side axle case cover
60 Stud 85 Passenger side axle case cover assembly
61 Hexagon head bolt 86 Bearing seat cover
62 Bevelled washer 87 Hexagon head bolt
63 Oil sealing plate assembly 88 Bevelled washer
64 Cylindrical pin 89 Hexagon nut
65 Rear axle case 90 Shaft seal ring
66 Cylindrical driving gear 91 Flange unit
67 Hollow shaft 92 Flanged nut
68 Shaft spring lock washer 93 Split pin
69 Radial bearing with dust sealing 94 Shaft spring collar
70 Hexagon head bolt 95 Bush
72 Axle shaft gear gasket (rear) 96 O type seal ring
73 Axle shaft (rear) 97 Differential lock rocker arm assembly
74 Planetary gear gasket 98 Cylindrical tip grooved grub screw
76 Safety washer 99 Hexagon nut
77 Axle shaft gear (front) 100 Hexagon head bolt
78 Axle shaft gear gasket (front) 101 Hexagonal nut
79 Differential casing assembly 102 Pin
103 Steel wire circlip for shaft 108 Flat washer

104 Bevelled washer 109 Hexagonal lock nut
105 Rod assembly 110 Vehicle axle plate
106 Hexagon head bolt 111 Plate rivet
107 Spacer sleeve
Type of rear axle:

Bevelled pinion bearings. 2 with tapered rollers
Reduction ratio 4.42-4.8-5.73-6.72-9.49
Pre-tightening torque bevelled pinion bearings N 1.0~2.0
Thickness of bevelled pinion to gear adjustment

mm 0.05-0.10
shims
Clearance between pinion and crown wheel mm 0.20 0.48

682 ‒ Rear axles
Type of rear axle:

WHEEL HUBS
wheel hub bearings Two tapered rollers type
Pre-tightening torque tyre hub bearings: N 6~8N.m
Quantity Tutela Transmission W140/M-DA (1)

rear axle case Litres 8.3
wheel hubs Litres 2 (for each hub)
Maximum load kg 16000

682 ‒ Rear axles
TIGHTENING TORQUES
174560 Figure 65
TORQUE
DETAIL
Nm (kgm)
1 Input flange nuts 750 ÷ 800 (75 ÷ 80)
2 Fixing screws for crest cover and rear axle case cover 46 (4.6)
3 Differential casing grooved nuts 290 ÷ 310 (29 ÷ 31)
4 Differential casing ring nuts 190 ÷ 210 (19 ÷ 21)
5 Bearing seat fixing nuts 48 (4.8)
6 Output flange nuts 750 ÷ 800 (75 ÷ 80)
7 Driven gear and differential case fixing screws 290 ÷ 310 (29 ÷ 31)
8 Differential right and left half casing fixing screw 175 ÷ 195 (17.5 ÷ 19.5)
9 Fixing nut on middle section of the rear axle in tandem with the rear axle housing. 83 ÷ 95 (8.3 ÷ 9.5)
10 Fixing nuts for rear axle housing and main retarder seat 83 ÷ 95 (8.3 ÷ 9.5)
11 Fixing nuts for rear axle housing and cover seat 45 ÷ 52 (4.5 ÷ 5.2)
12 Fixing nuts for rear axle housing and bearing seat assembly 46 ÷ 52 (4.6 ÷ 5.2)

682 ‒ Rear axles
TIGHTENING TORQUES
174557 Figure 66
TORQUE
DETAIL
Nm (kgm)
1 Screws fixing cover to planet gear support 46 ÷ 52 (4.6 ÷ 5.2)
2 Rear axle housing fixing screws 120 ÷ 138 (55 ÷ 60)
3 Fixing screws for bottom plate and rear axle housing 315 ÷ 325 (31.5 ÷ 32.5)
4 Screws fixing the planet carrier to the reducer box 115 ÷ 125 (11.5 ÷ 12.5)

682 ‒ Rear axles
TOOLS
TOOLS
(99322205)

682 ‒ Rear axles
TOOLS
Pair of brackets (99341026)
Puller with locking device (99348001)
Wrench (94.5 mm) for wheel hub bearing adjusting nut (99354207)
Wrench for differential housing bearings adjustment ring nuts (99355025)

682 ‒ Rear axles
TOOLS
Wrench (60 mm) for differential bevel pinion nut (use with 99370317) (99355081)

682 ‒ Rear axles
TOOLS
Support for removal and refitting of transfer box between axles (99370630)

682 ‒ Rear axles
REMOVAL-REFITTING OF THE INTERMEDIATE AXLE
Tool for checking hub rolling torque (use with torque wrench) (99395026)
.525110. REMOVAL-REFITTING OF THE INTERMEDIATE AXLE
Work material
refitting
Main action
.525110. Intermediate axle removal
174561 Figure 67
1. Set the vehicle on level ground and lock the front wheels.

682 ‒ Rear axles
174561 Figure 67
2. Remove the nut guards (if any) and loosen the nuts.
3. Lift the rear end of the vehicle and position it on the service stands.
4. Position the hydraulic jack under the wheels, remove the wheel fastening nuts and remove the wheels.
5. Remove the propeller shaft (2) from the flange (4).
6. Disconnect the air hoses (7) from the actuator (6) and the electric cable (5) from the differential locking indication switch.
7. Disconnect air delivery hoses (1) from the brake cylinders.
8. Detach the brakes by undoing the manual braking screws (3) on the brake cylinders.

682 ‒ Rear axles
174562 Figure 68
9. Disconnect the air hoses (12) from the actuator (11) and the electric cable from the differential locking indication switch.
10. Unscrew the nuts (4) and remove the rear propeller shaft (2) from the intermediate axle (6).
11. Place a hydraulic jack fitted with specific support under the rear axle.
12. Remove the screws (3) and remove the upper longitudinal rod (1) from the rear axle casing.
13. Remove the screws (8) and remove the lower longitudinal rods (5) from the brackets (7).
14. Bring the axle backward so that the shoes (9) withdraw from the leaf springs(10).
.525110. Refitting the intermediate axle

15. To refit, carry out the operations described in the removal process in reverse order, tightening the screws and nuts to the
specified torques.
16. Finally check that no air leakage occurs from pneumatic pipes.
17. The lubricating oil in the axle casing should be at the correct level.
18. Verify that the differential locking indicator light is working correctly.

682 ‒ Rear axles
REPLACING THE DIFFERENTIAL TRANSFER BOX ASSEMBLY ON THE VEHICLE
.526010. REPLACING THE DIFFERENTIAL TRANSFER BOX ASSEMBLY ON THE VEHICLE
Work material
Gearbox support during removal and refitting from 99370629
vehicle.
Support for removal and refitting of transfer box 99370630
between axles
Main action
.526010. Differential transfer box removal
1. Drain the oil by unscrewing the lower cap (3) of the rear axle
casing and the caps (1) epicycloid reduction gear.
2. Remove the propeller shaft (5) from the flange (2) on the
differential-transfer box assembly.
3. Disconnect the electrical connections (4) on the transfer box
engage lock switch.
174494 Figure 69
4. Disconnect air delivery hoses from the brake cylinders (4) by

undoing the couplings (1).
5. Detach the brakes on the intermediate axle by fully undoing the
manual braking screw (3) on the brake cylinders (4).
6. Remove the split pin (2) and disconnect the brake cylinders (4)
from the brake lever (7).
7. Undo the screws (8) and remove the brake cylinders (4) from
the vehicle.
8. Disconnect the air delivery hoses on the transfer box engage
lock actuator (5) acting on the union (6).
174495 Figure 70

682 ‒ Rear axles
REPLACING THE DIFFERENTIAL TRANSFER BOX ASSEMBLY ON THE VEHICLE
9. Unscrew the screws (2) and remove the covers (1) on the
epicycloid reduction gear (3).
Caution!
▶ The differential lock side axle shaft must be released

for a maximum length of about ~ 110 mm.
▶ This is to prevent differential lock engagement inner
sleeve from falling and lodging into the rear axle and
housing, thus preventing extraction of the differential-
transfer assembly from the rear axle housing, given
that the axle shaft guide is no longer present.
10. Slide out the axle shafts (4) so that they are free of the differ-
ential.
174496 Figure 71
11. Underneath the differential-transfer box (2), place a jack with

a specific bracket (4) together with a weighbridge (5) and spe-
cific bracket (6).
code
Support for removal and refitting of transfer box between 99370630
axles
12. Using the nuts (7), put the plate (6) on the differential-transfer
box (2).
13. Unscrew the nuts (3) and screw in the two reaction screws in
the special threaded holes (1) so as to extract the differential-
transfer box assembly (2) from the rear axle casing.
174497 Figure 72
.526010. Refitting the differential transfer box

14. Carry out refitting operations by following the removal opera-
tions in reverse order.
15. Clean thoroughly and apply sealant (LOCTITE 573) on the
contact surfaces of the differential case and axle shaft covers.
16. Make sure that the differential - transfer lock coupling sleeve
(2) is placed properly onto the axle shaft (1) and that it does
not interfere with assembly of the differential-transfer unit
inside the rear axle housing.
17. Make sure that the differential locking fork (3) engages the
sleeve (2).
18. Tighten all the screws to the prescribed torque.
19. fill up the axle housing with oil.
174498 Figure 73

682 ‒ Rear axles
OVERHAULING THE HR INTERMEDIATE AXLE ASSEMBLY
20. Refit the brake cylinders while making sure to unscrew the
manual brake screws.
21. Connect air pipes and electrical connections previously discon-
nected.
174498 Figure 73
.525110. OVERHAULING THE HR INTERMEDIATE AXLE ASSEMBLY

Work material
Note During overhaul of the rear axle, reference is to be made to the manual jaw control adjustment devices. To correctly fit
the automatic devices, refer to the specific procedure .527217. Fitting the automatic adjustment device.
Main action
1. Place rear axle on specific stand for assembly overhauling.
code
185041 Figure 74

682 ‒ Rear axles
2. Drain the oil by unscrewing the lower plug of the rear axle case
(1).
185042 Figure 75
3. Check for oil in the differential housing (1).
185043 Figure 76
4. Drain the oil in the drums by unscrewing the plug (1).
185044 Figure 77

682 ‒ Rear axles
.525140. Epicyclic reduction gear disassembly
Work material
with 99370317)
Main action
1. Remove the two drum fixing screws (1).
185045 Figure 78
2. Insert the reaction screws (1) and detach the hub drum.
185047 Figure 79

682 ‒ Rear axles
3. Use adequate ropes and lifter to detach the drum (1) from the
hub.
185048 Figure 80
4. Unscrew the screws (1) and remove the cover (2).

Note Place a specific container beneath the hub to catch
falling oil.
185049 Figure 81
5. Unscrew the oil level inspection cap (1) and drain the oil from
the bottom cap into the container.
185050 Figure 82

682 ‒ Rear axles
6. Remove the cover (1).
185051 Figure 83
7. Fit the sealing ring (2) and the compensation ring (1).
185052 Figure 84
8. Extract the spacer ring (1);
185053 Figure 85

682 ‒ Rear axles
9. Remove the shaft with the gear (1).
185055 Figure 86
10. Extract the shaft (1).
185056 Figure 87
11. Remove the gear (1) from the end of the shaft.
185057 Figure 88

682 ‒ Rear axles
12. Extract the split pin (1).
185058 Figure 89
13. Fit the reaction lever (1) , using an Allen wrench unscrew the
lock nut (2) and slide away the drive attachment flange (3).
code
99370317)
185060 Figure 90
14. Use a suitable tool (1) to lift the brake shoes (2) and remove
the upper and lower rollers (3); Then remove the retaining
brackets (4) and detach the shoes (2).
Note Before releasing the locking spring of the shoes, tie
these down with a rope for safety reasons.
181988 Figure 91

682 ‒ Rear axles
15. Use the specific tool (1) to loosen the shoe locking spring.
185067 Figure 92
16. Release the springs (1) and remove the shoes (2) of the
brakes.
185068 Figure 93
17. Remove the stop ring (1) from its seat in order to extract the
axle shaft (2).
185069 Figure 94

682 ‒ Rear axles
18. Extract the pin (1) that locks the axle shaft to the rear axle.
185070 Figure 95
19. Remove the safety pin (1).
185071 Figure 96
20. Mark the exact point (1) of assembly on the shaft for sub-
sequent assembly.
185072 Figure 97

682 ‒ Rear axles
21. Remove the stop ring (1) using the specific pliers.
22. Extract the thrust ring (2) and spacer (3).
185074 Figure 98
23. Extract the drive (1) from the axle shaft.
185075 Figure 99
.525130. Wheel hubs disassembly
Work material
Pair of brackets 99341026
Wrench (94.5 mm) for wheel hub bearing adjusting nut 99354207
Drift for fitting bearing external races (134-215 mm) (use 99374094
with 99370007)

682 ‒ Rear axles
Main action
1. Insert the reaction screws (1) and detach the hub.
185077 Figure 100
2. Remove the differential housing assembly (1) using the specific

ropes.
185079 Figure 101
3. Remove the notching using a specific tool (1).
185080 Figure 102

682 ‒ Rear axles
4. Use the specific tool (1) to remove the adjustment flange (2).
code
185081 Figure 103
5. Lift the notching of the regulating ring nut.
185083 Figure 104

682 ‒ Rear axles
6. Remove screw adjustment ring nut (1).
185086 Figure 105
7. Use the specific puller to remove the flange (1).

code
185087 Figure 106
8. Extract the crown wheel (1) and bearing.
185088 Figure 107

682 ‒ Rear axles
9. Remove the wheel hub.
185089 Figure 108
10. Use the specific tool (1) to extract the bearings and the spacer
ring.
code
Pair of brackets 99341026
181993 Figure 109
11. Remove the adjusting ring (1) of the differential shaft.
185091 Figure 110

682 ‒ Rear axles
12. Check the oil manifold (1) undoing the fixing screws (2) and
replace if damaged.
185097 Figure 111
13. Using the specific drift (2) and specific handle, remove under
press the bearing (3) from the hub.
code
Drift for fitting bearing external races (134-215 mm) (use 99374094
with 99370007)
40064 Figure 112
14. Remove the brake axle connecting rod.

Note Repeat the operations described on the other side of
the rear axle.
185092 Figure 113

682 ‒ Rear axles
.525130. Checking the wheel hub components and the epicycloid reduction gear
Main action
1. Carefully clean wheel hub parts. Examine the axle shafts and make sure they are not deformed.
2. If necessary, straighten the axle shafts using a hydraulic press; if this does not provide satisfactory results, replace the axle
shafts.
3. Check the wheel fixing studs; if the threads are damaged or deformed they must be replaced; work under a press to extract
and reassemble the studs, on completion of assembly operations, check that the orthogonal deviation is no greater than 0.3
mm.
4. Lubricate the bearings and rotate the roller cage freely; rotation must be smooth and resistance-free.
5. Check the threads on the hub bearings adjustment nuts and on the load bearing sleeves; replace nuts as required.
6. Check the oil manifold; Replace if damaged. Replace all sealing elements with new ones.
7. Carefully clean all the epicyclic reduction gear components.
8. Visually check the toothing on crown wheel support, crown wheel, planetary and sun gears. Check spacers, shim, bearing
rollers and support pins.
9. Replace any damaged or worn parts.
.525130. Wheel hub mounting
Work material
Tool for checking hub rolling torque (use with torque 99395026
wrench)
Main action
1. Insert the brake axle shaft (1) and the brake engage pin.
185107 Figure 114

682 ‒ Rear axles
2. Insert the stop ring (1) of the axle shaft (2).
185106 Figure 115
3. Tighten the bearing cover (2) fastening screws (1).
185105 Figure 116
4. Insert the crown wheel (1) and bearing.
185088 Figure 117

682 ‒ Rear axles
5. Tighten the flange (1) with the specific tool and torque wrench
(2) to the specified torque.
code
185104 Figure 118
6. Slide on the ring nut spacer (1).
185103 Figure 119

682 ‒ Rear axles
7. From the other side of the rear axle, tighten the flange (1) with
the specific tool and torque wrench (2) to the specified torque.
code
185102 Figure 120
8. Lift the notching using a suitable tool and lock the flange in place.
185101 Figure 121

682 ‒ Rear axles
9. Tighten the drums using the specific tool and torque wrench
and tighten the retainers to prescribed torque, subsequently fill
with oil and check plug level.
code
Tool for checking hub rolling torque (use with torque 99395026
wrench)
185100 Figure 122
10. Insert the axle shaft (1).
185099 Figure 123

682 ‒ Rear axles
11. Insert the hub (1) using specific ropes.
185154 Figure 124
12. Tighten the hub locking screws to the specified torque.
185152 Figure 125
13. Install the gear (1) using the specific tool.
185055 Figure 126

682 ‒ Rear axles
14. Slide on the spacer ring (1) and locking ring (2).
185153 Figure 127
15. Tighten the screws (1) of the cover (2) to the specified torque.
185049 Figure 128
16. Fit the inspection cap (1) of the hub oil level.
Note Upon drum sealing, fill with oil and check plug level (1).
The plug must be sealed using specific sealant. Always
replace the copper gaskets during assembly.
187761 Figure 129

682 ‒ Rear axles
17. Insert the fixing screws (1) of the differential engage lever.
185119 Figure 130
18. Hook the springs (1) and set down the brake shoes (2).
185068 Figure 131
19. Use a suitable tool (1) to lift the brake shoes (2) and insert the
upper and lower rollers (3); then hook the retaining brackets
(4) and mount the shoes (2).
181988 Figure 132

682 ‒ Rear axles
20. Slide the drum (1) onto the hub (2) using specific ropes.
185169 Figure 133
21. Fit the reaction screws (1) to bring drum and hub into contact,
and tighten the nuts that lock the hub to the drum at the pre-
scribed torque.
185047 Figure 134
22. Screw the two drum fixing screws (1).
185045 Figure 135

682 ‒ Rear axles
REMOVAL OF TRANSFER BOX - DIFFERENTIAL (with axle on stand 99322215)
23. Apply a thin layer of LOCTITE 510 sealant on the cover (3) and
planetary gear support (4) contact surfaces and turn cover to
match support pins with indentations on cover.
24. Apply LOCTITE 573 sealant to the thread of the screws (1)
and tightened them to the correct torque (2) using a torque
wrench.
40073 Figure 136
.526010. REMOVAL OF TRANSFER BOX - DIFFERENTIAL (with axle on stand 99322215)
Work material
Main action
1. Turn the rear axle on the stand to proceed with removal of the
differential housing assembly.
code
185098 Figure 137

682 ‒ Rear axles
DIFFERENTIAL TRANSFER CASE UNIT OVERHAUL
2. Undo the screws (1) fixing the differential/transfer box as-

sembly to the axle housing; using lifting device, eyebolt and
metal cables remove the unit from the rear axle housing.
185113 Figure 138
.526010. DIFFERENTIAL TRANSFER CASE UNIT OVERHAUL
Work material
nuts
with 99370317)
Differential support bracket pair for overhauling (use 99371022
with 99322205-99322225)

682 ‒ Rear axles
Main action
.525140. Differential transfer case unit disassembly
1. Place the differential/transfer box assembly on a specific stand
along with support and a pair of brackets.
code
99322205-99322225)
185115 Figure 139
2. Remove the split pin (1) using the specific tool.
185116 Figure 140
3. Fit the reaction lever (2), using an Allen wrench (1) unscrew
the lock nut and slide away the drive attachment flange (3).
code
99370317)
40117 Figure 141

682 ‒ Rear axles
4. Remove the fixing screw (1) of the differential engage lever.
185119 Figure 142
5. Remove the screws (1) fastening the cover.
185120 Figure 143
6. Remove the transfer box / differential assembly using lifting

hooks and ropes.
185121 Figure 144

682 ‒ Rear axles
7. Loosen the nut and extract the flange.
185157 Figure 145
8. Use specific pliers to remove the stop ring by widening it (←)

(→).
185124 Figure 146
9. Remove the screws (1) and the sealing ring (2).
185122 Figure 147

682 ‒ Rear axles
10. Place the assembly of suitable supports to extract the bearings.
185127 Figure 148
.526042. REMOVING THE BEVEL PINION FROM THE SUPPORT

11. Place the assembly (3) in a vice and remove the stop ring (1),
then remove the internal spacer ring (2).
185129 Figure 149

682 ‒ Rear axles
12. Using the specific tool and specific reaction block extract the
bearing seal ring.
code
185130 Figure 150

682 ‒ Rear axles
13. Remove the spacer (1).
185134 Figure 151
14. Remove the planetary gear assembly (1).
185135 Figure 152

682 ‒ Rear axles
15. Remove the bolts (1).
185136 Figure 153
16. Remove the top half cap (1).
185137 Figure 154
17. Remove the gear (1) that mates with the bevelled gear.
185138 Figure 155

682 ‒ Rear axles
18. Extract the four bevelled gears (1).
185139 Figure 156
19. Remove the bevelled gear (2), followed by the stop ring (1).
185140 Figure 157

682 ‒ Rear axles
.526042. Assembly bevelled pinion support

20. Insert the bevelled gear (1), followed by the bevelled ring (2).
185140 Figure 158
21. Insert the four bevelled gears (1).
185139 Figure 159

682 ‒ Rear axles
22. Insert the top half cap (1).
185137 Figure 160
23. Tighten the bolts (1) for coupling of the half cap to the spe-
cified torque.
185136 Figure 161
24. Remove the planetary gear assembly (1).
185135 Figure 162

682 ‒ Rear axles
25. To fit the seal ring (1) of the bearing, heat it before fitting with
the specific tool .
code
185142 Figure 163
26. Fit the stop ring (1) using the specific pliers.
185143 Figure 164
.526010. Checking differential-transfer box components

27. Carefully clean all of individual differential-transfer box components, replacing worn parts and all sealing elements.
Note Carefully clean all the threads to ensure exact adjustments and precise tightening torque values.

682 ‒ Rear axles
Note If either the bevelled gear or pinion need to be replaced, both parts must be replaced as they are supplied as an as-
sembly.
Note Check the bushings mounted in the driven gear and crown wheel unit; if worn, replace using a press.
.526061. Reassembling the differential housing

28. Insert the shoes (1) in the control bracket (2).
Note Make sure that the differential engage adjustment pin is
not released when fitting into the casing.
185151 Figure 165
29. Insert the seal ring (2) and screw in the screws (1).
Note After fitting the bearing, mount the oil seal units using
the specific tool.
185122 Figure 166
30. Use specific pliers to remove the stop ring by widening it (←)
(→).
185124 Figure 167

682 ‒ Rear axles
31. Use LOCTITE sealant to fasten the flange.

Note Verify insertion of the differential sleeve from the ex-
ternal control cap.
185131 Figure 168
32. Fit the flange (1) and tighten securing nut (2) at prescribed
torque.
185125 Figure 169
33. Install the split pin (1) using the specific tool.
185116 Figure 170

682 ‒ Rear axles
.526060. Transfer box casing removal

34. Fix the differential / transfer box assembly onto the specific
stand and support .
code
185155 Figure 171
35. Loosen the securing screws (1) that fasten the retainer casing
to the transfer unit.
185156 Figure 172
36. Position the transfer box onto the bench using the specific
ropes.
185126 Figure 173

682 ‒ Rear axles
37. Mark the gear on toothing (1) for clearance adjustment as in

the figure.
185128 Figure 174
38. Position the differential housing assembly onto the bench using
the specific ropes.
185132 Figure 175
39. Using the specific tool (1) undo the bearing locking nut.
code
185163 Figure 176

682 ‒ Rear axles
40. Extract the bearing using the specific tool (1).

code
185133 Figure 177
41. Remove the shaft (1) from one side of the transfer box and
from the other side remove the bearing (2).
185159 Figure 178

682 ‒ Rear axles
42. Remove the nuts (1) fixing the output motion gear wheel seal
ring.
185160 Figure 179
43. Remove the adjustment shim (1).
185161 Figure 180
44. Remove the stop spacers (1) of the adjustment shim.
185170 Figure 181

682 ‒ Rear axles
45. Remove the securing nuts (1) of the bearing.
185171 Figure 182
46. Fit the two reaction screws (1) to remove the seal bushing (2)
of the bearing.
185274 Figure 183
47. Remove the bearing stop ring (1).
185422 Figure 184

682 ‒ Rear axles
48. Remove the bevelled pinion (1).
185421 Figure 185
49. Remove the toothed wheel (1) from the transfer box.
185420 Figure 186
50. Remove the stop ring (1) using the specific pliers to free the
bearing (2).
185419 Figure 187

682 ‒ Rear axles
51. Remove the bearing (1).
185418 Figure 188
52. Slide the bearing free from the gear wheel shaft.
187163 Figure 189
53. Extract the bearing left in its seat from the casing.
187165 Figure 190

682 ‒ Rear axles
54. Extract the bearing using a drift and plunger.
187164 Figure 191
.526060. Transfer box housing assembly

55. Fit the toothed wheel (1) into the casing.
187166 Figure 192
56. Fit the bearing (1) and heat to simplify shaft refitting.
187167 Figure 193

682 ‒ Rear axles
57. Fit the shaft (1).
187168 Figure 194
58. Seal the bearing using the seal flange via the specific tool (1).
code
187169 Figure 195
59. Fit the toothed wheel (1).
187170 Figure 196

682 ‒ Rear axles
60. Place the thrust ring (1) on the shaft (2).
187171 Figure 197
61. Fit the shim (1).
187172 Figure 198
62. Heat the bearing (1) so that it and the flange are easier to fit
onto the shaft.
187173 Figure 199

682 ‒ Rear axles
63. Tighten the fixing nuts (1) to the prescribed torque.
187174 Figure 200
64. Tighten the bolts (1) of the flange seal ring.
187175 Figure 201
65. Lift the safety tabs using an appropriate tool (1).
187176 Figure 202

682 ‒ Rear axles
66. Fix the differential transfer box assembly onto the rotating
stand (1) and specific support .
code
187177 Figure 203
67. Remove the seal ring (1) from the bevelled gear (2).
187178 Figure 204

682 ‒ Rear axles
68. Undo the locking pin (1).
187179 Figure 205
69. Remove the locking pin (1).
187180 Figure 206
70. Position the specific tool (1) to extract the flange.

code
nuts
187181 Figure 207

682 ‒ Rear axles
71. Remove the flange (1).
187182 Figure 208
72. Remove the nuts using the locking wrench (1) of the cover
bracket (2).
73. Use the specific tool (1) to lift the gear case (2) together with
the tapered roller bearings.
code
187183 Figure 209
74. Remove the bearing protection ring (1).
187184 Figure 210

682 ‒ Rear axles
75. Remove the bearing using a universal puller (1).
187185 Figure 211
76. Lower the screw secure tabs (1) using an appropriate tool in
order to remove the bolts (2).
187186 Figure 212
77. Unscrew the locking bolts (1) of the half cap (2).
185166 Figure 213

682 ‒ Rear axles
78. Lift the half cap (1).
185167 Figure 214
79. Remove the axle shaft gear (1) from the differential housing
assembly (2).
187762 Figure 215
80. Remove the cross-drive shaft, detach the planetary gear and
relative washer.
81. Remove the axle shaft gear and relative washer.
182003 Figure 216

682 ‒ Rear axles
82. Extract the gear (1) and the thrust ring (2).
185114 Figure 217
.526020. Assembling the differential housing assembly

83. Fit the gear (1) with the thrust ring (2).
185118 Figure 218
84. Fit the four planetary wheels (1) and position the gear (2) on
the planetary wheels (1).
185144 Figure 219

682 ‒ Rear axles
85. Close the half cap (1).
185145 Figure 220
86. Tighten the locking nuts (1) of the half cap to the specified
torque.
185141 Figure 221
87. Tighten the locking nuts (1) of the remaining half cap to the
gear wheel at the specified torque.
185146 Figure 222

682 ‒ Rear axles
88. Heat the bevelled bearing (1) before mounting it on the shaft
(2).
185147 Figure 223
89. Use the specific tool (1) to fit the bevelled gear into its seat.
code
185148 Figure 224
90. Tighten the U-bolt mounting nuts (1) to the specified torque.
185149 Figure 225

682 ‒ Rear axles
91. Position the specific tool (1) for flange fitting and tightening.
code
nuts
185150 Figure 226
92. Lock the differential in place to assure that the internal flange
does not fall when fitting the other axle shaft.
187760 Figure 227

682 ‒ Rear axles
93. Fit the axle shaft (1) until engaging the flange (2).
185111 Figure 228
94. Tighten the fixing screws (1) of the differential housing as-
sembly to the prescribed torque.
185112 Figure 229

682 ‒ Rear axles
REFITTING THE DIFFERENTIAL TRANSFER BOX
95. Insert the axle shaft into its seat (1).
185110 Figure 230
.526010. REFITTING THE DIFFERENTIAL TRANSFER BOX
Main action
1. Slowly lower the transfer box assembly into its seat (1).
185109 Figure 231
2. Fully insert the axle shaft (1) and secure the top lock so that the
bevelled gear is firmly mounted with the drive input flange so
that the bottom lock can be fitted.
3. Tighten all the fasteners to the specified torque.
185108 Figure 232

682 ‒ Rear axles
Fitting the automatic adjustment device
.527217. Fitting the automatic adjustment device
Main action
227889 Figure 233

1. Fit the adjustment device according to the direction of the brake cylinder thrust as indicated by the arrow (←).
2. Manually turn the outer hex nut until the holes on the brake
cylinder and adjustment device are correctly aligned.
Note It is not permitted to pull the self-adjusting device or act
on the brake cylinder in order to align the holes.
227890 Figure 234

682 ‒ Rear axles
3. After having aligned the holes, fit the cylinder.
227891 Figure 235
227892 Figure 236

4. Manually turn the control lever (1) in an anti-clockwise direction until it locks at the bracket hole.
Note Do not strike or hit the control lever while it is being turned.
5. Secure the control lever so that it is not inclined or loosened.

682 ‒ Rear axles
6. Turn the outer hex nut in a clockwise direction until it locks.
227893 Figure 237
7. Manually turn the outer hex nut slowly by approximately 270°

in an anti-clockwise direction.
227894 Figure 238
8. Before starting the vehicle, brake fully at least five times with air
pressure of approximately 6 bar. At the same time, check the
self-adjusting device which device must be able to move freely
in order to adjust automatically. If this is not the case, repeat the
fitting operations described above.
227895 Figure 239

682 ‒ Rear axles
122 SR REAR AXLE

682 ‒ Rear axles
SR REAR AXLE 123
Contents
Contents
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 125

682 ‒ Rear axles
124 SR REAR AXLE

682 ‒ Rear axles
SR REAR AXLE 125
DESCRIPTION
SR REAR AXLE
525010 DESCRIPTION
The rear axle is of the single reduction type and contains a reinforced cast steel box. The pinion is supported by two taper roller
bearings and by one straight roller bearing.
Adjustment of the bevel pinion assembly is made through adjusting rings placed between the two taper roller bearings. The rear
axle is provided with a pneumatic-control device for differential locking. The brake is drum type.

Type of rear axle:
Load-bearing, single reduction type with pneumatic
differential locking
Bevelled pinion bearings 2 with bevelled rollers and 1 with cylindrical rollers
5.286(7/37) - 4.625(8/37) - 4.111(9/37) - 3.7(10/37) -

Bevelled gear pair reduction ratio
3.36(11/37) - 3.083(12/37) - 2.846(13/37)
Bevelled drive pinion bearing rolling torque

new bearings Nm 1.5 ~ 4.0
old bearings Nm 1.5 ~ 3.0
27.73 - 27.76 - 27.79 - 28.33 - 28.36 - 28.39 - 28.93 -

Thickness of bevelled pinion bearing rolling
mm 28.96 - 28.99
torque adjustment shims
0.1 - 0.2 - 0.5
Clearance between pinion and crown wheel mm 0.20 ÷ 0.48
WHEEL HUBS
Wheel hub bearings Two tapered rollers type
Preload Nm 3.0 ~ 5.0
Axle shaft end clearance mm 0.1 ~ 0.15

quantity 4x2 Vehicles 17 litres
6x4 vehicles 24.4 (22 + 1.2x2) litres

682 ‒ Rear axles
126 SR REAR AXLE
TIGHTENING TORQUES
11
2
10 z
4
8
z
7 5
39383 Figure 240

DIFFERENTIAL CASING
TORQUE
DETAIL
Nm (kgm)
1 Bevelled pinion lock nut 1000 ± 100 100 ± 10
2 Bevelled pinion support to differential carrier securing screw 193.5 ± 13.5 19.3 ± 1.3
3 Screw for securing differential housing to rear axle unit 235 ± 35 23.5 ± 3.5
4 Bevelled gear to differential carrier securing screw 485 ± 35 48.5 ± 3.5

682 ‒ Rear axles
SR REAR AXLE 127
TIGHTENING TORQUES
86768 Figure 241

WHEEL HUB SECTION
TORQUE
DETAIL
Nm (kgm)
1 Axle shaft retaining screws 295 ÷ 315 (30 ÷ 32)
2 Wheel mounting nut 600 +50
-20 (60 +5
-2)
3 Load bearing sleeve securing screw 275 ÷ 305 (2.8 ÷ 3.1)

4 Drum fastening screw 36 – 44 (3.6 ÷ 4.4)
5 Adjustment ring nuts 500 (50)

682 ‒ Rear axles
128 SR INTERMEDIATE AXLE

682 ‒ Rear axles
SR INTERMEDIATE AXLE 129
Contents
Contents
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 131

682 ‒ Rear axles

682 ‒ Rear axles
DESCRIPTION
SR INTERMEDIATE AXLE
525110 DESCRIPTION
The intermediate axle is of the load-bearing, single reduction type. The differential housing, with bevelled gear, is supported by two
tapered roller bearings, which can be adjusted by means of two threaded ring nuts.
The bevelled pinion is supported by two tapered roller bearings, which can be adjusted by means of adjustment shims. The inter-
mediate axle is fitted with a flow divider unit that distributes the torque between the two axles. The axle is also provided with a
differential locking pneumatic device and another distributor locking device. The brake is drum type.

Type of rear axle:
Load-bearing, single reduction type with pneumatic
differential locking
Bevelled pinion bearings 2 with bevelled rollers and 1 with cylindrical rollers
5.286(7/37) - 4.625(8/37) - 4.111(9/37) - 3.7(10/37) -

Bevelled gear pair reduction ratio
3.36(11/37) - 3.083(12/37) - 2.846(13/37)
27.73 - 27.76 - 27.79 - 28.33 - 28.36 - 28.39 - 28.93 -

Thickness of bevelled pinion bearing rolling torque
mm 28.96 - 28.99
adjustment shims
0.1 - 0.2 - 0.5
Clearance between pinion and crown wheel mm 0.20 ÷ 0.48
Differential axle ring spacers mm 0.1 - 0.15 - 0.5

Differential axle bearings mm 2 with tapered rollers
Wheel hub bearings 2 with tapered rollers
Wheel hub bearing rolling torques: Nm 3.0 ~ 5.0
Wheel bearings final clearance Nm Using adjustment rings

quantity litres 22.4 (20 + 1.2x2)
– kg 20.5

682 ‒ Rear axles
TIGHTENING TORQUES
174449 Figure 242
TORQUE
DETAIL
Nm (kgm)
1 Input shaft fastening screw M12x1.75 100 ÷ 145 (10.1 ÷ 14.7)
2 Shaft to flange fastener M45x1.5 815 ÷ 1085 (83 ÷ 110.6)
3 Pinion screw M45x1.5 1220 ÷ 1765 (124.3 ÷ 180)
4 Pinion fastener guard M10x1.5 40 ÷ 70 (4 ÷ 7.1)
5 Fastening screw M26x1.5 > 65 (> 6.6)
6 Nuts fixing the oil pump to the cable gland 30 ÷ 45 (3 ÷ 4.5)
7 Guard fastening screw M20x2.5 430 ÷ 540 (43.8 ÷ 55)
8 Output shaft fastening screw M35x1.5 610 ÷ 880 (62.1 ÷ 6.9)

682 ‒ Rear axles
TIGHTENING TORQUES
TORQUE
DETAIL
Nm (kgm)
9 Output shaft cable gland fastening screw 47 ÷ 68 (4.7 ÷ 6.9)
10 Cylindrical distributor fastening screw M60x2 109 ÷ 136 (11.1 ÷ 13.8)
77210 Figure 243
TORQUE
DETAIL
Nm (kgm)
10 Sensor wheel nut M16x1 35 ÷ 75 (3.5 ÷ 7.6)

682 ‒ Rear axles
TIGHTENING TORQUES
77210 Figure 243
TORQUE
DETAIL
Nm (kgm)
11 Differential cylinder fastener M16x1 109 ÷ 136 (11.1 ÷ 13.8)
12 Half housing fastener M12x1.75 130 ÷ 155 (13.2 ÷ 15.8)
13 Half housing fastener M16x1.5 220 ÷ 290 (22.4 ÷ 29.5)
14 Oil filter fastener M22x2.5 55 ÷ 80 (5.6 ÷ 8.1)

682 ‒ Rear axles
TIGHTENING TORQUES
86768 Figure 244
TORQUE
DETAIL
Nm (kgm)
1 Axle shaft fastening nut 295 ÷ 315 (30 ÷ 32)
2 Wheel fastening nut 600 +50
-20 (60 +5
-2)
3 Load bearing sleeve securing screw 275 ÷ 305 (2.8 ÷ 31)
4 Drum securing screws 36 – 44 (3.6 ÷ 4.4)
5 Adjustment ring nuts 500 (50)

682 ‒ Rear axles
TIGHTENING TORQUES
86769 Figure 245

Wheel hub section
77211 Figure 246

Detail of wheel hub section for versions with ABS

682 ‒ Rear axles
DIAGNOSTICS 137
Contents
Contents
Faulty gearbox noise . . . . . . . . . . . . . . . . . . . . . 139
Lubricant leaks . . . . . . . . . . . . . . . . . . . . . . . . 139
Wheel hub bearing uneven or loose . . . . . . . . . . . 139
Seized braking system components that case the

drum brake to overheat . . . . . . . . . . . . . . . . . . 140
The vehicle pulls to one side when braking. . . . . . . 140
Elevated hub temperature . . . . . . . . . . . . . . . . . 141
Jerk at starting . . . . . . . . . . . . . . . . . . . . . . . . 141

682 ‒ Rear axles
138 DIAGNOSTICS

682 ‒ Rear axles
DIAGNOSTICS 139
Faulty gearbox noise
DIAGNOSTICS
Faulty gearbox noise
1 Differential gear clearance not correct. Cause confirmed ▶ Replace the shoulder ring or the gear.
2 Drive gear and conduit clearance not cor- Cause confirmed ▶ Adjust the adjustment ring or replace
rect. the sealing washer of the bearing.
3 Damaged bearing. Cause confirmed ▶ Replace the bearing.
4 Axle shaft gear, planetary and washer worn Cause confirmed ▶ Replace all defective components.
or damaged. Cause not confirmed Check: 5
5 Damaged gear. Cause confirmed ▶ Replace the gears.
6 Metallic dust or foreign bodies in the lubric- Cause confirmed ▶ Change the lubricant oil.
ant oil. Cause not confirmed ▶ Contact the Service Network.
Lubricant leaks
1 Oil retainer ring worn, loose or damaged. Cause confirmed ▶ Remove the oil retainer ring.
2 Sealant damaged. Cause confirmed ▶ Re-apply the sealant.
3 Mounting bolt loose. Cause confirmed ▶ Tighten the bolts to the recommended
torque.
4 Drain plug loose. Cause confirmed ▶ Tighten the plug to the specified
torque or replace it.
5 Breather plug blocked. Cause confirmed ▶ Clean or replace the breather plug.
Wheel hub bearing uneven or loose

1 Pre-tensioning strength of wheel hub bearing Cause confirmed ▶ Adjust the pre-tensioning strength.
too high. Cause not confirmed Check: 2
2 No lubrication for bearing or impurities in Cause confirmed ▶ Clean or replace the lubricant.
the lubricant. Cause not confirmed Check: 3
3 Pre-tightening strength of the bearing too Cause confirmed ▶ Adjust again.
low. Cause not confirmed Check: 4
4 Damaged bearing. Cause confirmed ▶ Replace the bearing.

682 ‒ Rear axles
140 DIAGNOSTICS
Seized braking system components that case the drum brake to overheat
Seized braking system components that case the drum brake to overheat
1 Too little clearance between brake shoe Cause confirmed ▶ Adjust again.
friction pad and brake drum. Cause not confirmed Check: 2
2 Loss of brake drum roundness. Cause confirmed ▶ Revise, the loss of roundness should
not exceed 0.35 mm.
3 Brake shoe deformation. Cause confirmed ▶ Calibrate or replace.
4 Brake shoe support pin or camshaft seized. Cause confirmed ▶ Lubricate. After lubricating, replace the
bushing if necessary.
5 Friction pad worn or broken. Cause confirmed ▶ Replace.
6 Brake shoe return spring stretched or Cause confirmed ▶ Replace.
broken. Cause not confirmed Check: 7
7 Spring brake not fully released. Cause confirmed ▶ Check and replace the spring brake
pipe.
The vehicle pulls to one side when braking.

1 The tyre pressure does not comply with the Cause confirmed ▶ Check/replace.
required pressure for the type of tyre. Cause not confirmed Check: 2
2 Adjustment does not correct brake clear- Cause confirmed ▶ Adjust again.
ance. Cause not confirmed Check: 3
3 Different friction pad wear. Cause confirmed ▶ Replace or repair.
4 Brake shoe friction pad contaminated by Cause confirmed ▶ Wash with petrol or alkaline water
sludge or degraded. and air dry.
5 Different friction pad materials. Cause confirmed ▶ Replace the friction pad with one
made of the same material.
not exceed 0.35 mm.

682 ‒ Rear axles
DIAGNOSTICS 141
Elevated hub temperature
Elevated hub temperature

1 Insufficient lubricant. Cause confirmed ▶ Add lubricant.
2 Oil incorrect or perishable. Cause confirmed ▶ Replace.
3 Too little clearance between brake shoe Cause confirmed ▶ Adjust again.
friction pad and brake drum. Cause not confirmed Check: 4
not exceed 0.35 mm.
5 Friction pad worn or broken. Cause confirmed ▶ Replace.
Jerk at starting
1 Bevelled gear engagement clearance too high. Cause confirmed ▶ Readjust the bevelled gear engagement
clearance.

682 ‒ Rear axles
142 DIAGNOSTICS

682 ‒ Axles
Contents 1
Contents
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 3

682 ‒ Axles
2 Contents

682 ‒ Axles
FRONT AXLE 3
Contents
Contents
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CENTRAL REMOVAL - REFITTING . . . . . . . . . . . . 10
VEHICLE ONBOARD CHECKS . . . . . . . . . . . . . . 13

Checking transverse tie rods . . . . . . . . . . . . . . 13
Ball joints check . . . . . . . . . . . . . . . . . . . . . . 13
AXLE ASSEMBLY OVERHAUL . . . . . . . . . . . . . . . 13
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 24
Stiff steering . . . . . . . . . . . . . . . . . . . . . . . . 24
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

682 ‒ Axles
4 FRONT AXLE

682 ‒ Axles
FRONT AXLE 5
DESCRIPTION
FRONT AXLE
520610 DESCRIPTION
Front axle
172700 Figure 1
1 Stop circlip 11 Hexagon head bolt
2 Adjustment washer 12 Brake cam shaft
3 Washer 13 Roller
4 Clearance adjustment arm 14 Return spring pin
5 Sleeve 15 Return spring
6 O-ring 16 Brake shoe assembly
7 Auxiliary washer 17 Bush
8 Seal ring 18 Plate position limited
9 Dust sealing assembly 19 Split pin
10 Spring washer 20 Hexagon nut surface

682 ‒ Axles
6 FRONT AXLE
DESCRIPTION
172700 Figure 1
21 Drum brake 37 Steering joint assembly
22 Cross bevelled screw 38 Steering linkage
23 Hexagon head bolt 39 Split pin
24 Spring washer 40 Hexagon nut surface
25 cover 41 Cylindrical pin
26 Hexagon nut 42 O-ring
27 Split pin 43 Adjusting screw
28 Washer 44 Support assembly
29 Single tapered roller bearing 45 Threaded nipple
30 Wheel bolt 46 Self-locking nut
31 Wheel nut 47 Stud
32 Front wheel drum assembly 48 Self-locking nut
33 Single tapered roller bearing 49 Steering joints
34 Gasket 50 Steering tie rod
35 Caulking ring 51 Axle joint pin
36 Brake shoe support pin

682 ‒ Axles
FRONT AXLE 7
52 Clearance adjustment spacer 53 Thrust bearing
Type of front axle CF7140 axle
STEERING JOINT
Clearance between axle and X1 steer-

mm 0.05 - 0.10
ing joint upper washer
S specific washer spacer mm 2 -2.1-2.2-2.3-2.4-2.5-2.6-2.7-2.8-2.9-3.0-3.1-3.2-3.3-3.4
Stub axle pin deviation angle – 3⁰
WHEEL HUBS
Wheel hub bearings 2, tapered roller bearing
Grease for wheel hub bearing Lithium grease (Tutela MR2 or MR3)
Amount per hub kg 1
WHEEL GEOMETRY
Wheel caster angle 1⁰
Stub axle pin inclination angle 3⁰
Wheel toe-in 4x2 - 6x4 models Models 8X4

Belted tyre mm 2-4 2-4
Radial tyre mm 0-2 0-2
Models 8X4
4x2 - 6x4 models
1st front axle 2nd front axle
b
Front wheels maximum steering angle Internal External Internal External Internal External
a
β β β β β β
35⁰ 45⁰ 35⁰ 45⁰ 29⁰ 38⁰
Axle weight (excluding steel wheels and
kg 450-470
tyres)
Nominal load capacity (capacity subject
to various conditions) See the values
kg 6500-7100-7500
on the vehicle nameplate for correct
figures.

682 ‒ Axles
8 FRONT AXLE
TIGHTENING TORQUES
172913 Figure 2
TIGHTENING TORQUES
TORQUE
DESCRIPTION
Nm (kgm)
1 Locking nut 70 ÷ 80 (7 ÷ 8)
2 Junction pin joint locking nut 265 - 325 (26.5 - 32.5)
3 Nuts on the steering joints 275 ÷ 335 (27.5 ÷ 33.5)
4 Screw fixing top bracket to stub axle 120 ÷ 160 (12 ÷ 16)
5 Screw fixing steering joint linkage 265 - 325 (26.5 - 32.5)
6 Screw fixing steering joint retaining plate 23 (2.3)
7 Brake shoe fastening nuts 256 ÷ 325 (25.6 ÷ 32.5)
8 Slotted hex nuts used to tighten the wheel bearing 450 (45)
9 Screws fixing cover and front wheel hub 23 (2.3)

682 ‒ Axles
FRONT AXLE 9
TOOLS
TOOLS
Extraction tool for steering linkage head pins (99347068)
Support for axle removal and refitting (99370628)

682 ‒ Axles
10 FRONT AXLE
CENTRAL REMOVAL - REFITTING
.520610. CENTRAL REMOVAL - REFITTING
Work material
Extraction tool for steering linkage head pins 99347068
Support for axle removal and refitting 99370628

682 ‒ Axles
FRONT AXLE 11
Main action
.520610. Axle removal
172914 Figure 3
1. Park the vehicle on flat ground and block the rear wheels.
2. Slacken off the front wheel nuts.
3. Using a hydraulic jack, raise the front of the vehicle and rest it on two stands.
4. Remove the wheel fixing nuts and take off the wheel.
5. Using the specific extractor (2) disconnect the swivel head of the tie rod (4) from the lever (3).
6. Unscrew the nuts (5) and (1) and remove the stabiliser bar (6).
7. Disconnect the pneumatic pipes (7) from the diaphragm brake cylinder.
8. ABS transmitter electric cable (if present).

682 ‒ Axles
12 FRONT AXLE
172915 Figure 4
9. Unscrew the nuts (1) fastening the shock absorber.
10. Place a hydraulic jack (4) equipped with support under the front axle.
Support for axle removal and refitting 99370628
11. Loosen the nuts (2) and remove the stands (3).
12. Lower the hydraulic jack and extract the axle (4).
.520610. Refitting the axle

Caution!
▶ Check and adjust the front wheel geometry.
13. For refitting, perform in reverse order the operations that have been described for removal.

682 ‒ Axles
FRONT AXLE 13
VEHICLE ONBOARD CHECKS
VEHICLE ONBOARD CHECKS

.520635. Checking transverse tie rods
Main action
1. Check nuts and bolts of terminals: there should be no signs of wear and they must be tightened to the prescribed torque; the
tie rods must not be damaged or deformed.
2. Otherwise, replace them.
.520636. Ball joints check
Main action
1. Clean traverse and longitudinal tie rod ball joints.
2. Check that king pin components do not show signs of deterioration or breakage.
3. Otherwise replace as necessary.
4. Checking ball joint clearance for transversal tie-rod

and longitudinal tie-rod.
5. The vehicle does not need to be lifted.
6. With a gauge (1) measure distance "X" with the vehicle in
straight running position.
7. Repeat the measurement in the bottom left steering position
(X 1) and on the right (X 2);
8. note the values found.
9. Calculate the clearance "A" according to the following formula:
A = B - X , where B is the largest of the measurements X1 and
X2.
10. If the value is more than 2 mm replace the ball joint. 36914 Figure 5
.520610. AXLE ASSEMBLY OVERHAUL
Consumables
MR3 grease
Work material
Tightening torques
Hexagonal bolt - king pin bolt 450 N⋅m
Hexagonal bolts 23 N⋅m

682 ‒ Axles
14 FRONT AXLE
AXLE ASSEMBLY OVERHAUL
Nuts torque Nuts torque 275 N⋅m to335 N⋅m

Swivel head nuts Swivel head nuts torque 265 N⋅m to325 N⋅m
Retaining_nut Retaining nut torque 70 N⋅m to80 N⋅m
Retaining_screws Retaining screws torque 265 N⋅m to325 N⋅m
Hexagon nut Hexagon nut torque 256 N⋅m to325 N⋅m
Hexagonal head bolts 23 N⋅m
Self-locking nuts Self-locking nuts 120 N⋅m to160 N⋅m
Nuts - tie-rod Nut - tie-rod 70 N⋅m to80 N⋅m
Main action
1. Using a suitable tool, lift the axle assembly (1) onto the specific
stand (2) and fasten it for overhaul.
code
173580 Figure 6
.520620. Wheel hub removal

2. Loosen the screws (1) and elastic washers, remove the cover
(2).
172916 Figure 7

682 ‒ Axles
FRONT AXLE 15
3. Unscrew the screws (2) securing the brake drum (1).

4. Insert two screws (3) in the brake drum(1).
5. Tighten them gradually until separation of the drum (1) from
the wheel hub is achieved.
172917 Figure 8
6. Extract the split pin (1), remove the hexagonal nut (2) and the
washer (3) using the specific wrench, then extract the external
bearing (4), the wheel hub, the internal bearing and the spacer
ring with a universal extractor.
code
172918 Figure 9
.520622. Sealing ring replacement

7. Use a suitable drift to remove the seal (1) from the hub (3).
8. Use the drift to extract the external ring of the bearing (2) at
the two sides of the front wheel hub.
Note Check that the surface of the hub is not battered.
172919 Figure 10

682 ‒ Axles
16 FRONT AXLE
9. Clean the bearing and apply oil to the outside.

10. Position the external ring and press it into the seat of the front
wheel hub.
11. Turn over the front wheel hub and press the outer ring of the
bearing into the other side using the same method.
172920 Figure 11
12. Fit the seal (3) with the keying device (1) and the hand shank
(2).
13. Apply universal lithium lubricant for vehicles to the tracks of
the external bearing rings and the seal ring on both sides of the
front wheel hub.
40364 Figure 12
14. Assembly position of the seal ring (a) in the wheel hub (b).
49142 Figure 13

682 ‒ Axles
FRONT AXLE 17
.520625. Replacing wheel studs

15. Remove the studs (1) using suitable pressure.
16. Ensure that the contact surface of the heads of the studs on the
front wheel hub is free of burrs.
17. Accurately position the studs; The machined margin must be
correctly positioned in the seat on the hub and pressed into
place.
40369 Figure 14
.520620. Wheel hub refitting

18. Heat the spacer ring (1) to 100°C fit it on the king pin bolt (3)
with a drift, heat the internal ring of the tapered roller bearing
(2) to 100°C and fit it outside of the spacer ring.
Note Make sure that surfaces of all parts inside the wheel
hub are accurately clean, free from burrs.
172921 Figure 15
19. Fit the front wheel hub assembly (1) on the stub axle pin.
20. Then fit the external bearing (2) and the washer (3).
21. Wait for the bearing to cool and grease it as follows:
22. Refill the internal compartment of the hub with the prescribed
grease. Grease the bearing (2).
Tool / Material
MR3 grease
172922 Figure 16

682 ‒ Axles
18 FRONT AXLE
.520620. Wheel hub bearing end clearance adjustment

23. Screw the hexagonal nut (2) with the specific wrench on the
stub axle pin to the specified torque.
Tightening torque
Hexagonal bolt - king pin bolt 450 N⋅m

code
24. To correctly assemble the bearings give a few hits in the axial
direction on the front wheel hub with a brass bar.
25. The front wheel hub should not be manually turned, or should
be very difficult to turn.
26. Loosen the hexagonal nut by about 120°.
27. The hexagonal nut must be aligned with the hole in the split pin.
28. Give a few hits in the axial direction on the front wheel hub 172923 Figure 17
with a brass bar.; the wheel hub should move without force, it
should not lock and the washer should not move.
29. Fit the split pin (1) and lock it.
30. Clean the surface of the front wheel hub, apply sealant to the
surface internally with respect to the threaded holes, secure the
cover (4), the elastic washers and the hexagonal bolts (3).
31. Tighten the hexagonal bolts to the recommended torque.
Tightening torque
Hexagonal bolts 23 N⋅m
32. Fit the brake drum (1) on the front wheel hub and secure in
position with the two screws (2).
172924 Figure 18
.520632. Steering lever removal - refitting

33. Using a wrench, loosen the nuts (1) e and remove the steering
lever (2).
34. For refitting reverse the order of the operations carried out for
the removal, tightening the nuts to the recommended torque.
Tightening torque
Nuts torque Nuts torque
275 N⋅m to335 N⋅m
172925 Figure 19

682 ‒ Axles
FRONT AXLE 19
.520635. Transverse tie rod removal and refitting

.520635. Transverse tie bar removal
35. Straighten out and take off the split pin (1).
36. Unlock the nut (2) and partially unscrew it so as to prevent the
rod falling at the time of removal.
43370 Figure 20
37. Free the lever (3) from the swivel head (2) with the specific
extractor (1).
code
38. Repeat the same operation on the opposite side.

39. Completely unscrew the nuts and remove the linking assembly.
40371 Figure 21
.520635. Track rock refitting

40. To fit, carry out the operations described in the removal process in reverse order.
41. Tighten the nut of the swivel head to the specified torque.
Tightening torque
Swivel head nuts Swivel head nuts torque
265 N⋅m to325 N⋅m
42. Fit the split pin and lock it well.
.520636. Tie rod ball joint replacement

43. Lock the screw (4), loosen the nut (3) and unscrew the ball
joint (2) from the tie-rod (1).
Note To facilitate reattachment of the tie rod and adjust-
ment of wheel convergence, note the number of turns
needed to loosen each joint so as to screw in the new
ones with the same number of turns.
44. Screw in the new tie-rod joint and tighten to the specified
torque with the retaining nut (3).
71755 Figure 22

682 ‒ Axles
20 FRONT AXLE
Tightening torque
Retaining_nut Retaining nut torque
70 N⋅m to80 N⋅m
45. Check and adjustment the convergence (if necessary).

Note The terminal (5) must be tightened with the nut (posi-
tioned in one of the set-ups shown in the figure) (3).
71755 Figure 22
.520631. Transverse tie rod lever removal and refitting

46. Remove the split pin and use a wrench to unscrew the nuts (1)
and remove the tie-rod lever (2).
process in reverse order, tightening the retaining screws to the
specified torque.
Tightening torque
Retaining_screws Retaining screws torque
265 N⋅m to325 N⋅m
Note The widest end of the bevelled hole of the tie-rod

lever must be facing up.
172926 Figure 23
.527016. Removing - reassembling the brake control shaft

.527016. Removing the brake control shaft
48. Check that the braking gasket is not worn and replace it when the thickness is ≤ 6.7 mm as described in the relative chapter
"Removal - refitting of the brake shoe assembly" (527012 Brake shoe replacement ).
49. Remove the return spring (6) and the split pins (2), loosen the
hexagonal nuts (3) e and the retaining plate (1).
50. Remove the roller (7) and the brake shoe assembly (5).
51. Remove the pins (4) supporting the brake shoes.
172928 Figure 24

682 ‒ Axles
FRONT AXLE 21
52. Remove the circlip, the spacer, the gasket and the washer with
pliers.
53. Unscrew the nut (1) and extract the brake control shaft (3)
and remove the brake clearance adjustment lever assembly
(2)the washer and the O-ring.
172929 Figure 25
.527016. Refitting the brake control shaft

54. To fit, carry out the operations described in the removal process in reverse order.
Tightening torque
Hexagon nut Hexagon nut torque
256 N⋅m to325 N⋅m
Note Once the roller is fitted, the brake shoe should open when the brake lever is activated, and close when the lever is
released. If this is not the case, check the assembly conditions of each part to verify that there are not problems.
55. While installing the brake clearance adjustment assembly (2), ensure that the axial clearance of the assembly (2) is between
0.5 - 0.8 mm, choosing a suitable spacer thickness.
Note The control shaft should freely turn when the adjustment lever is activated.
Note After replacing the brake control shaft adjust the brake shoe clearance.
.527019. Removal - refitting of brake dust sealing assembly

56. Remove the hexagonal head bolts (2) and the elastic washers
and remove the brake dust sealing assembly (1).
57. To fit, carry out the operations described in the removal pro-
cess in reverse order.
Tightening torque
Hexagonal head bolts 23 N⋅m
172930 Figure 26

682 ‒ Axles
22 FRONT AXLE
.520611. Removal - refitting of the stub axle assembly

.520611. Removal of the stub axle assembly
58. Using a wrench, loosen the nuts (3), beat with a brass bar and
remove the bracket assembly (1).
59. Remove the stub axle assembly (2).
172931 Figure 27
60. Remove the spacer (1) and the bearing (2).
172932 Figure 28
.520611. Refitting the stub axle assembly

61. Remove all the burrs from all mounting surfaces and holes, and
clean.
62. Align the nylon bearing protective ring surface with the surface
of the axle, and place it on the stub axle pin (2).
63. Fit the stub axle (1) on the stub axle pin (2) after sufficiently
greasing the inside of the joint bushing.
64. Keep the correct position of the stub axle and measure distance
A between the upper surface of the stub axle and the upper
surface of the axle with a gauge.
172933 Figure 29

682 ‒ Axles
FRONT AXLE 23
65. Measure the protrusion length B on the bracket (1).

66. Position a suitable spacer (1) between the top surface of the
axle and the stub axle (gasket thickness A-B-0.1 mm) and en-
gage the cylindrical pin (3) in the seat on the stub axle (2).
67. Install the O-ring inside the hole in the bracket (1) and position
the bracket in the hole of the stub axle (3), hitting it with a
brass bar.
172934 Figure 30
68. Ensure that the flap (3) and the tie-rid(4) are on the same side
as the cross member.
69. Fasten the front bracket (5), the brake clearance adjustment
lever (2) and the washer (6) to the stud.
70. Flex and tighten the 4 self-locking nuts (1) to the specified
torque.
Tightening torque
Self-locking nuts Self-locking nuts
120 N⋅m to160 N⋅m
173546 Figure 31
.520611. Inspection and registration of axial clearance of

the steering joint
71. Measure the axial clearance of the steering joint with a feeler
gauge (4).
72. The permitted interval is between 0.05 and 0.1 mm.
73. Apply a suitable tool to the stub axle (2) that rotates the joint
at a constant speed and verify that there are no obstacles to the
rotation.
74. If the clearance is not correct, remove the bracket (1) and
replace the gasket (3) until axial clearance is correct.
75. Adjust the axial clearance of the steering joint with spare wash-
ers of a suitable thickness.
76. The descriptions for the thickness of the spare washer are
provided in the Characteristics and Data table. 173547 Figure 32
77. Use a greaser to lubricate until the grease comes out of the
stub axle pin.

682 ‒ Axles
24 FRONT AXLE
DIAGNOSTICS
.520610. Adjusting front wheel convergence

78. Loosen the locking nut (3) on the tie-rod (1), measure and
adjust the convergence.
79. Measure the distance between the right and left brake hubs (2)
on the outer diameter; the measured value on the opposite side
of the tie-rod is A and the value measured on the same side of
the tie-rod is B.
80. It is compliant if B -A= (2 - 4)mm. If it is not compliant, turn the
tie-rod and adjust it again until it is compliant.
81. After adjustment, proceed to tighten the nut (3) on the tie-rod.
Tightening torque
Nuts - tie-rod Nut - tie-rod
70 N⋅m to80 N⋅m 173548 Figure 33
DIAGNOSTICS
Stiff steering

1 Incorrect convergence Cause confirmed ▶ Accurately adjust the convergence of
the front wheels.
2 Tyre pressure irregular Cause confirmed ▶ Inflate tyres to specified pressure.
3 Clearance adjustment between steering com- Cause confirmed ▶ Re-adjust.
ponents incorrect Cause not confirmed Check: 4
4 Incorrect adjustment of swivel heads Cause confirmed ▶ Re-adjust.
5 Steering limit screw loosened or bent Cause confirmed ▶ Tighten or replace the steering limit
screw.
6 Stub axle pin bushing worn Cause confirmed ▶ Replace the stub axle pin bushing.
Cause not confirmed
Shimming

1 Nuts fastening the steering level are Cause confirmed ▶ Tighten again.
loosened Cause not confirmed Check: 2
2 Ball joints excessively worn Cause confirmed ▶ Replace the defective ball joints.
3 Excessive stub axle steering clearance Cause confirmed ▶ Re-adjust or replace the shock absorb-
ing bearing.
4 Insufficient tightening of front wheel hub Cause confirmed ▶ Re-adjust the tightening force of the
bearing.
5 Excessive wear of the stub axle pin bushing Cause confirmed ▶ Replace the stub axle pin bushing.

682 ‒ Axles
FRONT AXLE 25
DIAGNOSTICS

5 Excessive wear of the stub axle pin bushing Cause not confirmed Check: 6
6 Stub axle pin bushing worn Cause confirmed ▶ Replace the brake shoe assembly.
7 Irregular contact of the drum and the brake Cause confirmed ▶ Re-bore it and check that the round-
shoes, or excessive difference in the right ness is 0.35 mm.
and left contact surfaces Cause not confirmed
Noise

1 Insufficient lubrication of wheel hub bearings Cause confirmed ▶ Add sufficient grease.
2 Wheel hub bearings worn Cause confirmed ▶ Replace the defective bearing and
adjust the axial clearance.
3 Stub axle pin bushing worn Cause confirmed ▶ Replace the stub axle pin bushing.

682 ‒ Axles
26 FRONT AXLE

682 ‒ Suspensions
Contents 1
Contents
SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 25

682 ‒ Suspensions
2 Contents

682 ‒ Suspensions
SUSPENSIONS 3
Contents
Contents
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Shock absorbers . . . . . . . . . . . . . . . . . . . . . . 15
FRONT SUSPENSION WITH PARABOLIC LEAF
SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REAR SUSPENSION WITH SEMI-ELLIPTICAL
LEAF SPRINGS (4x2 vehicles) . . . . . . . . . . . . . . 16
REAR SUSPENSION WITH PARABOLIC LEAF
SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 17
"CANTILEVER" REAR SUSPENSION WITH
PARABOLIC LEAF SPRINGS . . . . . . . . . . . . . . 18
General torques . . . . . . . . . . . . . . . . . . . . . . 18
FRONT LEAF SPRING REMOVAL - REFITTING . . . . 20
REMOVAL - REFITTING OF FRONT SHOCK

ABSORBERS . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL - REFITTING OF THE FRONT

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL - REFITTING OF REAR LEAF SPRING

(6x4 - 8x4 vehicles) . . . . . . . . . . . . . . . . . . . . . . 23

682 ‒ Suspensions
4 SUSPENSIONS

682 ‒ Suspensions
SUSPENSIONS 5
DESCRIPTION
SUSPENSIONS
5004 DESCRIPTION
Front suspension
The front suspension system is comprised of parabolic or semi-elliptical leaf springs with double-acting hydraulic shock absorbers
and an anti-roll bar.
Rear suspension
4x2 Vehicles: Parabolic or semi-elliptical leaf springs with double-acting hydraulic shock absorbers and anti-roll bars.
6x4 and 8x4 vehicles: Parabolic or semi-elliptical leaf springs and anti-roll bars.
Front suspension components
174417 Figure 1
1 Quick release support 5 Steel leaf spring
2 Quick release 6 Shock absorber
3 Leaf spring pin 7 Leaf spring pressure
4 Clearance adjustment gasket 8 Rubber stop

682 ‒ Suspensions
6 SUSPENSIONS
DESCRIPTION
Rear suspension components
174418 Figure 2
1 Quick release 6 Pressure part
2 Leaf spring pin 7 Rubber stop
3 Clearance adjustment gasket 8 Limited support
4 Steel leaf spring 9 Quick release support
5 U-bolt

682 ‒ Suspensions
SUSPENSIONS 7
Rear suspension with rocker arm suspension
174419 Figure 3
1 Steel leaf spring 5 Rocker arm shaft assembly
2 U-bolt 6 Thrust lever
3 Leaf spring pressure part 7 Rubber stop
4 Side position limit plate

Front suspension: light version vehicles
Parabolic leaf springs No. 2
L
Leaf spring length (measured at eyelet centre) mm 1800 ± 3
Leaf spring H height

P = 0 (N) mm 120 ± 6
P = 31230 (N) mm 20 ± 6
Leaf thickness (measured at centre)
S
1st leaf mm 25
2nd and 3rd leaf mm 28.5
S Thickness between leaves mm 3

682 ‒ Suspensions
8 SUSPENSIONS
Leaf width mm 90
D Main leaf eye inner diameter (Bushing seat) mm 36 0

- 0,33
D = bush outer diameter mm 36 ++ 0,12

0,07
D d
d = Bushing internal diameter mm 30 ++ 0,12
0,033
Front suspension: standard version vehicles

L
Leaf spring length (measured at eyelet centre) mm 1800 ± 3
Leaf spring H height

124 ± 6 (left)
P = 0 (N) mm
119 ± 6 (right)
42.5 ± 6 (left)
P = 32600 (N) mm
37.5 ± 6 (right)
S
Leaf thickness (measured at centre) mm 28.5
Leaf width mm 90

- 0,33

0,07
D d
0,033
Rear suspension for light version vehicles: 4x2 Vehicles (CAB)

L Leaf spring length (measured at eyelet centre) mm 1800 ± 3

Auxiliary spring length mm 1350 ± 3

682 ‒ Suspensions
SUSPENSIONS 9
Leaf spring H eccentricity

P = 0 (N)
Main spring mm 125 ± 6
Auxiliary spring mm 86 ± 6
S
Main spring mm 30
Auxiliary spring mm 25
Leaf width mm 100

- 0,33

0,07
D d
0,033
Rear suspension for light version vehicles: 6x4 Vehicles (CAB)

L
Spring length mm 1350

P = 0 (N) mm 54 ± 6
P = 78500 (N) mm 30
S
Leaf thickness (measured at centre) mm –
Leaf width mm 90

682 ‒ Suspensions
10 SUSPENSIONS
D Main leaf eye inner diameter (Bushing seat) mm –
D = bush outer diameter mm

D d
d = Bushing internal diameter mm
Rear suspension for standard version vehicles: 4x2 Vehicles (CAB)

L Leaf spring length (measured at eyelet centre) mm 1800 ± 3

Auxiliary spring length mm 1350 ± 3
P = 0 (N)
S Leaf thickness (measured at centre)

Thickness of main leaf spring mm 180
Thickness of auxiliary leaf spring mm 84
Leaf width mm 100

- 0,33

0,07
D d
0,033
Rear suspension for 6x4 standard version vehicles (CAB)

L

P = 0 (N) mm 60 ± 6
P = 78500 (N) mm 26.5 ± 8

682 ‒ Suspensions
SUSPENSIONS 11
S
mm 32
Leaf width mm 90
D Main leaf eye inner diameter (Bushing seat) mm

D d
Rear suspension for 6x4 standard version vehicles (TRACTORS)

L

P = 0 (N) mm 60 ± 6
P = 78500 (N) mm 26.5 ± 8
S
mm 6
Leaf width mm 90

D d

682 ‒ Suspensions
12 SUSPENSIONS
Rear suspension for light version vehicles: 4x2 vehicles (TRACTORS)

L Spring length
P = 0 (N)
S
Main spring mm 9
Leaf width mm 100

- 0,33

0,07
D d
0,033
Rear suspension for standard version vehicles: 4x2 vehicles (TRACTORS)

L Spring length
P = 0 (N)
S
Main spring mm 3
Leaf width mm 100

682 ‒ Suspensions
SUSPENSIONS 13

- 0,33

0,07
D d
0,033
Rear suspension for light version vehicles: 6x4 vehicles (TRACTORS)

L

P = 0 (N) mm 54 ± 6
P = 78500 (N) mm 30
S
Leaf thickness (measured at centre) mm 4
S Thickness between leaves mm –
Leaf width mm 90
D Main leaf eye inner diameter (Bushing seat) mm –

D d
Rear suspension for 6x4 - 8x4 standard version vehicles (TIPPER)

L

P = 0 (N) mm 54 ± 6
P = 78500 (N) mm 30

682 ‒ Suspensions
14 SUSPENSIONS
S
Leaf width mm 90

D d
Rear suspension for 6x4 - 8x4 light version vehicles (TIPPER)

L

P = 0 (N) mm 45 ± 6
S
Leaf width mm 90

D d

682 ‒ Suspensions
SUSPENSIONS 15
TIGHTENING TORQUES
Shock absorbers
SHOCK ABSORBERS
Length L
Open mm 735 ± 3
Closed mm 447 ± 3
Stroke mm 288

FRONT SUSPENSION WITH PARABOLIC LEAF SPRINGS
222107 Figure 4
TORQUE
DETAIL
Nm kgm
1 Front leaf spring U-bolt 400 - 520 40 - 52

682 ‒ Suspensions
16 SUSPENSIONS
TIGHTENING TORQUES
REAR SUSPENSION WITH SEMI-ELLIPTICAL LEAF SPRINGS (4x2 vehicles)
222110 Figure 5
TORQUE
DETAIL
Nm kgm
1 Fastening for lower suspension mount 320 - 360 32 ÷ 36
2 Fastening for upper suspension mount 220 - 250 22 - 25
3 Rear leaf spring U-bolt 630 - 670 63 - 67

682 ‒ Suspensions
SUSPENSIONS 17
TIGHTENING TORQUES
REAR SUSPENSION WITH PARABOLIC LEAF SPRINGS
222108 Figure 6
TORQUE
DETAIL
Nm kgm
1 Fastening for front suspension mount 295 - 330 29.5 - 33
2 Stop fastening 95 - 110 9.5 - 11
3 Fastening for the central suspension mount 295 - 330 29.5 - 33
4 Fastening for the central suspension mount 295 - 330 295 - 330
5 Shock absorber support fastening 220 - 250 22 - 25
6 Leaf spring clevis 400 ÷ 500 40 ÷ 50
7 Fastening for the rear suspension mount 295 - 330 29.5 - 33
8 Fastening for the rear suspension mount 295 - 330 29.5 - 33

682 ‒ Suspensions
18 SUSPENSIONS
TIGHTENING TORQUES
"CANTILEVER" REAR SUSPENSION WITH PARABOLIC LEAF SPRINGS
222109 Figure 7
TORQUE
DETAIL
Nm kgm
1 Nuts 425 42.5
2 Nuts ≥ 800 ≥ 80
5004 General torques
Note Unless otherwise indicated by the diagram, refer to the torque values shown in this table:
TORQUE
DETAIL
Nm (kgm)
Front leaf spring U-bolt M20 460 ± 60 (46 ± 6)
Rear leaf spring U-bolt M20 460 ± 60 (46 ± 6)
Bolt connecting upper shock absorber to mount support M20 282.5 ± 27.5 (28.25 ± 2.75)
Bolt connecting lower shock absorber to mount support M20 252.5 ± 47.5 (25.25 ± 4.75)
Bolt connecting lower shock absorber to support part below M20 545 ± 55 (54.5 ± 5.5)
Front suspension - chassis fasteners M14 206.5 ± 28.5 (20.65 ± 2.85)
Front suspension swinging arm central bolts M20 400 ± 40 (40 ± 4)
Bolts connecting front suspension M12 121 ± 12 (12.1 ± 1.2)
Front suspension double head bolts and nuts M12 92 ± 9 (9.2 ± 0.9)
Rear suspension fasteners M10 62.5 ± 12.5 (6.25 ± 1.25)
Rear suspension fasteners M16 227.5 ± 22.5 (22.75 ± 2.25)

682 ‒ Suspensions
SUSPENSIONS 19
TIGHTENING TORQUES
TORQUE
DETAIL
Nm (kgm)
Front suspension nut M18 x 1.5 305 ± 30 (30.5 ± 3)
Rear suspension nut (rear axle in tandem) M24 x 2 920 ± 120 (92 ± 12)
Rear double suspension nut (rear axle in tandem) M24 x 2 920 ± 120 (92 ± 12)
Lifting eyelet support bolt M16 x 1.5 280 ± 40 (28 ± 4)
Suspension support stud for rear axle in tandem (standard version) M18 x 1.5 395 ± 55 (39.5 ± 5.5)
Suspension support bolt for rear axle in tandem (light version) M16 x 2 305 ± 45 (30.5 ± 4.5)
Screw / Nut TORQUE (Nm)

M14 192.5 ± 19.5
M16 250 ± 25
M20 400 ± 40

682 ‒ Suspensions
20 SUSPENSIONS
FRONT LEAF SPRING REMOVAL - REFITTING
.500410. FRONT LEAF SPRING REMOVAL - REFITTING
174351 Figure 8

682 ‒ Suspensions
SUSPENSIONS 21
FRONT LEAF SPRING REMOVAL - REFITTING
Preliminary actions
1. To replace the left leaf spring: remove the exhaust silencer (5) as described in the relative chapter (operation 542410).
2. To replace the right leaf spring: Remove the filter cassette as described in the relevant chapter (operation 505110).
Main action
.500410. Front leaf spring removal
1. Arrange the vehicle on flat ground and block the rear wheels.
2. Slacken off the front wheel nuts. Use a hydraulic jack to lift the front of the vehicle and place it on the two support stands.
Slacken off the front wheel nuts. Use a hydraulic jack to lift the front of the vehicle and place it on the two support stands.
3. Position a hydraulic jack suitable to support front axle when the leaf spring will be disconnected. Then, lower the hydraulic jack
below the axle until leaf spring tension is released.
4. Working from underneath the vehicle, remove the cab entrance footplate support bracket (7) and the footplate itself.
5. Unscrew the nut (1) and remove the pin (2) from the rear shackle (12).
6. Remove the bolt (8) and the pin (10) securing leaf spring to front support.
7. Disengage shock absorber (9) from suspension operating on fastener (4).
8. Remove leaf spring (3).
.500410. Front leaf spring refitting

9. To refit, carry out the removal operations in reverse order, according to the following instructions: Check the thread of the
brackets securing the leaf springs to the front axle; if there are anomalies, re-machine the thread or replace the brackets.
10. Check the conditions of the stop spring buffers (11); if they are worn out, replace them.
11. Refit the exhaust silencer (5) as described in the relative chapter (542410 Refitting the silencer ( ➠ Page 40)) if it was previ-
ously removed.
12. Refit the filter cassette as described in the relative chapter (505110 Refitting the air filter casing on the vehicle. ( ➠ Page 49))
if it was previously removed.

682 ‒ Suspensions
22 SUSPENSIONS
REMOVAL - REFITTING OF FRONT SHOCK ABSORBERS
.500910. REMOVAL - REFITTING OF FRONT SHOCK ABSORBERS
Main action
.500910. Removal of front shock absorbers
1. Remove the shock absorber (2) by removing the upper and
lower mounting nuts and screws (1).
2. Check that the bushings and rubber parts are not worn or de-
teriorated, otherwise replace them.
3. Use an appropriate device to check the efficiency of the shock
absorbers.
174352 Figure 9
.500910. Refitting the front shock absorbers

4. For refitting, carry out the steps performed for removal in reverse order and keep to the required tightening torques.

682 ‒ Suspensions
SUSPENSIONS 23
REMOVAL - REFITTING OF THE FRONT STABILIZER BAR
.528930. REMOVAL - REFITTING OF THE FRONT STABILIZER BAR
Main action
.528930. Front stabiliser bar removal
1. Working from underneath the vehicle, remove the nuts (2) and
the screws (7).
2. Unscrew the screws (4) and remove the caps (6) fixing the
stabiliser bar (6) to the axle.
3. Remove the stabiliser bar (5).
4. Check that the bushes and/or rubber parts are not worn or
deteriorated, otherwise replace them.
174353 Figure 10
.528930. Refitting the front stabiliser bar

5. For refitting, carry out the steps performed for removal in reverse order and keep to the required tightening torques.
.500430. REMOVAL - REFITTING OF REAR LEAF SPRING (6x4 - 8x4 vehicles)
Work material
refitting

682 ‒ Suspensions
24 SUSPENSIONS
REMOVAL - REFITTING OF REAR LEAF SPRING (6x4 - 8x4 vehicles)
Main action
.500430. Removing the rear leaf spring (6x4 - 8x4 vehicles)
71516 Figure 11
1. Position the vehicle on flat ground and lock the front wheels with wheel chocks and loosen the nuts of the rear wheels.
2. Place the bracket on the hydraulic lift, position it under the rear axle and lift the rear part of the vehicle; rest the chassis and
the intermediate and rear axles on supporting stands, keeping contact between the bracket and the axle.
3. Unscrew the fixing nuts and use the hydraulic trolley to take off the wheels.
4. Remove the nuts (4) for the brackets (1) fastening the leaf spring to the pivot bearing.
5. Remove the screws (3) and remove the longitudinal bars and the guide chain tensioner pad (2) from the axle housing sup-
port.
6. Proceed with removal of the leaf spring complete with the vehicle seat, by means of a lifting tool.
.500430. Refitting the rear leaf spring (6x4 - 8x4 vehicles)

7. To refit, carry out the removal operations in reverse order, observing the following warnings.
Note Check the thread of the brackets securing the leaf springs to the rear axle; if anomalies are found, go over the thread-
ing again or replace the brackets.

682 ‒ Suspensions
DIAGNOSTICS 25
Contents
Contents
Noisy suspension . . . . . . . . . . . . . . . . . . . . . . . . 27
The vehicle tends to drift to one side . . . . . . . . . . . 27
Excessive suspension flexibility . . . . . . . . . . . . . . . 28
Squeaking, knocking, excessive noise in general . . . . . 28

682 ‒ Suspensions
26 DIAGNOSTICS

682 ‒ Suspensions
DIAGNOSTICS 27
Noisy suspension
DIAGNOSTICS
Main mechanical errors
Noisy suspension
1 Insufficient lubrication. Cause confirmed ▶ Lubricate carefully.
2 Shock absorbers noisy or inefficient. Cause confirmed ▶ Check and replace the shock
absorbers if necessary.
3 Wheel bearings worn and with excessive Cause confirmed ▶ Replace bearings or adjust clearance.
clearance. Cause not confirmed Check: 4
4 Leaf spring supports loose. Cause confirmed ▶ Check the supports and replace chassis
mounting screws or rivets if they are
loose.
5 Loosening of the leaf spring pack due to the Cause confirmed ▶ Overhaul the leaf springs and renew
rupture of the central fixing pin. the centre bolt and self-locking nut.
6 Leaf spring pack loose due to breakage of Cause confirmed ▶ Check leaf spring locking brackets and
the spring locking bracket's mounting rivets. replace mounting rivets.
The vehicle tends to drift to one side

1 Tyre pressure low or incorrect. Cause confirmed ▶ Check and accurately inflate tyres to
the prescribed pressure.
2 Incorrect front wheel alignment. Cause confirmed ▶ Check and correct wheel alignment.
3 Inefficient hydraulic shock absorbers. Cause confirmed ▶ Remove shock absorbers and replace
them.
4 Leaf spring broken. Cause confirmed ▶ Overhaul the leaf spring and make any
necessary replacements.
5 Incorrect vehicle loading. Cause confirmed ▶ Check the load and arrange it evenly
over the load bed.

682 ‒ Suspensions
28 DIAGNOSTICS
Excessive suspension flexibility
Excessive suspension flexibility

1 Leaf spring central pin broken. Cause confirmed ▶ Replace the component.
2 Leaf spring leaves weakened or broken. Cause confirmed ▶ Overhaul the spring and replace any
unusable components or, if necessary,
the entire spring.
Squeaking, knocking, excessive noise in general

1 Leaf spring supports loose. Cause confirmed ▶ Check the supports and replace chassis
mounting screws or rivets if they are
loose.
2 Loosening of the leaf spring pack due to the Cause confirmed ▶ Overhaul the leaf springs and renew
rupture of the central fixing pin. the centre bolt and self-locking nut.
3 Leaf spring pack loose due to breakage of Cause confirmed ▶ Check leaf spring clamps and replace
pins securing the spring clamps. the fixing pins.
4 Wheel bearings worn. Cause confirmed ▶ Replace bearings, if necessary.

682 ‒ Wheels and tyres
Contents 1
Contents
wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Contents

wheels and tyres 3
Contents
Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WHEEL REPLACEMENT . . . . . . . . . . . . . . . . . . . . 5
Static wheel balancing . . . . . . . . . . . . . . . . . . . . . . 7
Tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tyre behaviour depending on pressure . . . . . . . . 10
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 11
Excessive wear . . . . . . . . . . . . . . . . . . . . . . . 11
Irregular wear . . . . . . . . . . . . . . . . . . . . . . . 11
Vehicle pulls to one side . . . . . . . . . . . . . . . . . 12

4 wheels and tyres

wheels and tyres 5
Description
wheels and tyres

5025 Description
The wheel rim represents the rigid structure of the wheel and is identified with the following dimensions:
● rim diameter, measured at the base of the circumference groove;

● width of the wheel rim circumference groove (i.e. the distance between the surfaces on which the cover rests).
The tyre has the following functions:
● to absorb most of the impacts caused by roughness of the road surface by utilising the elasticity of air;
● developing the drive force provided by the engine on the ground, necessary for moving the vehicle;
● to ensure maximum grip and stability of contact between the tyre and the road, with satisfactory tyre lifespan;
● to withstand forces generated by sudden braking, hard acceleration and by the thrust of centrifugal force on bends;
● guarantee vehicle stability also at high speeds; to ensure the vehicle directional power.

WHEELS Wheel rims Pneumatic
8.0-20 11.00R20
8.0-20 12.00R20
Disc type, with specific continuous rims 22.5x9.0 315/80R22.5
22.5x9.0 295/80R22.5
22.5x9.0 13R22.5
TIGHTENING TORQUES
DETAIL TORQUE
Nm (kgm)
Nut fastening front and rear wheel 600+50
-20 (60+5
-2 )
.502510. WHEEL REPLACEMENT

Tightening torques
Wheel mounting nuts 580 N⋅m to650 N⋅m
Main action
.502513. Changing the rear wheels
1. Stop the vehicle on firm and level ground.
2. With the tyre to be changed still in contact with the ground, partially loosen the nuts of the wheel studs.

6 wheels and tyres
WHEEL REPLACEMENT
3. Lift the wheel by applying the jack to the jacking points (→)
shown in the picture.
223109 Figure 1
Conditions
● Vehicles with the IVTM system for checking tyre pressure
▶ Unscrew the couplings (1) on the tyre valves.

▶ Suitably mark the sensors (2) before removing the wheels
to prevent inverting them when remounting them.
225151 Figure 2
4. Place the hydraulic trolley under the wheels.

5. Remove the wheel mounting nuts and remove the wheels.
40510 Figure 3

wheels and tyres 7
Static wheel balancing
6. Mount the wheels and tighten the fixing nuts to the required
torque according to the diagram shown in the figure.
Tightening torque
Wheel mounting nuts 580 N⋅m to650 N⋅m
60229 Figure 4
.502511. Changing the front wheels
223110 Figure 5
A Front axle B Front axle
7. To replace front wheels follow procedureChanging the rear wheels ( ➠ Page 5) applying the jack to the jacking points (→)
shown in the picture.
.502511. Static wheel balancing
Note The following procedure is illustrative and refers to the use of generic static balancing equipment.
Note Front wheel balancing can be done when the wheels are mounted on the vehicle by using an electronic wheel balancer
This allows a large advantage in balancing the wheels with other rotating parts.

8 wheels and tyres
Static wheel balancing
Main action
1. Raise the front of the vehicle and make sure that the wheels
rotate freely.
2. Place the detector (1) under the axle near the wheel to be
checked, adjust the height so that the roller starting the tool
(2) is in contact with the tyre; place a supporting stand on the
opposite side of the axle and lower the hydraulic jack.
177330 Figure 6
3. Connect the detector cable (3) to equipment.

4. Make a reference mark on the tyre by drawing a radial mark
with chalk or using a strip of sticky paper.
5. Place switch (2) in the static balancing position and the sensitiv-
ity switch (4) next to reference No. 5 in the graduated scale.
6. Turn on the switch (5) for the instrument light (1) and the
switch (8) for the strobe light.
7. Set the starting switch (6) of equipment in the first speed posi-
tion so that the wheel starts to turn.
8. Turn the start switch (6) to the second speed and place the
balancing machine against the tyre.
9. While the wheel is dragged in rotation, the stroboscopic effect
shows the reference mark as stable; the instrument needle (1)
starts from zero and reaches a maximum scale value and then 16997 Figure 7
drops to zero again.
10. When the pointer has begun to fall back, withdraw the balan-
cing machine, turn the start switch (6) completely off and brake
the engine using the brake lever (7). The wheel will continue
to rotate due to inertia and the reference mark made on the
tyre will move, thus the point to which the reference mark has
moved should be noted.
11. Read off from the instrument (1) the value shown by the
pointer, multiply it by 10, to obtain the value of the balance
weight to be fitted to the rim.

wheels and tyres 9
Tyre pressure
12. Fit the calculated balance weight as shown in the figure. If the
instrument pointer stays in the green area during the test, the
wheel is balanced.
Note If the required weight for balancing the wheel is greater
than 600 ÷ 800 grams, divide the weight by half and
position the two parts produced one halfway inside and
the other halfway outside the rim, making sure they are
in the same position.
16998 Figure 8
.502511. Correction of residual static unbalance

13. Repeat the previous operations to correct the unbalance; ac-
cording to the new indications detected by the instrument refer
to the diagram and proceed as follows to adjust it:
◁ If the weight is in the area marked with the letter A, this
means that it is too light and thus weight needs to be ad-
ded as indicated by the instrument.
◁ If the weight is in the bottom area marked with the letter
C, this means that it is too heavy and thus the weight needs
to be reduced as shown by the measuring instrument.
◁ If the weight is in the area marked by letters B and D, do
not add or remove any weight, but move it upward by 5
cm in the direction of the arrows, see figure.
23885 Figure 9
502510 Tyre pressure

Tyre pressures must be checked when the tyres are cold.
Make sure that the pressure is correct; if higher than required, it causes stiffness and excessive wear of the centre of the tread;
while if lower, the load will not be distributed over the whole tread but concentrates at either sides, causing premature wear of
these areas, also damaging the internal structure of the tyre.
Unequal pressures between tyres affect the driving stability of the vehicle and impairs operating safety.
Abnormal tyre wear can occur in different areas of the tread.

10 wheels and tyres
Tyre pressure
502510 Tyre behaviour depending on pressure
Caution!
Tyres Replacement warnings
▶ If abnormal wear of front tyres is found (either inside or outside the tread), have front wheel toe-in checked.
Never exceed the maximum load prescribed per axle (the vehicle gross weight being unchanged). The pair of tyres
fitted on an axle shall be replaced when continuous bands appear over the full width of the tread due to wear.
▶ Tyres are also provided with wear indicators: replacement is mandatory if these indicators are reached.
Diagrams showing tyre behaviour and performance in relation to pressure.
Note The value in each figure indicates the quantity of tire pressure, whereas the efficiency refers to the life of the tire.
Efficiency 90%
177326 Figure 10
Efficiency 40%
177325 Figure 11

wheels and tyres 11
DIAGNOSTICS
Efficiency 100%
188035 Figure 12
DIAGNOSTICS
Excessive wear

1 Excessive speed on particularly uneven Cause confirmed ▶ Reduce speed.
ground. Cause not confirmed Check: 2
2 Sudden variations in driving speed due to Cause confirmed ▶ Avoid unnecessary acceleration or
abrupt departures or harsh braking. braking.
3 Excessive speed with under-inflated tyres. Cause confirmed ▶ Check tyre pressures when tyres are
cold.
4 Tyres over-inflated. Cause confirmed ▶ Reduce pressures.
5 Vehicle overloaded. Cause confirmed ▶ Consult data on permitted loads.
Irregular wear

1 Difference in tyre pressures between differ- Cause confirmed ▶ Check pressures.
ent pairs of wheels. Cause not confirmed Check: 2
2 Insufficient inflation pressure: wear is concen- Cause confirmed ▶ Inflate the tyres.
trated on the edges of the tread rather than
at the centre.
3 Tyres over-inflated: wear concentrated in the Cause confirmed ▶ Reduce pressure.
centre of the tread. Cause not confirmed Check: 4
4 Insufficient front wheel toe-in: excessive Cause confirmed ▶ Check and adjust toe-in.
wear on inner edges of tyre treads. Cause not confirmed Check: 5
5 Incorrect front wheel alignment. Cause confirmed ▶ Restore correct wheel geometry.

12 wheels and tyres
DIAGNOSTICS

6 Distortion of wheel rims causing unbalance. Cause confirmed ▶ If possible, repair the rims or replace
them; Balance the wheels.
7 Tyres incorrectly fitted to rims. Cause confirmed ▶ Fit the tyre correctly and balance the
wheel.
8 Rear axle misaligned due to breakage of leaf Cause confirmed ▶ Overhaul the suspension.
spring centre pin, springs of different lengths
or buckled springs.
9 Excessive front wheel toe-in: excessive wear Cause confirmed ▶ Check and adjust toe-in.
on outer edges of tyre treads. Cause not confirmed ▶ Contact the Service Network.
Vehicle pulls to one side

1 Front wheels out of balance. Cause confirmed ▶ Balance the wheels.
2 Front tyres at different pressures. Cause confirmed ▶ Check pressures ensuring that both
are at the correct value.
3 Excessive difference in wear between a pair Cause confirmed ▶ Replace excessively worn tyre.
of tyres. Cause not confirmed ▶ Contact the Service Network.

682 ‒ steering
Contents 1
Contents
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

682 ‒ steering
2 Contents

682 ‒ steering
steering 3
Contents
Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING CONTROL DIAGRAMS . . . . . . . . . . . . . 7

Steering control diagram for 4x2 - 6x4 vehicles . . . . 7
Steering control diagram for 8x4 vehicles . . . . . . . 8
General torques . . . . . . . . . . . . . . . . . . . . . . 10
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVING-REFITTING THE POWER STEERING

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removing-refitting the steering control assembly . . . . 13
Bleeding air from the power steering circuit . . . . . . . 18
Measurement of the clearances on the steering box

detected on the steering wheel . . . . . . . . . . . . . . . 18
Checking the maximum pressure of the power

steering system . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the automatic hydraulic steering limit . . . . . . 20
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 21
Steering stiff when turning right and left . . . . . . . 21
Steering stiff only when turning left or right . . . . . 22
Steering stiff when the wheel is turned
quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hard knocks on the steering wheel when
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Torsional vibration of the steering wheel . . . . . . . 23
Excessive steering wheel clearance . . . . . . . . . . 23
Loss of fluid . . . . . . . . . . . . . . . . . . . . . . . . . 23
Insufficient pressure in the circuit . . . . . . . . . . . 24

682 ‒ steering
4 steering

682 ‒ steering
steering 5
Description
steering
501430 Description
The power steering ZF 8098 is equipped with a ball recirculation control system; this basically consists of one housing including the
mechanism for manual steering, one hydraulic cylinder governed by a rotary control valve and automatic valves for hydraulic limiting
of steering and for safety.
ZF 8098 Power steering
142699 Figure 1
A ECC 200 code C Production date
B Progressive production number

682 ‒ steering
6 steering
steering Hydraulic
ZF 8098 ball recirculation type with integral pressure limiting valve

Power steering and hydraulic device with automatic adjustment to limit the steering
angle.
Operating pressure variable 140 ± 14 bar
vehicles
Variable reduction ratio Cabs and Tractors
steering centre 22.2 : 1
maximum steering 26.2 : 1
no. of turns of steering wheel
3.1
from straight ahead to full lock
Power steering pump ZF
Minimum speed rpm 500
Maximum speed rpm 3500
Maximum pressure (without
bar 180
limiting valve)
Capacity dm3/min 16
Oil
type HYDRAULIC CAR 32 HVI
Quantity L 12

682 ‒ steering
steering 7
STEERING CONTROL DIAGRAMS
501410 STEERING CONTROL DIAGRAMS

Steering control diagram for 4x2 - 6x4 vehicles
227427 Figure 2

682 ‒ steering
8 steering
STEERING CONTROL DIAGRAMS
Steering control diagram for 8x4 vehicles
227430 Figure 3

682 ‒ steering
steering 9
TIGHTENING TORQUES
sez. C-C
sez. A-A
137224 Figure 4
Tightening torques
DETAIL TORQUE
Nm (kgm)
1 Hexagonal nut with collar for steering support and idler arm 226 ± 22.5 (22.6 ± 2.3)
2 Castellated nut for steering linkage and hydraulic cylinder * 300 (30)
3 Fixing collar for track rod and drag link arm 80 ± 10 (8 ± 1)
4 Flanged hexagonal head screw for fixing steering gear stand 278 ± 28 (27.8 ± 2.8)
5 Self-locking flanged hex nut for steering gear stand 226.5 ± 22.5 (22.6 ± 2.2)
6 Hexagonal head screw for steering box 527.5 ± 52.5 (52.7 ± 5.3)
7 Hexagonal nut for lever on the steering box 575 ± 55 (57.5 ± 5.5)
8 Calibrated hexagonal head screw for steering box 527.5 ± 52.5 (52.7 ± 5.3)
9 Self-locking nut for universal joint 55 ± 5 (5.5 ± 0.5)
10 Calibrated screw for universal joint 55 ± 5 (5.5 ± 0.5)
M16 310 ± 45 (31 ± 4,5)
11 Screws fixing steering box to the chassis
M18 447.5 ± 62.5 (44.75 ± 6.25)
M24 265 ± 15 (26.5 ± 1.5)
12 Nuts fixing ball-joints on steering tie-rods
M20 220 ± 10 (22 ± 1)
Single 80 ± 10 (8 ± 1)
13 Nuts fixing steering tie-rod collars
Dual 40 ± 5 (4 ± 0.5)
14 Nuts fixing steering shaft universal joint M10 55 ± 5 (5.5 ± 0.5)
* If at the specified torque, the slot does not match the hole, continue to tighten until it becomes possible to insert the split pin.

682 ‒ steering
10 steering
TOOLS
501410 General torques
Note Unless otherwise specified, refer to the torque values contained in this table.
General torques
M12 120
M16 350
M20 600
M22 900
M24 1100
M27 1650
TOOLS
Extraction tool for steering linkage head pins (99347068)
.501430. REMOVING-REFITTING THE POWER STEERING SYSTEM
Work material
Main action
.501430. Removal
1. Set the vehicle with its wheels straight.
2. Lift up the front casing and tilt up the cab.
3. Remove the front bumper as described in the relating chapter (operation 500210).

682 ‒ steering
steering 11
REMOVING-REFITTING THE POWER STEERING SYSTEM
4. Undo the screws (2) and remove the step (1).

5. Undo the screws (4), remove the brackets (5) and remove the
cab access footplate (3).
174274 Figure 5
6. Unscrew the couplings (3) and drain the power steering system
oil into a suitable container.
7. Disconnect the couplings (1) and (7) from the power steering
box (8) and remove the oil pipes (2).
8. Remove the split pin and loosen the nut (6).
9. Use puller to remove the longitudinal tie rod (5) from the
steering lever (4).
code
174275 Figure 6

682 ‒ steering
12 steering
REMOVING-REFITTING THE POWER STEERING SYSTEM
10. Mark the assembly position of the universal joint (1) on the
power steering.
11. Remove the bolt (1) and disconnect the universal joint (2)
from the power steering box shaft (3).
174276 Figure 7
12. Unscrew the screws (6) and remove the power steering (2)
from the vehicle together with the support bracket (1) and
steering lever (4).
13. Fix the power steering in a vice and keep the lever stopped (4)
to prevent rotation of the power steering shaft, use a suitable
wrench to unscrew the nut (5) and remove the arm (4).
14. Unscrew the screws (3) and remove the power steering (2)
from the support bracket (1).
174277 Figure 8

682 ‒ steering
steering 13
Removing-refitting the steering control assembly
.501430. Refitting
15. Carry out the steps performed for removal in reverse order.
16. Lubricate the screws securing the hydraulic power steering box with oil.
17. Replace the O-rings on the couplings of the disconnected pipes.
18. Tighten the screws to the recommended tightening torques.
19. Bleed system as directed in the relevant section.
Note Where the hydraulic power steering box is replaced, after refitting it on the vehicle, the automatic adjustment of the
steering hydraulic limitation must be set as described in the relevant chapter.
.5014. Removing-refitting the steering control assembly
Main action
.501411. Steering wheel removal
1. Lift the cab cowling.
2. Set the wheels straight and check that the steering box is in the
«driving centre» position, so the reference mark ← of the
shaft (1) corresponds to the reference mark → of the steering
box (2).
38660 Figure 9
3. Engage the steering lock by taking the ignition key out.

4. Remove the cover (1) of the steering wheel (2).
72849 Figure 10

682 ‒ steering
14 steering
5. Disconnect the connection (4) of the ground cable.

6. Remove the nut (1), mark the mounting position of the steering
wheel (3) on the shaft (2) and remove the steering wheel (3).
4
5
1
2
72850 Figure 11
.501422. Removing the spring block (interconnection box)

7. Take off the screws (1 e 3) and remove the side guards (2 e
4).
72851 Figure 12
Caution!
Spiral cable Warnings during support disassembly
▶ Remove the interconnecting box (4) from the steering control mount (2), keeping strictly to the procedures de-
scribed hereunder. This to prevent damaging the clock spring at assembly, and to avoid a wrong reading of the
steering wheel angle.

682 ‒ steering
steering 15
8. Disconnect the electrical connections (5 e 6).

9. Take the key out of the steering wheel .
10. Secure the cover (1) of the interconnection box (2) to the box
by inserting the key (7) in the slots (8 e 9).
11. This prevents the cover (1) and the box (2) from turning to
each other at disassembly and to keep this condition unchanged
until assembly.
12. If there is no key (7) use a screw and a nut of suitable length
and diameter.
13. Hold the interconnection box (2), then lift it carefully so that
the retaining spring pins (3) come off the mounting (4) and put
the box aside.
72852 Figure 13
.501415. Steering column mount Removal

14. Remove the push-button panels (3 e 5) and the screw caps (4)
from the instrument panel (1).
15. Remove the screws (2 e 4), remove the instrument panel (1)
and place it aside.
72831 Figure 14
16. Unplug the connections (1) of the windscreen wiper, (2) of the
drive control system and (3) of the immobilizer.
72832 Figure 15

682 ‒ steering
16 steering
17. Remove mat (5).

18. Unscrew the screws (4) securing the kickplate (3).
19. Detach the kickplate (3) from the vehicle.
20. Operate on fasteners (←) and remove the air intake (2) on the
floor.
21. Unscrew the side screws (1) fixing the steering column guard.
77108 Figure 16
22. Unscrew the screws (2) fixing the steering column guard in the
area of the pedal board.
23. Detach the steering column guard (1) from the vehicle.
90002 Figure 17
24. Mark the assembly position of the shaft (2) on the mount(3)
and on the universal joint (4).
25. Unscrew the screw (1) and extract the universal joint (4) from
the top shaft.
26. Disconnect the pipe (2).
72854 Figure 18

682 ‒ steering
steering 17
27. Take out the screws 3 (1) and remove the steering gear
mounting (3) from the pedal assembly (2).
72855 Figure 19
.501413. Removal of the steering control shaft

28. From outside the cab, loosen the screw (2) and disconnect the
lower shaft (1) from the power steering shaft (3).
29. Take off the screws (4) and remove the steering lower shaft
(1) together with the guard (5).
72856 Figure 20
.501413. Refitting steering control shaft

Caution!
Interconnecting box Replacement warnings
▶ The interconnecting box (1) is supplied as a spare with the stop key assembled as illustrated in the figure. After
fitting it on the steering control mount, turn the key (2) until collapsing occurs at the point shown by the arrow,
then put the key in the steering wheel housing, see figure.

682 ‒ steering
18 steering
Bleeding air from the power steering circuit
verse order, tightening the screws and/or nuts to the specific
torque.
72857 Figure 21
.501430. Bleeding air from the power steering circuit
Main action
1. Fill up the circuit tank with the required oil type.
2. Crank the engine with the starter motor and top up the oil continuously in order to prevent the pump from sucking in air.
3. Top up the fluid until the level is no longer below the minimum level on the dipstick notch.
4. Start the engine and run at idle, checking that the oil level does not drop below the minimum notch mark on the dipstick.
5. Rotate the steering wheel several times from stop to stop so that air cannot go out of the hydraulic power steering cylinder,
until no air bubbles can be seen coming into the tank.
6. Speed up the engine to maximum, stop it and check that the oil level in the tank does not rise more than 1 - 3 cm.
.501430. Measurement of the clearances on the steering box detected on the steering wheel
Work material
Tool with pressure gauge for keeping hydraulic pressure 99374393
of ZF and power steering in check.
Graduated sector and index for steering wheel play con- 99374398
trol (use with 99374393)
Pair of expanders to lock wheels (to be used with 99374399
99374393 and 99374398)
Main action
1. Check there is no mechanical clearance in the related connection linkage.
2. Lock the left-hand wheel in the straight-ahead position using the expanders; lift the axle.
Pair of expanders to lock wheels (to be used with 99374393 and 99374398) 99374399

682 ‒ steering
steering 19
Checking the maximum pressure of the power steering system
3. Attach the fixed pointer (2) to the windscreen with suction

cups, and attach the graduated scale (1) to the steering wheel.
code
Graduated sector and index for steering wheel play control 99374398
(use with 99374393)
4. Set the pair of gauges (3) from 0 ÷ 10 bar and from 0 ÷ 160
bar connected to each other by a short circuit valve.
code
Tool with pressure gauge for keeping hydraulic pressure of 99374393
ZF and power steering in check.
33694 Figure 22
5. Connect the gauges pipe on the power steering oil delivery pipe
fitting.
6. Top up the oil level if required.
7. Start the engine and run at idle speed, rear the pressure reading
shown on the 0 – 10 bar pressure gauge in that moment.
8. Turn the steering wheel slowly to the left to increase the pres-
sure by 1 bar; hold the steering wheel in this position and on
the millimetre graduation mark the value in mm that has been
reached.
code
(use with 99374393)
9. Turn the steering wheel to the right until the pressure reading
is again increased by 1 bar, and note the value on the graduated
scale, add together the two values obtained for left and right
steering; the total should not exceed 40 mm.
code
(use with 99374393)
10. Lower the axle.
.501430. Checking the maximum pressure of the power steering system
Work material
Tool with pressure gauge for keeping hydraulic pressure 99374393
of ZF and power steering in check.
Main action
1. Using the pressure tester, connected as described above, and the driver's side wheel locked, start the engine and run at idle.
Apply a steering force of 10 ÷ 20 kg to the steering wheel and record the pressure reading on the 0 ÷ 160 bar gauge.
Tool with pressure gauge for keeping hydraulic pressure of ZF and power steering in check. 99374393

682 ‒ steering
20 steering
Setting the automatic hydraulic steering limit
2. Carry out the same operation steering in the opposite direction. If the measured values are lower than those required, find
the cause.
Note The maximum pressure is given on the data plate attached to the ZF steering box.
.501430. Setting the automatic hydraulic steering limit
Tightening torques
Fastening grip bush 64.5 ±6.5 N⋅m
Technical data
Pressure values to check setting of the automatic hydraulic limit 35 bar to70 bar
Main action
1. This adjustment is made after fitting the power steering system
on the vehicle, with the vehicle unloaded and the front wheels
raised or set on revolving platforms.
Note Adjustments shall be performed in both steering direc-
tions.
Make sure that the Transmission is in neutral.
The procedure must be carried out with the engine off
or on.
2. Turn the steering wheel slowly in one direction until the stop
bush (2) installed on the knuckle (3) touches the axle (1).
Note Make sure that the limit stop of the axle is reached
effectively, otherwise the hydraulic power steering
would be considerably reduced just before reaching
the limit stop.
3. In this position, apply an additional force on the steering wheel
to determine the automatic setting.
4. Repeat the same operations in the other steering direction. 060925B Figure 23
5. Should the range of the steering control lever (1) be reduced,

replace the faulty steering limiting bush (2) with a new one, or
both bushes, if the defect also affects the range in the opposite
direction.
6. Tighten the new bush to the prescribed torque.
Tightening torque
Fastening grip bush 64.5 ±6.5 N⋅m
Note The steering angle can always be increased without

replacing the bushes.
219224 Figure 24

682 ‒ steering
steering 21
DIAGNOSTICS
.501430. Check
7. Carry out the check by fitting a pressure gauge (minimum end of scale value 200 bar) to the pressure test fitting on the supply
line from the pump to the hydraulic power steering and apply a steering force at the steering wheel of 50 ± 20 Nm (corres-
ponding to 200 ± 80 N on a 500 mm diameter steering wheel), turning the wheel to the full lock position. The pressure read-
ing should be within the range shown below.
Technical data
Pressure values to check setting of the automatic hydraulic limit 35 bar to70 bar
Note In the case of excessively high pressure, the adjustment bushes must be replaced with new ones, and the adjustment
operation must be repeated.
If the pressure is too low, check that the hydraulic system is operating properly and that there are no leaks.
DIAGNOSTICS
Steering stiff when turning right and left

1 Insufficient oil in the system Cause confirmed ▶ Check the level while the engine is
running; top up the oil until the top
mark of the level rod and flush the
system.
2 Air in the hydraulic system Cause confirmed ▶ Check intake tube and pump shaft seal
for leaks and top up the fluid.
▶ Bleed the system.
3 Pump regulating valve jammed or blocked Cause confirmed ▶ Remove the valve, wash and check.
The opening should not be blocked.
4 Insufficient oil pump flow Cause confirmed ▶ Replace the pump.
5 Universal joint does not slide well Cause confirmed ▶ Free the joint by moving it back and
forth several times so that it can tilt
under its own weight.
6 Poor lubrication of the transmission lever Cause confirmed ▶ Grease the transmission lever bearings.
bearings (for vehicles with steering third
axle)
7 Bearings for transmission levers worn out Cause confirmed ▶ Overhaul the transmission levers and
(for vehicles with third steering axle). replace worn parts.
8 Hydraulic cylinders not working (for vehicles Cause confirmed ▶ Replace the involved cylinders.
with third steering axle) Cause not confirmed ▶ Contact the Service Network.

682 ‒ steering
22 steering
DIAGNOSTICS
Steering stiff only when turning left or right

1 Internal seals not serviceable Cause confirmed ▶ Send steering gear to a ZF service
centre.
2 Incorrect position of hydraulic centre (when Cause confirmed ▶ Have hydraulic power steering adjus-
wheel is released, the steering automatically ted by a ZF service centre.
returns to one end of travel position) Cause not confirmed ▶ Contact the Service Network.
Steering stiff when the wheel is turned quickly

1 Limiter valve blocked Cause confirmed ▶ Remove the valve, wash and clean.
2 Insufficient hydraulic pump flow Cause confirmed ▶ Overhaul the hydraulic pump or re-
place it.
3 Air in the steering system Cause confirmed ▶ Check the intake tube and pump shaft
seal for leaks and top up the oil.
Hard knocks on the steering wheel when steering

1 Universal joint backlash Cause confirmed ▶ Replace the universal joint.
2 Hydraulic power steering internal breakdown Cause confirmed ▶ Send hydraulic power steering to a ZF
service centre.
3 Insufficient oil in the system Cause confirmed ▶ Top up oil and bleed the system.
4 Front wheel geometry is incorrect Cause confirmed ▶ Carry out the checks and adjustments
according to the specification data
given in the "AXLES" section.
5 Wheels out of balance Cause confirmed ▶ Balance in accordance with instruc-
tions given in the section "Wheels and
tyres".
6 Steering tie rod joints loose on the levers Cause confirmed ▶ Replace any worn parts.
7 Hydraulic pump not operating correctly Cause confirmed ▶ Replace the hydraulic pump.
8 Leakage of oil from hydraulic power steering Cause confirmed ▶ Check the efficiency of the coupling
circuit couplings seals, replacing any which are worn.

682 ‒ steering
steering 23
DIAGNOSTICS
Torsional vibration of the steering wheel

1 Wheels out of balance Cause confirmed ▶ Balance in accordance with instruc-
tions given in the section "Wheels and
tyres".
2 Wrong wheel toe-in Cause confirmed ▶ Carry out the checks and adjustments
according to the specification data
given in the "AXLES" section.
3 Air in the hydraulic system Cause confirmed ▶ Check intake tube and pump shaft seal
for leaks and top up the fluid.
Excessive steering wheel clearance

1 Clearance in ball joints and/or rubber sup- Cause confirmed ▶ Secure the supports.
ports are loose ▶ Replace the ball joints.
2 Universal joint backlash Cause confirmed ▶ Replace the universal joint.
3 Hydraulic power steering internal breakdown Cause confirmed ▶ Send hydraulic power steering to a ZF
service centre.
Loss of fluid

1 Tank cover not secured tightly Cause confirmed ▶ Secure the cover.
2 Seal gaskets are worn Cause confirmed ▶ Replace the worn gaskets, top up fluid
and bleed.
Cause not confirmed ▶ In any case it is necessary to determine
the place and the reason the oil is
leaking, eliminate the cause and top up
oil in the tank with the engine started
up to the upper mark of the dipstick.
If the problem persists, contact the
Service Network.

682 ‒ steering
24 steering
DIAGNOSTICS
Insufficient pressure in the circuit

1 Hydraulic pump not operating correctly Cause confirmed ▶ Overhaul the hydraulic pump or re-
place it.
2 Leakage of oil from hydraulic power steering Cause confirmed ▶ Check the efficiency of the coupling
circuit couplings seals, replacing any which are worn.
3 Insufficient oil level in the tank Cause confirmed ▶ Top up the oil level and bleed the
circuit.

682 ‒ Pneumatic system - Brakes
Contents 1
Contents
Pneumatic systems - brakes . . . . . . . . . . . . . . . . . . 3

2 Contents

Pneumatic systems - brakes 3
Contents
Contents TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
BRAKING SYSTEM GENERAL INFORMATION . . . . . 5 BRAKES SYSTEM MAIN COMPONENT

CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
BRAKING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . 7
ABS control unit replacement . . . . . . . . . . . . . . . . 43
BRAKING SYSTEM DIAGRAM FOR 4X2
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacing pipelines and couplings . . . . . . . . . . . . . . 45
BRAKING SYSTEM DIAGRAM FOR 6x4
VEHICLES isolated . . . . . . . . . . . . . . . . . . . . 11 Replacement of the dryer . . . . . . . . . . . . . . . . . . 51
BRAKING SYSTEM DIAGRAM FOR 6x4
FRONT BRAKE OVERHAULING . . . . . . . . . . . . . 51
VEHICLES Towing . . . . . . . . . . . . . . . . . . . . . 15
BRAKING SYSTEM DIAGRAM FOR 6x4 REAR BRAKE OVERHAUL . . . . . . . . . . . . . . . . . 51
VEHICLES Towing (with shut-off valve) . . . . . . . . 19
BRAKING SYSTEM DIAGRAM FOR 8x4 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 52
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Main mechanical malfunctions . . . . . . . . . . . . . . 52
Main electronic - electric malfunctions . . . . . . . . 57
BRAKING SYSTEM MAIN COMPONENTS . . . . . . . 25
DTC ABS control unit . . . . . . . . . . . . . . . . . . 58
Compressor . . . . . . . . . . . . . . . . . . . . . . . . 25
Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Duplex distributor . . . . . . . . . . . . . . . . . . . . . 27
Trailer servo control valve . . . . . . . . . . . . . . . . 28
Coupling heads . . . . . . . . . . . . . . . . . . . . . . . 29
Check valve (vehicles suitable for towing) . . . . . . 29
Handbrake manual control valve (vehicles suitable
for towing) . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rear axle / front axle brake relay valve . . . . . . . . 31
Parking brake relay valve . . . . . . . . . . . . . . . . . 32
Quick discharge valve . . . . . . . . . . . . . . . . . . . 33
Diaphragm brake cylinder . . . . . . . . . . . . . . . . 33
Combined brake cylinder . . . . . . . . . . . . . . . . 34
ABS SYSTEM (ANTI-LOCK BRAKE SYSTEM) . . . . . . 34

«ABS» (Anti-Lock Brake System) . . . . . . . . . . . . 34
ABS SYSTEM COMPONENTS . . . . . . . . . . . . . . . 35

Pressure sensor . . . . . . . . . . . . . . . . . . . . . . 35
Electronic control unit . . . . . . . . . . . . . . . . . . 35
ABS solenoid valve . . . . . . . . . . . . . . . . . . . . 36
Revs sensor . . . . . . . . . . . . . . . . . . . . . . . . . 36
MAIN DATA - PNEUMATIC SYSTEM . . . . . . . . . . 36
CHARACTERISTICS AND DATA - BRAKES . . . . . . 39
General torques . . . . . . . . . . . . . . . . . . . . . . 40

4 Pneumatic systems - brakes

BRAKING SYSTEM GENERAL INFORMATION
Pneumatic systems - brakes

79 BRAKING SYSTEM GENERAL INFORMATION
Service braking
Pedal-operated, pneumatic, acting on all the wheels and the trailer.
It is composed of two independent sections, one for activating the braking elements of the front axle, the other for activating the
braking elements of the rear axle.
A third section, assisting the two distributor sections, brakes the trailer.
The duplex distributor controls the two separate sections and the triple control servo distributor; this in turn controls the third
section.
If one section breaks down, the division of the air system allows the others to remain efficient.
Emergency braking
This is combined with the parking braking.
The twin circuit system allows a single axle to brake even when the other axle brake is faulty, by acting on the service brake pedal.
Retarding braking
The I.T.B. (Iveco Turbo Brake) engine brake used on Cursor engines is composed of a hydraulically controlled mechanism that
eliminates the exhaust valve clearance.
By applying this mechanism, at the end of the compression phase, a few degrees before the T.D.C., the exhaust valves open slightly
with a consequent reduction in the pressure formed in the cylinder.
This takes advantage of the braking torque of the compression phase but without the subsequent return thrust on the piston.
To improve decompression engine brake Iveco Turbo Brake (ITB), performance the CEB (Combined Engine Brake) is introduced
in combination.
For this reason, there is a butterfly valve operated by a pneumatic cylinder in the engine exhaust manifold.
When the driver activates the engine brake, the throttle valve actuates, blocking the exhaust gas outlet.
The exhaust gas thus returns to the cylinder where it provides resistance to the up stroke of the piston.
This resistance extends throughout the entire kinematic chain, applying a braking effect on the driving wheels.
Parking braking
This is mechanical and operated by the manual distributor set at the end of its stroke; it operates on the rear wheels of the tractor
discharging the air from the spring section of the pneumatic cylinder and the servo distributor control section, locking the trailer or
semi-trailer wheels.
From the driver's seat it is possible to check if the trailer can ensure the efficiency of the combined tractor-trailer parking brake
with the trailer brakes released.


BRAKING SYSTEM DIAGRAMS

BRAKING SYSTEM DIAGRAM FOR 4X2 VEHICLES
222079 Figure 1

1 Compressor 10 Air tank

2 Air filter 11 Air tank
3 Front axle ABS solenoid valve 12 Air drier
4 Front axle cylinder diaphragm brake 13 4 way protection valve
5 Brake control relay valve (front axle/rear axle) 14 Air tank
6 Parking brake control relay valve 15 Air tank
7 Rear axle ABS solenoid valve 16 Duplex distributor
8 Combined axle brake cylinder 17 Parking brake hand control distributor
9 Bleed valve
A Version without ABS

LOCATION OF COMPONENTS FOR 4x2 VEHICLES
222080 Figure 2
1 Front axle ABS solenoid valve 3 Air drier
2 Front axle cylinder diaphragm brake 4 Front axle brake control relay valve

5 Rear axle /parking brake control relay valve 7 Combined axle brake cylinder
6 Rear axle ABS solenoid valve

BRAKING SYSTEM DIAGRAM FOR 6x4 VEHICLES isolated
222081 Figure 3
1 Compressor 3 Front axle ABS solenoid valve
2 Air filter 4 Front axle cylinder diaphragm brake

5 Brake control relay valve (front axle/rear axle) 13 Air drier

6 Combined intermediate axle brake cylinder 14 4 way protection valve
8 Rear axle ABS solenoid valve 15 Air tank
9 Combined rear axle brake cylinder 16 Air tank
10 Bleed valve 17 Duplex distributor
11 Air tank 18 Parking brake hand control distributor
11 Air tank

LOCATION OF COMPONENTS FOR 6x4 VEHICLES isolated
222082 Figure 4
1 Front axle ABS solenoid valve 3 Front axle brake control relay valve
2 Front axle cylinder diaphragm brake 4 Combined axle brake cylinder

5 Rear axle /parking brake control relay valve 7 Air drier

6 Rear axle ABS solenoid valve

BRAKING SYSTEM DIAGRAM FOR 6x4 VEHICLES Towing
222084 Figure 5

5 Trailer semi-coupling joints 14 Air tank

6 Trailer brake servo control valve 15 Air drier
7 Brake control relay valve (front axle/rear axle) 16 4 way protection valve
8 Combined intermediate axle brake cylinder 17 Air tank
10 Rear axle ABS solenoid valve 19 Duplex distributor
11 Combined rear axle brake cylinder 20 Parking brake hand control distributor
12 Bleed valve 21 On-off valve
13 Air tank

LOCATION OF COMPONENTS FOR 6x4 VEHICLES Towing
222083 Figure 6
1 Front axle ABS solenoid valve 3 Front axle brake control relay valve
2 Front axle cylinder diaphragm brake 4 Combined axle brake cylinder

5 Rear axle /parking brake control relay valve 7 Trailer half-couplings

6 Rear axle ABS solenoid valve 8 Air drier

BRAKING SYSTEM DIAGRAM FOR 6x4 VEHICLES Towing (with shut-off valve)
222085 Figure 7

5 Trailer semi-coupling joints 13 Air tank

6 Trailer brake servo control valve 14 Air tank
7 Brake control relay valve (front axle/rear axle) 15 Air drier
8 Combined intermediate axle brake cylinder 16 4 way protection valve
10 Rear axle ABS solenoid valve 18 Air tank
11 Combined rear axle brake cylinder 19 Duplex distributor
12 Bleed valve 20 Parking brake hand control distributor

BRAKING SYSTEM DIAGRAM FOR 8x4 VEHICLES
222105 Figure 8
1 Air filter 3 Front axle first cylinder diaphragm brake
2 Compressor 4 Front axle second cylinder diaphragm brake

5 Front axle brake control relay valve 13 Air tank (40 L)

7 Air tank (40 L) 14 4 way protection valve
7 Air tank (20 L) 15 Air drier
8 Parking brake control relay valve 16 Regeneration air tank (5 L)
9 Combined intermediate axle brake cylinder 17 Duplex distributor
10 Combined rear axle brake cylinder 18 Parking brake hand control distributor
11 Air tank (20 L) 19 Rear axle brake control relay valve
12 Air tank (40 L)

LOCATION OF COMPONENTS FOR 8x4 VEHICLES
222106 Figure 9
1 Front axle cylinder diaphragm brake 3 Front axle brake control relay valve
2 Front axle second cylinder diaphragm brake 4 Air drier

5 Combined intermediate axle brake cylinder 7 Combined rear axle brake cylinder
6 Rear axle /parking brake control relay valve

BRAKING SYSTEM MAIN COMPONENTS

790510 Compressor
Produces sufficient compressed air to feed the braking system and
ancillary services.
Depending on the version, it may be a single- or twin-cylinder ver-
sion.
60231 Figure 10
.790510. Head locking screw tightness
Tightening torques
Screws fixing air compressor cylinder head 1. Phase 1 15 N⋅m to20 N⋅m
2. Phase 2 30 N⋅m to33 N⋅m
Main action
▶ Following the order shown in the figure, tighten the screws
fixing the cylinder head to the required torque.
Tightening torque
Screws fixing air compressor 1. Phase 1
cylinder head 15 N⋅m to20 N⋅m
2. Phase 2
30 N⋅m to33 N⋅m
Note The tightening sequence refers to the twin-cylinder

compressor. For a single-cylinder version, the sequence
is reduced to 4 screws. 60232 Figure 11

798850 Drier
Its function is to keep the air clean and at the right moisture level
in the distribution system and keep the pressure needed for the
operation of the connected systems at the outlet.
173826 Figure 12
This component integrates the 4-way valve shown in the figure.
222102 Figure 13

793110 Duplex distributor

It takes air from the tanks and distributes it to the braking elements.
It is self-limited, that is it limits the delivery of air at a set maximum
pressure, the outcome of which is a greater availability of energy and
a constant maximum braking pressure irrespective of the pressure
swings in the tanks.
73914 Figure 14
11 Supply from the rear 21 Outlet for servo con-
axle tank trol valve rear axle
12 Supply from the front and trailer control re-
axle tank lay valve
22 Valve output to front
axle relay
3 Venting to outside air
Performance curve
A Outlet pressure p21/p22 B Shoe travel [mm]
[bar]
90639 Figure 15

793332 Trailer servo control valve

The device, controlled by the two independent circuits of the duplex
distributor and the spring brake circuit of the tractor, controls the
trailer braking.
The unit houses a device to actuate the trailer brake, also in case of a
fault in the control pipe.
98887 Figure 16
11 From trailer air 41 From Duplex (con-
tank/APU trol)
12 From the automatic 42 From Duplex distrib-
coupling joint utor (control)
21 To automatic coupling 43 From outlet 22 of the
joint lever
22 To adjustable coupling 3 Exhaust
joint
.793332. Prevalence regulation
Main action
1. To regulate servo control valve predominance, proceed as
follows:
2. Remove the screws (2) and extract the cover (3). 41
3. Operate on predominance adjusting screw (1).
1
4. Rotate CLOCKWISE to decrease predominance.
5. Rotate COUNTERCLOCKWISE to increase predomin- 42
ance.
22
11
12
43
2 3 2
60256 Figure 17

798510 Coupling heads

Their task is to allow connecting the air system of the tractor with
that of the trailer.
The pneumatic jack relative to the Adjustable pipe is equipped
with a yellow lid and safety guide (1) which allows the correct coup-
ling with the pneumatic jack of the trailer.
This pipe handles trailer braking via service brakes.
The pneumatic jack relative to the Automatic pipe, is equipped
with a red lid and a side safety guide (2) which allows the correct
coupling with the pneumatic jack of the trailer.
This pipe supplies the air tank on the trailer.
The safety projections are used to avoid coupling errors.
52871 Figure 18
793319 Check valve (vehicles suitable for towing)

This allows compressed air to pass in the direction shown by the
arrow on the valve body, preventing its flowing back.
1 2
33987 Figure 19

794310 Handbrake manual control valve (vehicles suitable for towing)
222100 Figure 20
The device enables emergency and parking braking of the tractor and the trailer.
Pneumatic connections
1 - Power supply
21 - Delivery
22 - Delivery to trailer
3 - Adjustable outlet
Positions
A - Driving position (Brake disengaged - lever released)
B - Parking position (Brake engaged)
C - Test position (Trailer brake disengaged from the tractor - unstable position)

793333 Rear axle / front axle brake relay valve

Its function is to reduce the trip time of the system to which it is
connected.
This component is used to activate the following functions:
● front axle service braking;

● rear axle service braking.
222099 Figure 21
1 Power supply 3 Exhaust
2 Output towards brak- 4 Control
ing elements

793333 Parking brake relay valve
222101 Figure 22
1 Power supply 3 Exhaust
2 Output towards braking elements 41/42 Controls
Its function is to reduce the trip time of the system to which it is connected.
The component is used for parking brake activation.

76 Quick discharge valve

The component has the function of releasing compressed air from
the spring cylinders to achieve rapid parking braking.
150023 Figure 23
1 From the dual control 2 To spring cylinders
relay valve 3 Exhaust
794911 Diaphragm brake cylinder

This device transmits the force given by the compressed air, as the
brake pedal is pressed, to the mechanical service braking device. In
case of failure, the complete cylinder is to be replaced (the figure
shows the drum brakes version).
227428 Figure 24

ABS SYSTEM (ANTI-LOCK BRAKE SYSTEM)
794922 Combined brake cylinder

This device is composed of two parts: a diaphragm for service brak-
ing and a spring brake for parking and emergency brake if the braking
system fails.
227429 Figure 25
ABS SYSTEM (ANTI-LOCK BRAKE SYSTEM)

79 «ABS» (Anti-Lock Brake System)
The braking of a moving vehicle and resulting deceleration and stopping distances mainly depend on the grip between the tyres and
the road surface.
With a fully efficient braking system, a further improvement in braking can only be achieved by acting on the friction of the tyres or
on the grade of the road surface.
Even in these optimum conditions, absolute braking safety is in any case not guaranteed when faced with especially difficult situ-
ations, such as poor grip due to a wet or icy road surface. The driver is forced to moderate use of the brakes in order to avoid
partially locking one or more wheels, with the risk of skidding dangerously.
The function of the ABS device is therefore to ensure vehicle stability (under all braking conditions), preventing the wheels from
locking irrespective of the state of the road surface, so as to ensure the available grip is made full use of.
Even in the case of emergency braking, the system makes it possible to keep direction, that is to turn the steering wheel to avoid
obstacles with no risk of skidding.
In short, the anti-lock braking system (ABS):
● Prevents the wheels to lock while braking, irrespectively of the grip condition of the road surface.
● Shortens stopping distances.
● Provides safety for the driver who can keep the vehicle's stability and direction.

ABS SYSTEM COMPONENTS
ABS SYSTEM COMPONENTS

526732 Pressure sensor
In ABS/EBL systems, its purpose is to inform the electronic control
unit of the extent of action required by the driver.
In EBS systems, this component is integrated in the front axle, rear
axle and trailer control valves.
52722 Figure 26
526711 Electronic control unit

The control unit is the brain of the system.
It has the task of controlling the system's solenoid valves according to
the signals from the wheel speed sensors.
Each channel has four operating circuits; the first is the input circuit
which receives the analogue signals from the sensor on the corres-
ponding wheel, the signal is filtered and converted to digital informa-
tion by cycle time measurement.
There is also a main circuit which has a microprocessor to process
the information received from the input circuit.
It has a complex program to determine the wheel acceleration and
deceleration values, and to carry out the logic combination of the
different adjustment signals.
If necessary it emits two control signals that are sent to the relevant
32370 Figure 27
anti-lock distributor via the third control unit circuit (control circuit)
to appropriately adjust the braking pressure.
The fourth and last circuit is the safety circuit, that checks the effi-
ciency of the various system components.
If an anomaly is found, it informs the driver, switching on the warning
light on the dashboard, and automatically disconnects the complete
ABS system, leaving the traditional braking system able to work effi-
ciently.

MAIN DATA - PNEUMATIC SYSTEM
526716 ABS solenoid valve

This component modulates the air pressure in the brake circuit.
When the electronic control unit detects a wheel with a tendency to
lock, the valve intercepts the brake cylinder supply, thus preventing
the wheel locking.
35805 Figure 28
Pneumatic connections
● 1 - Supply from proportional relay valve
● 2 - Outlet for front axle brake cylinder
● 3 - Discharge
526713 Revs sensor

The speed sensors and the phonic wheels have the job of measuring
the speed of the respective wheels.
The phonic wheel is housed on the wheel hub and turns at the same
speed as the wheel.
It generates alternating voltages in the sensors by induction, the fre-
quency of these voltages is in proportion to the speed of rotation of
the respective wheel.
These voltage signals are sent to the control unit to be processed.
Each wheel has a sensor and an impulse wheel installed.
This arrangement makes it possible to control an individual braking
pressure for each wheel during adjustment, optimising travelling 35383 Figure 29
stability and braking distance.

Name
Compressor
Type: Single-cylinder / Twin-cylinder
Displacement 360 cm3/ 630 cm3
Drier
Type:
Working pressure bar max.10
Supply pressure bar 10.5
Circuit 1 2 3 4
Union for second: 21 22 23 24
Dynamic opening pressure bar 6.50- 0.3 6.50- 0.3 7.50- 0.3 6.50- 0.3

Name
Dynamic closing pressure bar ≥ 6.0
0 ≥ 5.0 ≥ 5.0 ≥ 5.0
≥ 5.0 0 ≥ 5.0 ≥ 5.0
Static closing pressure bar
≥ 5.0 ≥ 5.0 0 ≥ 5.0
≥ 5.0 ≥ 5.0 ≥ 5.0 0
Limiting pressure bar 8.5
+0
-0.3 8.5
+0
-0.5
Pressure limiter on / off pressure difference bar ≤ 0.65

Air tanks
Front axle 40 litres
Rear axle 40 litres
Trailer parking 20 litres
Services 20 litres
Engine brake control pedal distributor
Type: BOSCH A 481 110 125 - WABCO 463036019 - BENDIX CP6A
Duplex distributor
Type:
Supply pressure max 11 bar
Working pressure 10 bar
Proportional reducing valve
Type: KNORR DB 2116
Ratio 1.15 ∶ 1
Relay valve
Type: WABCO 973 011 001 0
Quick discharge valve
Type: -
Working pressure max. 10 bar
Dual control relay valve
Type: KNORR - CAFF CP3518BA010
Control maximum pressure 13 bar
Service and supply coupling heads
Type: MARELLI - BOSCH - KNORR - BREMSE - WABCO - GRAU
Working pressure 8.5 bar
Triple control servo distributor
Type: WABCO 973 009 001 0
Supply pressure 8.5 bar
Predominance 0.2 bar
Differential control pressure (ducts 41 and 22) 2.5 -0.5
+0.3 bar
Parking brake control valve (truck-trailer vehicles)
Type: KNORR DPM 60EY
Supply and working pressure 8.5 bar

Name
Control lever excursion (discharging) with safety braking start (resistance point) 68⁰
Parking braking 73⁰
Test braking to check supply to triple control valve 85⁰
Parking brake control valve (rigid trucks)
Type: KNORR DPM 61EY
Control lever excursion (discharging) with safety braking start (resistance point) 68⁰
Parking braking 73⁰
Trailer retarder control valve (optional)
KNORR CAFF
Control lever maximum angular excursion 73⁰
Air pressure switch
TDS F13043 - F13047
Working pressure max. 15 bar
Setting pressure
with increasing pressure 5.5 ± 0.5 bar
with decreasing pressure 6.6 ± 0.3 bar
Controlled pressure valve
WABCO 434 100 199 - KNORR - BREMSE 1B 435 47 - BENDIX VPC 4M
Opening pressure 7 -0.1
+0.3 bar
ABS wheel anti-lock distributor
Type: WABCO 472 195 016 0
Type: KNORR - BREMSE IC 57664
Maximum operating pressure 10.2 bar
Check valve
Type: KNORR CAFF 531 105 001 0
Pressure sensor
3800 - 5205 - 18
Measurement principle piezo-resistive
Permissible overpressure 13 bar
E.C.U. (Electronic Control Unit)
MAGNA 3800 - 30060
Power voltage 24 V
Diaphragm brake cylinder
Type 14
Sleeve length 152 mm
Stroke 53 mm
Type 22

CHARACTERISTICS AND DATA - BRAKES
Name
Sleeve length 141 mm
Stroke min. 64 mm
Type 24
Maximum working pressure 8.5 bar
Stroke 57 mm
Combined brake cylinder
Type 16/24 HF
Spring load 7900 N
Stroke min 53 mm
Type 18/24 HF
Spring load 7900 N
Stroke min 53 mm
Type 24/24
Spring load 5000 N
Stroke max 64 mm
CHARACTERISTICS AND DATA - BRAKES

DRUM BRAKES FRONT AXLE REAR AXLE
Drum diameter: 419.9 ÷ 420.1
S
Brake lining thickness: 15.5
408 ÷ 409
Brake lining diameter:
418.9 ÷ 419.1
Brake lining width: L mm 160 ÷ 220

L
G
Clearance between brake linings and drum: Gm 0.3 ÷ 0.5
Maximum error of concentricity in the drum diameter

E E mm 0.1
after turning

TIGHTENING TORQUES
TIGHTENING TORQUES
DETAIL TORQUE
Compressor Nm (kgm)
Compressor
Head fastening screws 30 (3)
Pulley fixing nut 190 +1
-0 (19)
Combined brake cylinder
Manual brake release ring nut 300 + 30 (30 ± 3)
Manual brake release screw 15 + 20 (1.5 ± 2)
Diaphragm brake cylinder (for drum brakes)
Manual brake release ring nut 300 + 30 (30 ± 3)
Axle drum brakes
Wheel mounting nut 600+50
-20 (60+5
-2 )
Rear axle drum brakes

Drum fastening screw 25 ± 3 (2.5 ± 0.3)
Cover retaining screw 50 ± 5 (5 ± 0.3)
Countersunk screw 50 ± 5 (2.5 ± 0.3)
Wheel mounting nut 615 ± 35 (61.5 ± 3.5)
79 General torques
Note Unless otherwise specified, refer to the torque values contained in this table.
General torques
M12 120
M16 350
M20 600
M22 900
M24 1100
M27 1650
TOOLS
Air circuit control instruments (0-16bar) (99305117)

BRAKES SYSTEM MAIN COMPONENT CHECKS
79 BRAKES SYSTEM MAIN COMPONENT CHECKS

As the vehicle's system is type-approved according to European standards, the efficiency check on the system and related compon-
ents must be done with equipment 99305117.
The checks are carried out with the vehicle at a standstill, using compressed air from the tanks recharged by the compressor with
the engine running.
Note Always block the vehicle before starting any type of operation. Periodically check the gauges comparing them with a refer-
ence gauge.
BRAKE SYSTEM MAIN COMPONENT CHECKS

DEVICE NAME OPERATIONS
Check tightness of fittings and compressor fastening; make sure that cooling fins are
Compressor
not dirty.
Operate on a bleeder valve or loosen a screw plug (with built-in bleeder hole) to
check that the air dryer is operating properly. The air should come out from the tank
with no signs of condensate water.
Before replacing the APU (dryer and protection valve) perform the following steps:
1. Check the seal in the dryer and in the protection valve:
■ fill the system until the dryer trips;
■ switch off the engine;
■ check for any air leaks in the unions and breathers using soapy water.
2. Preparation:
■ connect the pressure gauges to circuits 21 and 22 using the pressure
points;
■ connect the pressure gauge to circuit 23 using the red half-coupling.
3. Check the dryer operating pressure:
■ read the pressure values of the circuits 21 - 22 - 23 - 25 on the pres-
A.P.U.
sure gauges (for APU with 12.5 bar);
(Air Processing Unit)
■ compare the measured pressures with those shown on the dashboard.
If there is a significant difference in the values, replace only the double
pressure sensor which is available as a repair kit.
4. Check the pressure at which the dryer trips and switches back on and check
the seal of the discharge valve
■ stop the engine and discharge circuit 21 to 9 bar;
■ disconnect the discharge pipe pressing the release ring and pulling the
pipe (union 3, at the base of the dryer);
■ switch on the engine (idling speed);
■ wear ear protections;
■ when the pressure is increasing before tripping (between 8.5 and 10.5
bar), stop the engine and check whether there are any leaks from the
exhaust;
■ reconnect the discharge pipe to the dryer.
Air tanks for:
● Front axle
● Rear axle Check the seal and corrosion protection.
● Parking + trailer Discharge the condensate from the tanks through the bleeder valve.
● Services
● For regeneration

BRAKES SYSTEM MAIN COMPONENT CHECKS
Check that the pedal gasket is not worn, that the brake linkages are properly
Duplex distributor tightened and lubricated and are not deformed.
Check that lever housings are neither worn nor oxidised.
Pneumatic pressure control

Ensure that the protection plugs are inserted.
points
Operate the parking brake control valve until it triggers; the gauge on the control
Parking brake control valve
socket shall indicate pressure release to 0 bar in 1 second.
Parking brake control valve (with At the same time, at the automatic coupling pipe, the pressure gauge has to show a
check position) pressure of 7.5 bars.
Check fastening, integrity and seal.

Membrane cylinder
The bleeding hole must be oriented downwards and must not be clogged.
Check fastening, integrity and seal.

Combined cylinder
The bleeding hole must be oriented downwards and must not be clogged.
Check its working order and seal, assessing the speed of operation of the brake cylin-
Relay valve
ders.
Fill the tank.

Connect one pressure gauge to the automatic coupling head and one to the ad-
justable coupling head.
Trailer braking triple control At a pressure of 1 bar, delivered by the duplex distributor, the service coupling head
servo-distributor , with integ- should have a pressure ranging between 0.8 and 1.5 bar.
rated supply dump valve Carry out a total braking (unmoving vehicle).
The coupling head must have available the required braking pressure or a pressure
decreased by 0.5 bars. Put the parking brake on; at the adjustable coupling head, the
pressure must stay unchanged or decreased by 0.5 bars.
Check there is no dirt or damage on the coupling slots.
After coupling is made, press the brake pedal and check the seal and stability
Coupling heads
between the coupling heads introducing air at 8.5 bars.
Check there is no air leakage from the coupling gaskets.
Disc brake calliper

Check brake lining wear condition, brake disc scoring and wear, piston efficiency, and
Brake disk
dust cover wear conditions.
Brake linings

ABS control unit replacement

Make sure that metal pipes are in a perfect condition, without dents nor cracks; poly-
amide pipes must not show fissures, cuts or incisions.
Also make sure that they are not near sharp edges of the bodywork or chassis that
could damage them.
Check that all brackets fastening the pipes are securely fixed; loose fastenings cause
vibrations that could lead to breakage.
Check that the polyamide pipes have not come into contact with oil or mineral
grease, rubber solvents.
Pipes and fittings
Press forcefully on the brake pedal and check the pipes do not swell.
Check there is no leakage from the various fittings or it will be necessary to tighten
them fully, but taking care not to cause any abnormal torsion on the pipes. In all the
above cases the parts are to replaced if there is a minimum doubt as to their effi-
ciency.
Apart from their condition, it is recommended to replace hoses after considerable
mileage, or after a period of long vehicle use. This will prevent sudden breakages due
to age and fatigue.
This check is carried out by introducing air pressure into the system of no less than
5 bars, spreading fairly dense soapy water over the couplings and fittings with a soft
Pneumatic system seal tightness
brush and seeing there is no leakage.
with engine off less than activa-
An air leak is within tolerance if it corresponds to a soap bubble with a diameter of
tion pressure
25 mm in 5 seconds, or a pressure drop within 10 minutes amounting to 2% of the
disengagement pressure = 0.22 + 0.02 bar.
Pneumatic system seal in partial For 3 min the pressure must be kept stabilised in the pneumatic system. The check is
braking range with 3 bar made with the parking brake deactivated.
.526711. ABS control unit replacement
Caution!

gnostic instrument;

ABS control unit replacement
Main action
.526711. Removal
1. Remove the passenger side kickplate by acting on the fasteners 1
and remove the passenger side mat.
2. Remove all fasteners (3) from the lower passenger side dash-
board.
3. Remove the trim (2) to access the switches (1).
2 3
171951 Figure 30
4. Remove all fasteners (3) from the upper passenger side dash- 1 2
board.
5. Remove the trip (2) so as to access the body computer control
unit (1), the fuses and the diagnosis socket.
171952 Figure 31
6. Disconnect the electrical connections (1) from the ABS control

unit (3).
7. Remove the ABS control unit (3) from the vehicle by acting on
the retainers (2).
217717 Figure 32
.526711. ABS control unit refitting

8. To refit, carry out the operations described in the removal process in reverse order, by tightening the screws and nuts to the
specified torque.
Note It may be necessary to disconnect the battery negative to complete programming.

Replacing pipelines and couplings
.799510. Replacing pipelines and couplings
Work material
Polyamide pipe shears 99387050
Tool kit for polyamide pipe (6-8-10-12-15-16 mm) dis- 99387051
connection from Raufoss fittings
Main action
.799510. General information
1. The pipelines on the braking system of the industrial vehicles are hoses in polyamide with a single layer or dual layer structure;
spares are ordered by the meter.
.799510. Replacing flexible hoses with quick release couplings

Conditions
● For rotary unions:
▶ Screw the coupling into the threaded seating provided

on the air valve, and tighten it to the torque shown in the
table Swivelling and adjustable couplings.
39306 Figure 33
Conditions
● For adjustable unions:
▶ Check that the seal ring (1) is in its seat.

▶ 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 torque indicated in
the table.
Swivel and banjo couplings
TIGHTENING TORQUE (Nm ±
UNION THREAD
10%)
M 10 x 1.0 mm 22
M 12 x 1.5 mm 24
M 14 x 1.5 mm 28
M 16 x 1.5 mm 35
M 22 x 1.5 mm 40
39307 Figure 34

2. Cut the hose to 90°, maximum error 15° with reference to

the axis. Use proper pipe cutting-pliers to cut to the required
length.
code
Polyamide pipe shears 99387050
Note Use only approved hoses.

Check the condition of the new hose; there must be no
cracks, cuts or incisions on it.
33977 Figure 35
3. Use indelible ink to clearly mark two reference notches on both

diametrically opposite faces of the pipe at an angle of ≥ 75° set
to distances L1 and L2 to ensure correct fitting in place.
Markings for correct assembly
D [mm] L0+0.5[mm] L-0.5
1 +1[mm] L-0.5
2 +1[mm]
6 19.8 17 22
8 20.5 18 23
12 25 22 28
16 27.1 24 30
Note The distances L1 and L2 vary according to the pipe dia-

meter and must be measured from the longest side of
the pipe (see figure).
33976 Figure 36
A Mark to identify end
of hose travel
4. Insert the hose (2) manually into the coupling (1), with a force
between 30 and 120 Nm according to the hose diameter, so
that reference mark L1 is inside the hose whereas L2 remains
visible.
39308 Figure 37

5. In case of disassembly of the connectors (1) from the pneu-

matic components, check the seal ring condition (2), if neces-
sary replace it.
Sealing ring dimensions
SEALING RING
UNION THREAD
DIMENSIONS
M 10 x 1.0 10.1 x 1.6
M 12 x 1.5 11.0 x 2.0
M 14 x 1.5
M 16 x 1.5 15.0 x 2.0
M 22 x 1.5
Note Whenever a hose is removed from a quick coupling,

the coupling itself must be replaced. 33978 Figure 38
Spare quick couplings are supplied complete.
Note Quick release and threaded couplings are not inter-

changeable. This also applies to flexible hoses used with
quick release couplings and flexible hoses used with
threaded couplings.
.799510. Replacing the flexible pipes with Raufoss couplings

Note Precautions for use of specific tool:
- Bleed pressure from air system.
- Push pipe against the union before fitting the tool.
- Do not apply excessive force.
- Use tools that are not damaged.
6. Insert specific tool (2) on pipe (1).

code
Tool kit for polyamide pipe (6-8-10-12-15-16 mm) discon- 99387051
nection from Raufoss fittings
7. Push the tube (1) against the coupling (3); slide the specific tool
inside the coupling.
125239 Figure 39

8. Keep the specific tool (2) pressed and extract the tube (1)
from the coupling (3).
code
Tool kit for polyamide pipe (6-8-10-12-15-16 mm) discon- 99387051
nection from Raufoss fittings
125240 Figure 40
.799530. Replacing type Raufoss couplings

.799530. Discoupling type Raufoss unions
Note Perform this operation only after draining all pressure from the system.
9. Remove the rotolock (1) from the locking seat.
174605 Figure 41

10. Open the arms(2) using the appropriate tool (1).
174606 Figure 42
11. While keeping the arms apart (⇒), extract the union (2) from
the joint (1).
174607 Figure 43
.799530. Coupling type Raufoss unions

Note The undamaged parts can be reused.
12. Insert the fitting (2) into the joint (1) and press in the arrow
direction (⇒) to fit the coupling.
Note Coupling is done in 2 clicks
174608 Figure 44

13. The 1st click allows rotation of the union (2) with respect to
the joint (1).
174609 Figure 45
14. Pressing again in the arrow direction (⇒) couples the fitting in
the 2nd clip.
Technical data
X = 1 mm
174610 Figure 46
15. With the coupling of the 2nd click the union (2) is locked with
respect to the joint (1).
174611 Figure 47

Replacement of the dryer
.798850. Replacement of the dryer
Main action
.798850. Removal of the dryer
1. Remove the four air pipes (6) by working on the couplings (7).
2. Remove the electrical connection (4).
3. Remove the three fasteners (3) of the dryer (1) which fasten it
to the support bracket (2).
4. Remove the air pipe by working on the coupling (5).
5. Remove the dryer (1).
173827 Figure 48
.798850. Refitting the dryer

.5270. FRONT BRAKE OVERHAULING

Main action
▶ For the overhaul of the front brakes, refer to the indications provided in the following procedure AXLE ASSEMBLY OVER-
HAUL ( ➠ Page 13).
.5272. REAR BRAKE OVERHAUL

Main action
▶ For the overhaul of the rear brakes, refer to the indications provided in the following procedure OVERHAULING THE HR
INTERMEDIATE AXLE ASSEMBLY .

DIAGNOSTICS
DIAGNOSTICS
Poor or abnormal system charge

1 Leakages or breakages in pneumatic system Cause confirmed ▶ Tighten or replace loose or damaged
pipes. fittings. Replace broken or damaged
pipes.
2 Air compressor not working properly. Cause confirmed ▶ Overhaul or replace the air com-
pressor.
3 Drier functioning inefficiently. Cause confirmed ▶ Overhaul/replace drier.
Cause not confirmed
Irregular or poor braking of the front axle

1 Inefficient operation of the foot control Cause confirmed ▶ Overhaul or replace the Duplex dis-
valve. tributor.
2 Brake linings worn and/or vitrified. Cause confirmed ▶ Overhaul or replace the brake linings.
3 Inefficient operation of the front brakes. Cause confirmed ▶ Overhaul the front brakes.
4 Inefficient operation of the relay valve. Cause confirmed ▶ Overhaul or replace the relay valve.
5 Inefficient operation of the diaphragm brake Cause confirmed ▶ Overhaul or replace the diaphragm
cylinders. brake cylinders.
6 Inefficient operation of the automatic wear Cause confirmed ▶ Replace the complete brake caliper.
recovery device. Cause not confirmed Check: 7
7 Inefficient operation of the ABS solenoid Cause confirmed ▶ Check the electric wiring.
valve. ▶ Replace the ABS solenoid valve.
Cause not confirmed
Irregular or poor braking of the front axle

pipes.
Cause not confirmed

DIAGNOSTICS
Poor or irregular service braking of the rear axle

pipes.
3 Inefficient operation of the rear brakes. Cause confirmed ▶ Overhaul the rear brakes.
valve. tributor.
5 Inefficient operation of the brake cylinders. Cause confirmed ▶ Overhaul or replace the brake cylin-
ders.
6 Inefficient operation of the ABS solenoid Cause confirmed ▶ Check the electric wiring.
valve. ▶ Replace the ABS solenoid valve.
7 Inefficient operation of the automatic wear Cause confirmed ▶ Replace the complete brake caliper.
recovery device. Cause not confirmed
Poor or abnormal trailer service braking

pipes.
2 Inefficient operation of the triple control Cause confirmed ▶ Overhaul or replace the triple control
servo control valve. servo control valve.
valve. tributor.
6 Inefficient operation of the trailer brakes. Cause confirmed ▶ Overhaul the trailer brakes.
Cause not confirmed

DIAGNOSTICS
Inefficient or no parking brake

pipes.
2 Inefficient operation of the combined brake Cause confirmed ▶ Overhaul or replace the combined
3 Inefficient operation of the parking brake Cause confirmed ▶ Overhaul or replace the lever.
hand control valve (lever). Cause not confirmed Check: 4
Cause not confirmed
Parking brake release delayed

pipes.
3 Inefficient operation of the combined brake Cause confirmed ▶ Overhaul or replace the combined
Cause not confirmed
Trailer parking brake release delayed

pipes.

DIAGNOSTICS

4 Inefficient operation of the trailer brakes. Cause not confirmed
Vehicle skids when braking

pipes.
valve. tributor.
3 Inefficient operation of the front brakes. Cause confirmed ▶ Overhaul the front brakes.
Cause not confirmed
Insufficient trailer deceleration braking

pipes.
hand control valve (lever). Cause not confirmed
Inefficient or no trailer parking brake

pipes.

DIAGNOSTICS

4 Brake linings worn and/or vitrified. Cause not confirmed Check: 5
6 Inefficient operation of the trailer control Cause confirmed ▶ Check the electric wiring.
servo control valve. ▶ Replace the trailer control servo con-
trol valve.
Cause not confirmed
Rapid brake lining wear

valve. tributor.
2 Brakes are faulty. Cause confirmed ▶ Overhaul brakes.
Cause not confirmed
Brake system warning light on

pipes.
3 Wrong wiring of the electric circuit of the Cause confirmed ▶ Identify the wrong connection and
indicator light. restore correct wiring.
Cause not confirmed
Parking brake indicator light on with lever in driving position

1 Wrong wiring of the electric circuit of the Cause confirmed ▶ Identify the wrong connection and
indicator light. restore correct wiring.
Cause not confirmed

DIAGNOSTICS
Noisy brakes

2 Inefficient jaw return springs. Cause confirmed ▶ Overhaul the rear brakes.
3 Excessive ovality of the brake drums. Cause confirmed ▶ Lathe turn or if necessary replace the
drums.
Cause not confirmed ▶ "Contact the Service Network".


DTC ABS control unit
58
DTC FMI Faulty Error type Visible fault Possible Cause Repair operation Controls to be Measuring Values Notes
DIAGNOSTICS
682 - Pneumatic system - Brakes
compon- carried out conditions to be
ent detected
0x0001 0x0000 SENSORS FRONT LEFT The error is Check and verify the Measurement type: Connector Typical value: Carry
(1) (0) SPEED SENSOR caused by a wiring and the correct Resistance (KOhm) disconnec- 11KOhm out the
wiring short assembly of the sensor. Measurement ted; Key +15 indicated
circuit or faulty Replace sensor if dam- point 1: Connector OFF measure.
sensor. aged. Check the integrity, X2 Pin: 12 Meas-
cleanliness and correct urement point 2:
assembly of the phonic Connector X2 Pin:
wheel, reset the distance 15
– between the sensor and
phonic wheel if necessary
(values to be observed:
0.7 ± 0.05 mm). Check
the correct control unit
configuration. If the fault
persists, please contact
the market THD or the
CET.
0x0002 0x0000 SENSORS FRONT RIGHT The error is Check and verify the Measurement type: Connector Typical value: Carry
(2) (0) SPEED SENSOR caused by a wiring and the correct Resistance (KOhm) disconnec- 11KOhm out the
0.7 ± 0.05 mm). Check
CET.
ent detected
0x0003 0x0000 SENSORS REAR LEFT The error is Check and verify the Measurement type: Connector Typical value: Carry
(3) (0) SENSOR caused by a wiring and the correct Resistance (KOhm) disconnec- 11KOhm out the
0.7 ± 0.05 mm). Check
CET.
0x0004 0x0000 SENSORS REAR RIGHT The error is Check and verify the Measurement type: Connector Typical value: Carry
(4) (0) SENSOR caused by a wiring and the correct Resistance (KOhm) disconnec- 11KOhm out the

0.7 ± 0.05 mm). Check

DIAGNOSTICS
CET.
59
60
ent detected
DIAGNOSTICS
0x0007 0x0000 SOLENOID FRONT LEFT The error may Use the wiring diagrams Measurement type: Connector Typical value: Carry
(7) (0) VALVES ABS SOLENOID be caused by to check the conformity resistance (Ohm) disconnec- 400Ohm out the
VALVE faults in the wir- of the wiring and the in- Measurement ted; Key +15 indicated
ing or by a faulty tegrity of the connectors. point 1: Connector OFF measure.
– component. Check the integrity of X2 Pin: 3 Meas-
the component. If the urement point 2:
fault persists, please con- Connector X2 Pin:
tact the market THD or 6
the CET.
0x0008 0x0000 SOLENOID FRONT RIGHT The error may Use the wiring diagrams Measurement type: Connector Typical value: Carry
the CET.
0x0009 0x0000 SOLENOID REAR LEFT ABS The error may Use the wiring diagrams Measurement type: Connector Typical value: Carry
(9) (0) VALVES SOLENOID be caused by to check the conformity resistance (Ohm) disconnec- 400Ohm out the
the CET.
0x000A 0x0000 SOLENOID REAR RIGHT The error may Use the wiring diagrams Measurement type: Connector Typical value: Carry
the CET.
ent detected
0x000D 0x0000 THIRD THIRD BRAKE The error may Use the wiring diagrams Measurement type: Connector Typical value: Carry
(13) (0) BRAKE RELAY be caused by to check the conformity Resistance (KOhm) disconnec- 2KOhm out the
RELAY faults in the wir- of the wiring and the in- Measurement ted; Key +15 indicated
the CET.
0x000E 0x0000 VOLTAGE POWER SUPPLY The error is Check the condition of Measurement type: Connector Typical value: Carry
(14) (0) caused by the the battery charge. Use Voltage (V) Meas- Connected; 12/24 V out the
power supply the wiring diagrams to urement point 1: Key +15 indicated
voltage to the check the conformity of Connector X1 Pin: ON measure.
–
ECU the wiring and the integ- 7 Measurement
rity of the connectors. point 2: Connector
Check the integrity of X1 Pin: 4
the electronic module.
0x000F 0x0000 SOLENOID DIFFERENTIAL The error may Use the wiring diagrams Measurement type: Connector Typical value: Carry
(15) (0) VALVES VALVE be caused by to check the conformity resistance (Ohm) disconnec- 400Ohm out the
faults in the wir- of the wiring and the in- Measurement ted; Key +15 indicated

the CET.
0x0010 0x0000 SENSORS PRESSURE The error is Use the wiring diagrams Measurement type: Connector Minimum Carry
(16) (0) SENSOR caused by a to check the conformity Resistance (KOhm) disconnec- value: out the
wiring short of the wiring and the in- Measurement ted; Key +15 8KOhm; indicated

circuit or faulty tegrity of the connectors. point 1: Connector OFF Maximum measure.
– sensor. Check the integrity of X1 Pin: 2 Meas- value:
the component. If the urement point 2: 8.5KOhm;
DIAGNOSTICS
fault persists, please con- Connector X1 Pin: Typical value:
tact the market THD or 4 8.25KOhm
the CET.
61
62
ent detected
DIAGNOSTICS
0x0012 0x0000 SOLENOID ASR SOLENOID The error may Use the wiring diagrams Measurement type: Connector Typical value: Carry
(18) (0) VALVES VALVE be caused by to check the conformity Voltage (Ohm) Connected; 12/24Ohm out the
faults in the wir- of the wiring and the in- Measurement Key +15 indicated
ing or by a faulty tegrity of the connectors. point 1: Connector ON measure.
the CET.
0x0013 0x0000 SOLENOID TRAILER SOLEN- The error may Use the wiring diagrams
(19) (0) VALVES OID VALVE be caused by to check the conformity
faults in the wir- of the wiring and the in-
ing or by a faulty tegrity of the connectors.
– component. Check the integrity of – – – –
the component. If the
fault persists, please con-
tact the market THD or
the CET.
0x0017 0x0000 WARNING TRACTOR ABS The error may Use the wiring diagrams Measurement type: Connector Typical value: Carry
(23) (0) LIGHTS be caused by to check the conformity Voltage (V) Meas- Connected; 2.5V out the
faults in the wir- of the wiring and the in- urement point 1: Key +15 indicated
ing or by a faulty tegrity of the connectors. Connector X1 Pin: ON measure.
– component. Check the integrity of 4 Measurement
the component. If the point 2: Connector
fault persists, please con- X1 Pin: 15
tact the market THD or
the CET.
0x004F 0x0000 TYRES TYRE PRESSURE Low Tyre Pres- Restore the correct tyre
– – – – –
(79) (0) sure pressure.
ent detected
0x00E7 0x0000 CAN LINE COMMUNICA- The error is Use the wiring diagrams Measurement type: Connector Typical value: Carry
(231) (0) TION ERROR caused by a delay to check the conformity resistance (Ohm) disconnec- 60Ohm out the
in the reception of the wiring and the Measurement ted; Key +15 indicated
of messages on integrity of the connect- point 1: Connector OFF measure.
the CAN line ors. Check the correct X1 Pin: 1 Meas-
coming from electric connection of urement point 2:
– other electronic the CAN line with the Connector X1 Pin:
systems or electronic module. Check 3
functions present that all the vehicle's con-
on the vehicle. trol units connected to
the CAN line are cor-
rectly configured and
functioning.
0x00FB 0x0000 VOLTAGE OVERVOLTAGE The error is Check the condition of Measurement type: Connector Typical value: Carry
(251) (0) caused by high the battery charge. Use Voltage (V) Meas- Connected; 12/24 V out the
supply voltage the wiring diagrams to urement point 1: Key +15 indicated
of the internal check the conformity of Connector X1 Pin: ON measure.
ECU compon- the wiring and the integ- 7 Measurement
– ents. Possible rity of the connectors. point 2: Connector
causes: - High Check the integrity of X1 Pin: 4
battery voltage - the electronic module.
Defective wiring

- control unit
internal fault
0x00FD 0x0000 ELEC- EEPROM The error is If the fault occurs under
(253) (0) TRONIC caused by wrong normal operating con-
CONTROL programming or ditions, use the wiring
UNIT the EEPROM diagrams to check the
is faulty when conformity of the wiring

– programming and the integrity of the – – – –
data. connectors. Check the
integrity of the electronic
DIAGNOSTICS
module. If the fault per-
sists, please contact the
market THD or the CET.
63
64
ent detected
DIAGNOSTICS
0x00FE 0x0000 ELEC- INTERNAL The error is If the fault occurs under
(254) (0) TRONIC FAULT caused by wrong normal operating con-
CONTROL programming or ditions, use the wiring
UNIT the EEPROM diagrams to check the
is faulty when conformity of the wiring
– programming and the integrity of the – – – –
data. connectors. Check the
integrity of the electronic
module. If the fault per-
sists, please contact the
market THD or the CET.
682 ‒ Bodywork and chassis
Contents 1
Contents
BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

2 Contents

BODYWORK 3
Contents
Contents MANUALLY DRIVEN CAB TILT . . . . . . . . . . . . . . 59

Hydraulic cab tilt cylinder replacement . . . . . . . . 60
MAIN DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . 5
Check oil level . . . . . . . . . . . . . . . . . . . . . . . 61
4x2 Tractors . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bleeding cab tilting system . . . . . . . . . . . . . . . . 61
6x4 Tractors . . . . . . . . . . . . . . . . . . . . . . . . . 7
4x2 cab versions . . . . . . . . . . . . . . . . . . . . . . . 9 CAB MECHANICAL SUSPENSION . . . . . . . . . . . . 63
6x4 cab versions . . . . . . . . . . . . . . . . . . . . . . 11 Location of cab suspension components . . . . . . . 63
6x4 Tippers . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cab driving position adjustment . . . . . . . . . . . . 63
8x4 Tippers . . . . . . . . . . . . . . . . . . . . . . . . . 15 CAB PNEUMATIC SUSPENSION . . . . . . . . . . . . . 64
General information . . . . . . . . . . . . . . . . . . . . . . 17 Location of cab suspension components . . . . . . . 64

Cab suspension pneumatic system schematic
CHARACTERISTICS AND DATA . . . . . . . . . . . . . 18 diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Adjusting the levelling valve linkage . . . . . . . . . . 65
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REPAIR OPERATIONS ON DOORS . . . . . . . . . . . 66
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
CAB REPAIR INTERVENTIONS . . . . . . . . . . . . . . 21
Bumper removal-refitting . . . . . . . . . . . . . . . . 21 SEAT REPAIR OPERATIONS . . . . . . . . . . . . . . . . 84
Replacing the side baffles . . . . . . . . . . . . . . . . . 24
CAB AIR-CONDITIONING . . . . . . . . . . . . . . . . 101
Cab removal and refitting . . . . . . . . . . . . . . . . 24
Principles . . . . . . . . . . . . . . . . . . . . . . . . . 101
Instrument Cluster (IC) Replacement . . . . . . . . . 31
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . 102
DASHBOARD REMOVAL - REFITTING . . . . . . . 34
Climate control . . . . . . . . . . . . . . . . . . . . . 102
Replacement of the BC2 control unit (Body
Computer) . . . . . . . . . . . . . . . . . . . . . . . . . 42 air-conditioning . . . . . . . . . . . . . . . . . . . . . 102
ROOF UNIT REPLACEMENT . . . . . . . . . . . . . 44 heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
AIR INTAKE HATCH REPLACEMENT . . . . . . . . 45 characteristics and data . . . . . . . . . . . . . . . . . . . 109

DRIVER'S SEAT REPLACEMENT . . . . . . . . . . . 46
CLIMATE CONTROL SYSTEM REPAIR
Passenger's seat replacement . . . . . . . . . . . . . . 46
INTERVENTIONS . . . . . . . . . . . . . . . . . . . . . . 110
Replacing the windscreen . . . . . . . . . . . . . . . . 47
REPLACEMENT OF HEATER CONTROLS
WINDSCREEN WIPER BODY COMPLETE WITH BOWDEN CABLES . . . . . . 111
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 48
Heater Removal and Refitting . . . . . . . . . . . . . 113
WINDSCREEN WIPER MOTOR
Removing - Refitting the air recirculation door
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 49
control motor . . . . . . . . . . . . . . . . . . . . . . 115
WINDSCREEN WIPER ARM
Electrical fan Removal - Refitting . . . . . . . . . . . 115
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 49
Heater radiator Removal - Refitting . . . . . . . . . 116
BATTERY REPLACEMENT . . . . . . . . . . . . . . . 50
Cock Removal and Refitting . . . . . . . . . . . . . . 118
Horn replacement . . . . . . . . . . . . . . . . . . . . . 50
Pollen filter removal - refitting . . . . . . . . . . . . 119
CAB ANCHORING . . . . . . . . . . . . . . . . . . . . . . 51 Air conditioner condenser removal-refitting . . . . 119
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 51

4 BODYWORK
Contents
Emptying and refilling of conditioning systems

with coolant R 134 a . . . . . . . . . . . . . . . . . . 120
Leak detector for air conditioning systems with
HFC R 134 a . . . . . . . . . . . . . . . . . . . . . . . 121
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . 122

BODYWORK 5
MAIN DIMENSIONS
BODYWORK
5501 MAIN DIMENSIONS
4x2 Tractors
217686 Figure 1
Vehicle dimensions
SC430G34/38TS
REFERENCE DIMENSION REFERENCE DIMENSION
A 1435 mm 1097-1149 mm (1)(2)
T
B 3650 mm 1169-1218 mm (1)(3)
C 1000 mm 1013-1049 mm (1)(2)

T1
D 2500 mm 1067-1121 mm (1)(2)
H 3759-3800 mm (1)
14-15° (1)(2)
α
H1 3726-3796 mm (1)
13-14° (1)(3)
P 280-305 mm (1)
21-23° (1)(2)
β
Q 212-246 mm (1)
25-27° (1)(3)
U 2481-2508 mm (1)
γ 15°
(1) In function of type of tyre mounted.
(2) Front and rear parabolic suspensions
(3) Front parabolic, rear semi-elliptical suspensions.
T, H: with vehicle unladen.
T1, H1: with vehicle load.

6 BODYWORK
MAIN DIMENSIONS
217686 Figure 1
Vehicle dimensions
SC430G48TS
A 1435 mm 1090-1111 mm (1)(2)
T
B 3650 mm 1141-1183 mm (1)(3)
C 1000 mm 1013-1049 mm (1)(2)

T1
D 2500 mm 1067-1121 mm (1)(2)
H 3770-3792 mm (1)
14-15° (1)(2)
α
H1 3726-3760 mm (1)
13-14° (1)(3)
P 280-305 mm (1)
21-23° (1)(2)
β
Q 212-246 mm (1)
25-27° (1)(3)
U 2481-2508 mm (1)
γ 15°

BODYWORK 7
MAIN DIMENSIONS
6x4 Tractors
217687 Figure 2
Vehicle dimensions
SC600G34/38 T-TS
A 1435 mm 1092-1137 mm (1)(2)
T
B 3300 mm 1078-1133 mm (1)(3)
C 1350 mm 1015-1049 mm (1)(2)

T1
D 685 mm 1020-1049 mm (1)(2)
E 2500 mm 14-15° (1)(2)

α
H 3726-3796 mm (1)
14-15° (1)(3)
H1 3726-3760 mm (1)
35-37° (1)(2)
β
P 271-305 mm (1)
36-38° (1)(3)
Q 212-246 mm (1)
γ 15°
U 2481-2508 mm (1)


8 BODYWORK
MAIN DIMENSIONS
217687 Figure 2
Vehicle dimensions
SC600G43/48 T-TS
A 1435 mm 1104-1146 mm (1)(2)
T
B 3300 mm 1124-1166 mm (1)(3)
C 1350 mm 1018-1047 mm (1)(2)

T1
D 685 mm 1038-1067 mm (1)(2)
E 2500 mm 14-15° (1)(2)

α
H 3760-3801 mm (1)
14-15° (1)(3)
H1 3726-3760 mm (1)
35-37° (1)(2)
β
P 267-301 mm (1)
36-38° (1)(3)
Q 255-289 mm (1)
γ 12°
U 2480 mm

BODYWORK 9
MAIN DIMENSIONS
4x2 cab versions
217688 Figure 3
Vehicle dimensions
SC/DC330G34/38H
A 1435 mm 3083-3117 mm (1)(2)
H
B 4600 mm 3103-3137 mm (1)(3)
C 2050/2500 mm (4)
3050-3084 mm (1)(2)
H1
D 250 mm 3070-3104 mm (1)(3)
E 320 mm 1081-1135 mm (1)(2)

T
F 2500 mm 1101-1155 mm (1)(3)
G 2410 mm 1015-1049 mm (1)(2)
720 mm (short cab) T1

L 1035-1069 mm (1)(3)
1155 mm (long cab)
I 2506-2528 mm (1)
P 274-308 mm (1)
α 22 ° Q 288-322 mm (1)
β 10-13° (1)
γ 19-20° (1)


10 BODYWORK
MAIN DIMENSIONS
217688 Figure 3
Vehicle dimensions
SC/DC190G29S
A 1435 mm 3083-3117 mm (1)(2)
H
B 5600 mm 3103-3137 mm (1)(3)
C 2050/2500 mm (4)
3050-3084 mm (1)(2)
H1
D 250 mm 3070-3104 mm (1)(3)
E 320 mm 1108-1146 mm (1)(2)

T
F 2500 mm 1128-1166 mm (1)(3)
G 2410 mm 1018-1047 mm (1)(2)

L 1038-1067 mm (1)(3)
1155 mm (long cab)
I 2506-2528 mm (1)
P 274-308 mm (1)
α 22-24° (1)
Q 288-322 mm (1)
β 10-13° (1)
γ 15-17° (1)


BODYWORK 11
MAIN DIMENSIONS
6x4 cab versions
217689 Figure 4
Vehicle dimensions
SC/DC260G34S
A 1435 mm 3088-3118 mm (1)(2)
H
B 3825/4425/5025 mm 3108-3138 mm (1)(3)
C 1350 mm 3017-3051 mm (1)(2)

H1
D 2050/2500 mm (4)
3037-3071 mm (1)(3)
E 250 mm 1128-1193 mm (1)(2)

T
F 320 mm 1148-1213 mm (1)(3)
G 2500 mm 1068-1102 mm (1)(2)

T1
I 2410 mm 1088-1122 mm (1)(3)
720 mm (short cab)

L P 270-304 mm (1)
1155 mm (long cab)
U 2506-2528 mm (1)
Q 276-310 mm (1)
α 34-35° (1)
γ 20°
β 12-13° (1)

12 BODYWORK
MAIN DIMENSIONS
217689 Figure 4
SC/DC260G34S

BODYWORK 13
MAIN DIMENSIONS
6x4 Tippers
217690 Figure 5
Vehicle dimensions
SC/DC330G34/38/43H
B = 3325/3625 mm
A 1435 mm 3065-3086 mm (1)(2)
H
C 1350 mm 3085-3106 mm (1)(3)
D 875/1500 mm (4)
3019-3040 mm (1)(2)
H1
E 570 mm 3039-3060 mm (1)(3)
F 2500 mm 1192-1239 mm (1)(2)

T
G 2410 mm 1212-1259 mm (1)(3)
I 2500 mm 1082-1103 mm (1)(2)

L 1102-1123 mm (1)(3)
1155 mm (long cab)
α 20-21° (1)
P 292-313 mm (1)
β (16/27 (4)
Q 271-292 mm (1)
γ 20°

14 BODYWORK
MAIN DIMENSIONS
217690 Figure 5
SC/DC330G34/38/43H
B = 3325/3625 mm
(4) In function of vehicle configuration.
Vehicle dimensions
SC/DC330G34/38/43H
B = 4225/4725 mm
A 1435 mm 3065-3086 mm (1)(2)
H
C 1350 mm 3085-3106 mm (1)(3)
D 1000 mm 3019-3040 mm (1)(2)

H1
E 570 mm 3039-3060 mm (1)(3)
F 2500 mm 1145-1174 mm (1)(2)

T
G 2410 mm 1165-1197 mm (1)(3)
I 2500 mm T1 1069-1090 mm (1)(2)

BODYWORK 15
MAIN DIMENSIONS
SC/DC330G34/38/43H
B = 4225/4725 mm
720 mm (short cab)
L T1 1089-1110 mm (1)(3)
1155 mm (long cab)
α 20-21° (1)
P 292-313 mm (1)
β 24-25°(1) Q 271-292 mm (1)
γ 16°
8x4 Tippers
217691 Figure 6
Vehicle dimensions
SC/DC330G34/38/43H
C = 2700/3025 mm
A 1435 mm 3065-3086 mm (1)(2)
H
B 1800 mm 3085-3106 mm (1)(3)

16 BODYWORK
MAIN DIMENSIONS
217691 Figure 6
SC/DC330G34/38/43H
C = 2700/3025 mm
D 1350 mm 3019-3040 mm (1)(2)
H1
E 1000 mm 3039-3060 mm (1)(3)
F 570 mm 1192-1239 mm (1)(2)

T
G 2500 mm 1212-1259 mm (1)(3)
I 2410 mm 1082-1103 mm (1)(2)

T1
M 2500 mm 1102-1123 mm (1)(3)
720 mm (short cab)

L P 292-313 mm (1)
1155 mm (long cab)
α 17-18° (1)
Q 271-292 mm (1)
β 24-25° (4)
γ 11°

BODYWORK 17
General information
Vehicle dimensions
SC/DC330G34/38/43H
C = 3325/3925 mm
A 1435 mm 3065-3086 mm (1)(2)
H
B 1800 mm 3085-3106 mm (1)(3)
D 1350 mm 3019-3040 mm (1)(2)

H1
E 1000 mm 3039-3060 mm (1)(3)
F 570 mm 1192-1239 mm (1)(2)

T
G 2500 mm 1212-1259 mm (1)(3)
I 2410 mm 1082-1103 mm (1)(2)

T1
M 2500 mm 1102-1123 mm (1)(3)
720 mm (short cab)

L P 292-313 mm (1)
1155 mm (long cab)
α 17-18° (1)
Q 271-292 mm (1)
β 24-25° (4)
γ 11°
550101 General information

The cab is of an advanced type, hydraulically tilting by manual control.
Technical data
Tilting angle 60°
Pressed and welded steel framework.

Protection: anti-corrosion protection in boxed compartments.
Door and outer panel inner side frame coated with galvanised metal sheet.
Cab suspension type:
● mechanical;
● pneumatic on request only on AT vehicles with middle to high roof.
Cab types
CAB TYPE
VEHICLES CAB LOW ROOF HIGH ROOF
TRACTORS LONG (2460x2100 mm) ● ●
SHORT (2280x1670 mm)
TIPPER ● –
LONG (2460x2100 mm)

18 BODYWORK

NAME
Cab with mechanic suspension
Front suspension made up of:
− stabilizer bar 1
− shock absorber with coaxial cylindrical spring with adjusting device 2
Rear suspension made up of:
− shock absorber with coaxial cylindrical spring with adjusting device 2
− rubber buffers 2
TOOLS
Tool for removing and refitting cab front suspension bracket silentblocks (99346051)
Arm for cab removal and refitting (99378039)

Cab support for 4x2 - 6x4 vehicles

BODYWORK 19
TIGHTENING TORQUES
99119 Figure 7
TORQUE
DETAIL
Nm (kgm)
Nut 226.5 ± 22.5 (22.6 ± 2.2)
1
Screw 278 ± 28 (27.8 ± 2.8)
Nut
2 226.5 ± 22.5 (22.6 ± 2.2)
Screw
Nut 179 ± 18 (17,9 ± 1,8)
3
Screw 146.5 ± 14.5 (14,6 ± 1,4)
Cab support for 8x4 vehicles

20 BODYWORK
TIGHTENING TORQUES
99121 Figure 8
TORQUE
DETAIL
Nm (kgm)
Nut 226.5 ± 22.5 (22.6 ± 2.2)
1
Screw 278 ± 28 (27.8 ± 2.8)
Nut
2 226.5 ± 22.5 (22.6 ± 2.2)
Screw
Nut 179 ± 18 (17,9 ± 1,8)
3
Screw 146.5 ± 14.5 (14,6 ± 1,4)

BODYWORK 21
CAB REPAIR INTERVENTIONS
General torques
Note Unless otherwise indicated, refer to the torque values shown in this table:

M12 120
M16 350
M20 600
M22 900
M24 1100
M27 1650
M12 x 1.5 75 ÷ 113
M12 x 1.75 73 ÷ 111
M14 x 2 122 ÷ 185
M14 x 1.5 146 ÷ 205
M14 x 2 141 ÷ 200
M14 x 1.5 178 ÷ 235
M16 x 1.5 199 ÷ 270
M16 x 1.5 240 ÷ 335
M18 x 1.5 397 ÷ 507

.500210. Bumper removal-refitting
Caution!
▶ Before performing repair operations on the vehicle, disconnect batteries by operating on current main switch and
observe safety rules.

22 BODYWORK
Main action
.500210. Bumper removal
1. Remove the three fastening screws (1) and remove the bulk-
head cover (2).
2. Unscrew the four screws (3) retaining the bumper (4). 1
2
3 4
171978 Figure 9
3. Remove the brown connector (1) of bulkhead B with its

ground. 1
4. Remove the cable support bracket (2) by unscrewing the two
screws (3).
171981 Figure 10
5. Remove the trumpet cable connection (1).
171980 Figure 11

BODYWORK 23
6. In the lower part of the bumper, unscrew the screws fixing the
side internal brackets (1).
171979 Figure 12
7. With the bumper (1) moved aside, remove the cable clamps of
the headlamps and remove their connectors (2).
8. Then remove the bumper (1). 2
171982 Figure 13
.500210. Refitting the bumper

9. Position the bumper for mounting.
10. With the bumper set aside, put the clamps on the cables and reconnect the connectors of the headlamps.
11. Screw the four screws retaining the bumper in the front part.
12. Screw the screws fixing the internal side brackets retaining the bumper.
13. Reconnect the trumpet cable connection.
14. Reconnect the brown connector B to the bulkhead and its ground to the chassis.
15. Reconnect the cable support bracket after suitably clamping it.
16. Reconnect the bulkhead cover.
17. At the end of refitting, check the efficiency of the lights or the systems which were removed.

24 BODYWORK
.550232. Replacing the side baffles

Main action
1. Open the door (1) and remove the retaining screws (2) of the
side baffle.
217709 Figure 14
2. Raise the front grille, remove the screws (1) and (3) remove
the side baffle (2).
verse order.
217710 Figure 15
.550101. Cab removal and refitting
Work material
Arm for cab removal and refitting 99378039
Tightening torques
Tightening the screws and nuts 1. Cab support screws 490 N⋅m to600 N⋅m
2. Shock absorber retaining 161 N⋅m to197 N⋅m
nuts and screws

BODYWORK 25
Main action
.550101. Cab removal
1. Position the vehicle with the front wheels set straight forwards.
2. Lift the front radiator grille.
3. Remove the expansion tank cap, then partially drain the coolant off the engine cooling system.
4. On air conditioned cabs, remove plugs (1) and (2) and connect
pipes to couplings below and release the gas from AC cab sys-
tem as described in the relevant chapter.
Note This operation must be carried out only by authorised,
qualified skilled personnel.
5. Drain the pneumatic system.
99125 Figure 16
6. Tilt the cab, disconnect the bowden cables (1) from the side
under the cab and the red and black air pipes (2) and return
the cab to a normal position. 1
7. Position the two wooden dowels of suitable thickness onto the
cab supporting rear crossbar, to avoid cab lock engagement
after the cab has been lowered.
2
8. Lower the cab.
171987 Figure 17

26 BODYWORK
3
4
171988 Figure 18
9. Remove the bumpers as described in the relevant chapter (500210 Bumper removal ( ➠ Page 22)). Remove the gasket (4)
from door openings upper side.
10. Hook the swing bar (1) to a bridge crane or other suitable lifting means and harness the cab.
11. The swing bar (2) hooks (1) shall be positioned at approximately the centre line of the door compartments and secured to
the latter by means of the tensioner (3).

BODYWORK 27
12. Remove the nuts (1) and take off the cover (2) together with
the pipes from the bulkhead connector.
13. Take out the screws (3) and detach the cover (4) together
with the pipe from the control valve.
14. Remove screws (6) and take off the cover (7) from the bulk-
head connector together with the pipes from the distributor.
15. Disconnect the pipe (5) of the steering assembly control device.
87331 Figure 19
Caution!
▶ Properly occlude the pipe (2) and master cylinder adapter (1), to prevent the clutch fluid from damaging painted
parts. The clutch fluid is toxic and corrosive: in case of contact, wash immediately with water and mild soap.
16. Disconnect the pipe (2) from the distributor (1).

17. Place a container below the master cylinder (1), disconnect
from it the pipe (2) and drain the clutch fluid.
2
171989 Figure 20
18. Disconnect pipes (1) for engine coolant.

2 3
19. Cut the pipe-electric cable joining clamps.
20. Remove the clamps from the breather pipe.
21. Disconnect the couplings (2) of the pipes of the air conditioning 1
system acting on the fasteners (3).
171956 Figure 21

28 BODYWORK
22. Disconnect quick engagement air-conditioning system gas pipes

(1) and (2), if present, pressing them axially.
Note Seal air conditioning system piping to prevent moisture
or impurities from entering the system.
87333 Figure 22

BODYWORK 29
1 5
6
2
3 7
8
9
10
11
12
13
14
171990 Figure 23
23. Remove nuts (1) and take off the cover (2) from bulkhead connector.
24. Remove the covers (12), unhook the safety levers (11) and disconnect the connections (7 - 8 - 9 e 10).
25. Disconnect the electric connection (3) for the tank fluid level gauge.
26. Lift the protective cap (4), remove the nut (6) and disconnect the cable (5) from the cab.
27. Remove the nut (14) and disconnect the earth cable (13) from the chassis.

30 BODYWORK
28. Take out the screw (1) retaining the mating pin (2), bar (3)
and mount (4).
29. Remove the bolt (5) fixing the shock absorber with the coaxial
spring (2) to the chassis frame.
1
30. Repeat these steps on the opposite side.
3
4
2
5
171991 Figure 24
31. Remove the bolt (2) fixing the cylinder (3) for tilting the cab
from the cab mounting (1).
172501 Figure 25
32. Mark the assembling position of the universal joint (1) on the
power steering shaft (3).
from the power steering shaft (3).
73159 Figure 26

BODYWORK 31
34. Lift the cab and extract the pin (3) connecting the shock ab- 3
sorber (2), bar (4) and front cab mounting (1). Carefully lift 1
the cab until it is removed from the chassis, then put the cab 4
aside in a proper manner. 2
172502 Figure 27
.550101. Cab refitting

35. For refitting, perform the removal operation in reverse order and tighten the nuts or screws to the specified torques.
Tightening torque
Tightening the screws and nuts 1. Cab support screws
490 N⋅m to600 N⋅m
2. Shock absorber retaining nuts and screws
161 N⋅m to197 N⋅m
36. the O-rings in the pneumatic piping unions must not be reused once removed; they must be replaced with new ones each
time the union is disassembled.
37. Seal up the tachometer electric cable ring with the relevant safety lead.
38. Check correct operation of instrument panel warning lights.
39. In case of vehicles equipped with mechanic Transmission, restore the clutch hydraulic system oil tank level, then blow off air as
described in the relevant chapter.
40. Top up the engine coolant.
41. Refill the air conditioning system (if present), as described in the respective chapter.
.764210. Instrument Cluster (IC) Replacement
Caution!
Note Before starting the replacement, take note of:

the Part Number of the IC control unit in state of being replaced (old);
the Part Number of the replacement IC control unit (new);
alphacode IC control unit being replaced (old) to recover parameters of optionals.

32 BODYWORK

gnostic instrument.
Main action
ment to the diagnostic socket (→) and start the replacement
procedure. The instrument downloads the data in the control
unit being replaced. Two situations can occur.
◁ Control unit cannot be read: after replacement, program
the control unit by entering the annotated parameters.
◁ Control unit can be read: no data input required. The sys-
tem retrieves the operating data of the various optionals
from the old control unit and performs automatically the
programming.
Note Language setting can always be changed by selecting
the relative programming procedure on the diagnostics
tool.
215771 Figure 28
.764210. Removal
2. Remove the kickplate(2) by undoing the fastening screws (1)
and remove the mat (3). 3
171946 Figure 29

BODYWORK 33
3. Remove the trim from the lower side of the steering column
(2) by acting on the fasteners (1-3). 1
2
2
171947 Figure 30
4. Remove the trim (1-2) from the upper side of the steering
column by acting on the fasteners (3). 1
Note To remove the trim (2) it is necessary to turn the
steering column adjustment handle so as to facilitate
removal of the trim (2); take maximum care during
this operation, as the steering column may lift suddenly
when the handle is moved.
2
171948
171948 Figure 31
5. Remove the fastenings (1-3) of the cluster trim (2).

6. Disconnect the connectors (5-6) (blue and black) of the cluster
(2) and the various light switches (4-7-8).
7. Remove the tabs (air vents) of the central instrument panel,
enter a pressure by levering with a specific tool.
171949 Figure 32

34 BODYWORK
8. Remove the fasteners (1) from the IC (Instrument cluster)

control unit (2).
9. Remove the IC (Instrument cluster) control unit (2) from the
vehicle.
217716 Figure 33
.764210. Refitting the IC (Instrument Cluster) control unit

Caution!
specified torque.
Follow the instructions on the diagnostics tool.
.553710. DASHBOARD REMOVAL - REFITTING
Main action
.553710. Driver's side dashboard removal
Note Removal of the dashboard is done considering the entire unit; it is not possible to remove the dashboard in single parts.

BODYWORK 35
1. Remove the kickplate (2) by undoing the fastening screws (1)

and remove the mat (3). 3
171946 Figure 34
2. Remove the trim from the lower side of the steering column
(2) by acting on the fasteners (1-3). 1
2
2
171947 Figure 35
3. Remove the trim (1-2) from the upper side of the steering
column by acting on the fasteners (3). 1
2
171948
171948 Figure 36

36 BODYWORK
4. Remove the fastenings (1-3) of the cluster (2).

5. Disconnect the connectors (5-6) (blue and black) of the cluster
(2) and the various light switches (4-7-8).
6. Remove the tabs (air vents) of the central instrument panel,
enter a pressure by levering with a specific tool.
171949 Figure 37
1
6
8
7
3
4 10
171950 Figure 38
7. Remove the panel (1) by carefully removing the pressure fasteners (3) with a specific lever.
8. Remove the four fastening screws from the panel (1).
9. Disconnect the connectors (2) from the panel (1) and note the reference numbers of the connectors for refitting.

BODYWORK 37
10. Remove the parking brake lever (6) together with its pipe by acting on the fasteners (7) and place it in the dashboard.
11. Use a specific tool to remove the glovebox (9) complete with cigarette lighter (5) with its electrical connector (8).
12. Remove the second glovebox (10) using a specific tool.
13. Remove the radio (4) using specific extraction tools.
.553710. Passenger side dashboard removal

14. Remove the passenger side kickplate by acting on the fasteners and remove the mat as it has been done for the driver's side.
15. Remove all fasteners (3) from the lower passenger side dash- 1
board.
16. Remove the trim (2) to access the switches (1).
2 3
171951 Figure 39
17. Remove all fasteners (3) from the upper passenger side dash- 1 2
board.
18. Remove the trip (2) so as to access the body computer control
unit (1), the fuses and the diagnosis socket.
171952 Figure 40

38 BODYWORK
19. Remove the plate (2) from the driver's side mount, acting on
the screws in its seat (1).
20. Remove the driver's side lifting handle (3) by acting on the
fasteners (4).
171953 Figure 41
21. Remove the cover (1), unscrew the nut (2) and do not remove
the steering wheel (3). 1
2
3
171954 Figure 42
22. Remove the fastening plate (1) of the steering column(2) by

acting on the fasteners (3).
23. In the front part of the vehicle (underhood compartment),
undo the screws that fasten the heater to the chassis from the
outside of the vehicle.
1 2
171955 Figure 43

BODYWORK 39
24. Disconnect the coolant pipes (1) and fasteners (3) of the evap-
2 3
orator pipe group (2).
171956 Figure 44
25. Rotate the body computer (1) down from its seat to access the
internal compartment. 2
26. Disconnect the central air duct to access the fasteners (3) of
the bracket (2) that keeps the dashboard connected to the
chassis from the right passenger side.
3
1
171957 Figure 45
27. Move to the left driver's side to the height of the parking brake
lever.
28. Disconnect the central air duct (3) to access the fasteners (2)
of the bracket (1) that keeps the dashboard connected to the
chassis from the left driver's side. 3
1
171958 Figure 46

40 BODYWORK
29. Remove the bulkhead connector cover (2) by acting on the

2
fasteners. Remove the entire bulkhead unit (4) by acting on the
fasteners (1).
30. Remove the bulkhead connectors (3) then move the bulkhead
unit to the inside of the cab and secure it to the dashboard with
a clamp. 1
4
171959 Figure 47

BODYWORK 41
6
1
5
2
5
4 2
171960 Figure 48
31. Then remove the dashboard (7) from the vehicle; complete with structure (6), trim (7), electrical wiring (5), heater (1),
parking brake lever (4) complete with support and pipes, body computer (3), bulkhead unit (2) and place it on the specific
support stands.
.553710. Refitting the passenger side dashboard

32. Reposition the complete dashboard in the cab of the vehicle.
33. Tighten the fasteners of the bracket, which keep the dashboard connected to the chassis from the passenger side, and then
refit the central air duct.
34. Tighten the fasteners of the bracket, which keep the dashboard connected to the chassis from the driver's side, and then refit
the central air duct.
35. Refit the entire rear bulkhead unit (inside cab) and refit the bulkhead connectors on the outside of the cab.
36. Refit the bulkhead cover and tighten the fasteners.
37. Refit the coolant pipes and tighten the metallic clamps and the evaporator pipe group, tightening their fasteners.
38. Tighten the fasteners fixing the heater to the chassis in the front outside of the cab (underhood compartment).
39. Refit the fastening plate of the steering column by tightening the fasteners.
40. Refit the steering wheel and tighten the nut, and place the cover on the steering wheel with pressure.

42 BODYWORK
41. Refit the plate on the driver's site mount, tightening the fastener in its seat.
42. Refit all fasteners from the upper passenger side dashboard.
43. Refit the trim of the body computer control unit.
44. Reposition the passenger side mat.
45. Refit the kickplate and tighten the passenger side fasteners.
.553710. Driver's side dashboard refitting

46. Refit the radio with slight pressure.
47. Refit the glovebox with slight pressure.
48. With slight pressure, refit the glovebox complete with cigarette lighter and electrical connector.
49. Refit the parking brake lever and tighten the fasteners.
50. Refit the instrument panel connectors, referring to the numbers noted when removing the connectors, then insert the instru-
ment panel in its seat with slight pressure.
51. With slight pressure, insert the tabs (air vents) into their seats in the central dashboard area.
52. Refit the connectors (blue and black) of the cluster and the various light switch connectors.
53. Refit the trim from the lower side of the steering column by tightening the fasteners.
54. Refit the trim from the upper side of the steering column by tightening the fasteners.
55. Reposition the mat.
56. Refit the kickplate and tighten the fastening screws.
.766187. Replacement of the BC2 control unit (Body Computer)
Caution!

gnostic instrument:
Main action
1. Before removing the control unit, connect the diagnostic instrument to the diagnostic socket and start the replacement pro-
cedure as indicated in the Replacing the vehicle EDC control unit (F3B Engines) ( ➠ Page 16).

BODYWORK 43
.766187. Removal
2. Remove all fasteners (3) from the upper passenger side dash-
1 2
board.
3. Remove the trip (2) so as to access the BC2 - Body Computer
control unit (1), the fuses and the diagnosis socket.
4. Disconnect the connectors on the BC2 - Body Computer con-
trol unit (1).
5. Remove the BC2 - Body Computer control unit (1) from the
vehicle, by acting on its fasteners.
171952 Figure 49
.766187. Refitting
specified torque.
Follow the instructions on the diagnostics tool.

44 BODYWORK
.5522. ROOF UNIT REPLACEMENT
Main action
.5522. Roof unit removal
4 9
11
8 5
10
3 1 2
173607
173607 Figure 50
1. Remove the frame (1) with the tachograph (2) on the driver's side, acting on the fasteners (3).
2. Remove the glovebox (4) on the central side, acting on the fasteners (5).
3. Remove the glovebox on the passenger side, acting on the fasteners.
4. Remove the curtain (6) with its guide (7) acting on the interlocking fasteners (8) on the entire cab perimeter.
5. Remove the upper dashboard trim (9) from the vehicle.
6. Remove the buttons and fasteners (10) of the roof lining (11) and remove the latter through the passenger door of the cab.
.5522. Roof unit refitting


BODYWORK 45
.550250. AIR INTAKE HATCH REPLACEMENT
Main action
.550250. Air intake hatch removal
1. To remove the hatch (1) you have to remove the guard (2) by
loosening its fasteners (3).
174186 Figure 51
2. Disconnect the connection (3) if present; unscrew the nuts (1)

and remove the whole hatch (2).
87216 Figure 52
.550250. Air intake hatch refitting

3. Carry out the removal operations in reverse order.

46 BODYWORK
.555010. DRIVER'S SEAT REPLACEMENT
Main action
.555010. Driver's seat removal
1. Move the seat (1) back.
2. Remove the fastening screws (2) of the guides (3) of the seat
(1) in the front part.
3. Move the seat (1) forward.
4. Remove the fastening screws (4) of the guides (3) of the seat
(1) in the rear part.
5. Remove the seat (1) from the vehicle. 1
2
3 4
173608 Figure 53
.555010. Driver's seat refitting

.555020. Passenger's seat replacement

Main action
▶ To replace the passenger's seat, refer to the operation DRIVER'S SEAT REPLACEMENT ( ➠ Page 46).

BODYWORK 47
.552410. Replacing the windscreen
Main action
.552410. Windscreen removal
1. Lift the radiator cowling (10).
2. Remove the clip (2), extract the pin (7) with the thrust wash-
ers (3) and disconnect the suspensions (4) from the support
(1).
3. Repeat these steps for the other shock absorber.
4. Take out the screws (9) fixing the hinges (8) and remove the
grille (10) from the cab.
5. Disconnect the pipes (5) for the window-washer liquid from
the fitting (6).
6. Remove the nuts (12) and disconnect the windscreen wiper
(11).
73263 Figure 54
7. Open the door (3) and remove the retaining screws (1) of the
side baffle (2).
8. On the front-end, remove the screws (4) and remove the right
baffle (2) from the supports(5).
9. Repeat the operations for the left hand vent removal.
90043 Figure 55
10. If present, take out the retaining screws.

11. Remove the visor.
12. Apply the pair of suitable suction cups (1) to the windscreen
and with two operators: one inside the cab with appropriate
tools, take out the gasket while pushing on the top corners of
the windscreen, while the other outside the cab pulls on the
suction cup grips (1), and removes the windscreen from its
housing.
90044 Figure 56

48 BODYWORK
.552410. Refitting the windscreen

13. To refit the windscreen fit the rubber seal on the windscreen,
insert a cord (1) in the gasket (2).
14. Apply suitable suction cups to the windscreen.
15. Position it against the cab flanging.
16. Press firmly on the suction cups while pulling both ends of the
cord (1) from the inside so that the seal fits onto the flanging of
the bodywork.
17. finish fitting the parts taken down during removal.
18. Remove the outside mirror from the passenger's side, loosening
the four fastening screws.
73266 Figure 57
.766510. WINDSCREEN WIPER BODY REPLACEMENT
Main action
.766510. Windscreen wiper body removal
1. Remove the fasteners (1) of the bracket (2) supporting the
windscreen wiper motor (3).
2. Remove the fasteners (4) fixing the windscreen wiper (6)
supports (5) to the chassis.
3. Remove the windscreen wiper motor (3).
4. Remove the windscreen wiper brushes (8) by loosening the
fasteners (7).
5. Remove the complete windscreen wiper body (6).
173604 Figure 58
.766510. Windscreen wiper body refitting


BODYWORK 49
.766511. WINDSCREEN WIPER MOTOR REPLACEMENT
Main action
.766511. Windscreen wiper motor removal
1. Remove the windscreen wiper movement bracket (1), acting
on the fastener (2).
2. Remove the fastener (3) of the windscreen wiper motor (4).
3. Loosen the fasteners (5) of the windscreen wiper support
bracket (6) to facilitate removal of the windscreen wiper motor
(4).
4. Remove the windscreen wiper motor (4) electrical connection
(7).
5. Remove the windscreen wiper motor (4) from the vehicle.
173605 Figure 59
.766511. Windscreen wiper motor refitting

.766516. WINDSCREEN WIPER ARM REPLACEMENT
Main action
.766516. Windscreen wiper arm removal
1. Remove the fasteners (1) of the windscreen wiper arms (2).
2. Remove the windscreen wiper arms (2) after disconnecting the
window washing fluid pipes.
173606 Figure 60
.766516. Windscreen wiper arm refitting


50 BODYWORK
.762010. BATTERY REPLACEMENT
Main action
.762010. Batteries disconnection
1. Remove the battery cover (1) by acting on the rubber retainers
(2).
2. Remove the two brackets (3) sealing the batteries (4) by acting
on the fasteners (5) of the tie rods.
3. Remove the cables (6) with the terminals (7).
4. Remove the two batteries (4).
173828 Figure 61
.762010. Refitting the batteries

.762210. Horn replacement

Main action
1. Drain the air from the pneumatic system and disconnect the
pipes (3).
Note Do not disconnect the pipes (3) without removing the
air, as the pressure inside may cause movements not
controlled by the pipes.
2. Disconnect the electrical connection (1).
3. Unscrew the retaining screws (4) then remove and replace the
horn (2).
process in reverse order.
217712 Figure 62

BODYWORK 51
CAB ANCHORING
5542 CAB ANCHORING
222098 Figure 63
.5542. REPAIR OPERATIONS
Work material
Tool for removing and refitting cab front suspension 99346051
bracket silentblocks
Drift
Press
Tightening torques
Air spring/shock absorber upper fastening screw 400 N⋅m
Air spring/shock absorber lower fastening screw 490 N⋅m to600 N⋅m

52 BODYWORK
REPAIR OPERATIONS
Air spring/shock absorber lower fastening nut 398 N⋅m to487 N⋅m
Cab front support fastening nut 83 N⋅m to101 N⋅m
Front left support fastening screw 173 N⋅m to212 N⋅m
Front right support fastening screw 161 N⋅m to197 N⋅m
Cab front support fastening screw 109 N⋅m to133 N⋅m
Screws M16 250 N⋅m
Screw for fixing upper shock absorber 82 ±8 N⋅m
Shock absorber lower retaining nut 154.5 ±15.5 N⋅m
Cab lock retaining screws 82 ±9 N⋅m
Main action
.554243. REPLACING THE FRONT SHOCK ABSORBER
.554243. Removal
1. Using the arm, sling the cab as described under the chapter Cab
removal and refitting and proceed as follows.
code
2. Remove the front bumper (operation Bumper removal ) as

described under the same chapter.
3. Remove the bolt (7) fixing the shock absorber (5) to the
chassis frame.
4. Disconnect the pipe (6) from the shock absorber (5).
5. Take out the screw (4) retaining the shock absorber mating pin
(5), bar (8) and mounting (9).
6. For right-hand air spring only: Remove the nut (1) and
disconnect the tie rod (3) from the levelling valve (2).
99128 Figure 64
7. Lift the cab and extract the mating pin (3) of the shock ab-
sorber (2), bar (4), front cab mounting (1) and remove the
shock absorber (2).
73162 Figure 65

BODYWORK 53
REPAIR OPERATIONS
.554243. Refitting
8. Reverse the order of the operations carried out for the removal sticking to the recommended tightening torques.
Tightening torque
Air spring/shock absorber upper fastening screw 400 N⋅m
Air spring/shock absorber lower fastening screw 490 N⋅m to600 N⋅m
Air spring/shock absorber lower fastening nut 398 N⋅m to487 N⋅m
.554216. Cab suspension front mounting rubber-type bushs replacement

.554216. Removal
9. Using the arm, sling the cab as described under the chapter Cab
code
10. Remove the front bumper (operation Bumper removal ) as

described under the same chapter.
11. Remove the screws (5) and take out the guard (6).
73163 Figure 66
.554216. Right-hand front suspension mounting removal

12. Only for cab with air suspension: Remove the nut (5) and dis-
connect the tie rod (6) from the levelling valve (1).
13. Only for cab with air suspension: Take out the screws (2), and
remove the bracket complete with levelling valve (1).
14. Only for cab with air suspension: Disconnect the air pipe from
the shock absorber.
15. Take out the screw (3) joining the bar (7) to the mounting (4).
16. Remove the bolt fixing the shock absorber to the chassis frame.
17. Take out the screws (8) and remove the mounting (4) from
the chassis frame.
99130 Figure 67

54 BODYWORK
REPAIR OPERATIONS
.554216. Removing left-hand front suspension mounting

from the power steering shaft.
19. Repeat the steps described for removing the right-hand front
mounting.
20. Take out the screws (1) and remove the mounting (2) from
the chassis frame.
73164 Figure 68
21. The bushes (2) in right-hand (1) and left-hand (2) front sus-
pension mountings are replaced with the aid of a press and a
suitable drift.
Tool / Material
Press
Drift
99131 Figure 69
.554216. Refitting
Tightening torque
Cab front support fastening nut 83 N⋅m to101 N⋅m
Front left support fastening screw 173 N⋅m to212 N⋅m
Cab front support fastening screw 109 N⋅m to133 N⋅m

BODYWORK 55
REPAIR OPERATIONS
.554216. Replace the cab front mount bushs

.554216. Removal
23. Remove the shock absorbers as described in the REPLACING
THE FRONT SHOCK ABSORBER ( ➠ Page 52) chapter.
24. Extract the bush with elements (1, 2, 3) of specific tool and
remove it.
code
87291 Figure 70
.554216. Refitting
25. Use elements (3, 4, 5) of specific tool to fit the new bush in its
seat.
code
87292 Figure 71
.554246. Removing - refitting the stabilizer bar

.554246. Removal
26. Using the arm, sling the cab as described under the heading Cab
code
27. Remove the front bumper, Removal operation as described

under the same heading.
28. Cab with pneumatic suspension: remove the screws (5) and
disconnect the tie rod (6) from the levelling valve (1).
29. Cab with pneumatic suspension: Take out the screws (2) and
remove the bracket complete with levelling valve (1).
30. Remove the bolt and disconnect the universal joint (3) from 99132 Figure 72
the power steering shaft.
31. Remove the shock absorbers as described under the relevant
heading.
32. Remove the screws (3) and disconnect the stabilizer bar (9)
from the mount (4).

56 BODYWORK
REPAIR OPERATIONS
.554246. Refitting
Tightening torque
Screws M16 250 N⋅m
.554243. Replacing rear cab suspension dampers

.554243. Removal
34. Overturn the cab.
35. On pneumatic suspensions cabs, disconnect the pipe from the
air spring.
36. Unscrew bolts (2, 4) and remove shock absorber (3) from the
cross members: upper (1) and lower (5).
86949 Figure 73
.554243. Refitting
Tightening torque
Screw for fixing upper shock absorber 82 ±8 N⋅m
Shock absorber lower retaining nut 154.5 ±15.5 N⋅m
.554261. Replacing the transverse tie rod bushs

.554261. Removal
38. Remove bolts (4, 5) and remove cross link (2) from cross-
members (1, 3).
86951 Figure 74

BODYWORK 57
REPAIR OPERATIONS
.554261. Disassembly/Assembly
39. Transverse tie rod (1) rubber bushs (2, 3) can be replaced by
using a suitable drift and press for disassembling/reassembling
operations.
Tool / Material
Drift
Press
86952 Figure 75
.554261. Refitting
40. To refit the transverse tie rod, reverse the order of removal
operations, by tightening bolt (4, 5) nuts, to the specified
torque.
Note Nuts are of the self-braking type; it is recommended
that they are replaced with new ones every time disas-
sembling is performed.
86953 Figure 76
.793840. Replacing the levelling valve

.793840. Removal
Note The figure shows the front levelling valve; similarly, the description of removal operations also apply to the rear levelling
valve.

58 BODYWORK
REPAIR OPERATIONS
41. Disconnect pneumatic pipes (1, 2) from levelling valve (4).

Disconnect tie-rod (5) from the articulation pin, then remove
the retaining screws (3) and take off levelling valve (4).
99134 Figure 77
.793840. Refitting
42. Carry out removal operations in reverse order, tightening the screws to the specified torque.
43. For tie-rod (5) check and adjustment, see the relevant chapter.
.554210. Replacing the cab lock

.554210. Removal
44. Disconnect piping (4) from lock (1), then recover the oil in a
special container.
45. Remove the screws (3) and detach the lock.
86632 Figure 78
.554210. Refitting
Tightening torque
Cab lock retaining screws 82 ±9 N⋅m
Note The screws (3) securing the lock (4) should be locked when the cab mounting pin (2) is aligned with the lock hous-
ing.
47. After refitting, check the fluid level and bleed the system as directed in the relevant section.

BODYWORK 59
MANUALLY DRIVEN CAB TILT
554250 MANUALLY DRIVEN CAB TILT

Manually driven cab tilting system components
186858 Figure 79
1 Manual control pump 4 Cab lock engagement
2 Cab tilting cylinder A Main circuit
3 Hydraulic actuator for cab control telescopic link re- B Secondary circuit
lease

60 BODYWORK
Manual control pump

Specifications
Technical data
Nominal pressure 420 bar
Flow rate per pump 4 cm³ ±10 %
Operating torque 8 N⋅m
161406 Figure 80
1 Pump activation hex 3 Oil level check and
nut filler plug
2 Cock in assembly 4 Oil level
position 5 Cab return union
6 Cab lift union
.554255. Hydraulic cab tilt cylinder replacement
Main action
.554255. Removal
1. Place a container under the oil piping (3, 4) to collect the oil
from the system.
2. Disconnect the oil pipes (3, 4) from the cab tilting cylinder (2)
fitting. 2
3. Remove bolt (1) and nut (5) and detach cylinder (2). 1
Note This operation must be carried out with the cab
lowered.
3 4 5
99135 Figure 81
.554255. Refitting
4. To refit, carry out the operations described in the removal process in reverse order, by tightening the nuts to the specified
torque.
5. After refitting has been completed, fill up and blow air off the hydraulic system, as described in the relevant chapter.

BODYWORK 61
.554250. Check oil level
Note The cab must be lowered in driving conditions.
Main action
1. Position the pump drive lever (3) as indicated in figure.
2. Remove plug (2) and check that oil level X is above the plunger
(1) of about 2 mm, otherwise, top up.
102619 Figure 82
.554250. Bleeding cab tilting system
Note Bleed the air in the event of general tilt system malfunctioning and for the following operations (see figure).
1) Replacing manual drive pump.
2) Replacing cab tilting cylinder and main circuit pipes.
3) Replacing lock and secondary circuit pipes.
4) Replacement of all tilting system components.

62 BODYWORK
Main action
.554250. Bleeding manual control pump
1. Rotate tap (2) to the position shown in figure.
2. Take off plug (1).
3. Slowly drive lever (3) five times, (through full range).
4. Check the level as described in relevant chapter.
102620 Figure 83
.554250. Bleeding air from secondary circuit

5. Disconnect piping from the lock and from the hydraulic actuator.
6. Drive lever (3) (see previous figure) until oil is drained away into special container.
7. Check the oil level as described in the relevant chapter.
.554250. Complete air bleeding

8. If all the cab tilting system components should be replaced, perform the complete air bleeding of the system (manual air
bleeding and air bleeding from secondary circuit).

BODYWORK 63
CAB MECHANICAL SUSPENSION
5542 CAB MECHANICAL SUSPENSION

Location of cab suspension components
85698
85698 Figure 84
1 Cross member 6 Support
2 Rubber block 7 Front shock absorber
3 Rear shock absorber regulator 8 Front shock absorber regulator
4 Rear shock absorber 9 Torsion bar
5 Bracket 10 Bracket
.554243. Cab driving position adjustment
Technical data
X1 Centre distance between front shock absorber eyelets 380 mm
X2 Centre distance between rear shock absorber eyelets (HI-ROAD Vehicles) 400 mm
X2 Centre distance between rear shock absorber eyelets (HI-STREET Vehicles) 345 mm

64 BODYWORK
CAB PNEUMATIC SUSPENSION
Main action
1. With cab under static load condition, check length X1 of front shock absorbers (7) and length X2 of rear shock absorbers
(4). Such length, measured between the centre distances of shock absorber eyelets, must respect the value given below.
Technical data
X1 Centre distance between front shock absorber eyelets 380 mm
X2 Centre distance between rear shock absorber eyelets (HI-ROAD Vehicles) 400 mm
X2 Centre distance between rear shock absorber eyelets (HI-STREET Vehicles) 345 mm
Note Static load is exclusively the load determined by the type of cab fitting.
2. If different values are found, turn the regulator (3)or (8) of relevant shock absorbers with a suitable wrench.
Note The regulator is provided with 5 marks, each mark, starting from the central reference mark, corresponds to a change
in length of 4 mm.
5542 CAB PNEUMATIC SUSPENSION

Location of cab suspension components
11 10 9 8
2
6
3 4
177843 Figure 85
1 Ancillary equipment power supply 4 Front shock absorber
2 Rear shock absorber 5 Valve tie rod (3)
3 Front levelling valve 6 Torsion bar

BODYWORK 65
CAB PNEUMATIC SUSPENSION
7 Rear levelling valve 10 Valve tie rod (7)

8 Rubber block 11 Cab anchoring tie
9 Guide rod
Cab suspension pneumatic system schematic diagram
74094 Figure 86
1 Right front air spring 5 Rear levelling valve
2 Front levelling valve 6 Left rear air spring
3 Right rear air spring A Service supply (8.5 bar)
4 Left rear air spring
.793840. Adjusting the levelling valve linkage
Technical data
Front tie rod length X1 94 ±1 mm
Rear tie rod length X2 83 ±1 mm

66 BODYWORK
REPAIR OPERATIONS ON DOORS
Main action
▶ Check and/or adjust length X2 of tie rod (10) and length X1 of tie rods (5). Such length, measured between the centre dis-
tances of articulated pins, must be:
Technical data
Front tie rod length X1 94 ±1 mm
Rear tie rod length X2 83 ±1 mm
.5507. REPAIR OPERATIONS ON DOORS
Consumables
Soapy water
Detergent towelette BETACLEAN 3300
COMBI primer 5061
Polyurethane adhesive BETASEAL 1703 SPRINT
Work material
Suction cups 99378031
Compressed air
Blade
Adhesive tape
Pliers
Tyre gun
Sponge
Tightening torques
Rearview mirror lower retainers 8 N⋅m
Rearview mirror upper retainers 17 N⋅m

BODYWORK 67
Main action
.550710. Door replacement
.550710. Removal
1. Take off the side mirror mounting as described in operation
Removal ( ➠ Page 74).
2. Remove the inner door trim as described in operation Removal
.
3. Remove the electric window device as described in operation
Removal ( ➠ Page 71).
4. Disconnect the electrical connections (5), (6), (7), (8) and (9)
from the control unit and remove it (10).
5. Support the door (1), unscrew the screws (2) and (11) detach
the door (1) from the hinges (3) and (12).
Note When removing the door (1), extract the wiring (4)
from it with care.
73286 Figure 87
.550710. Refitting
6. Carry out the operations performed for removal in reverse order and respect the required tightening torques.
.553612. Replacing the sun visor

.553612. Removal
7. Lower the window.
8. Take out the screws (1) and remove the sun visor roller curtain
assembly (2) from the door.
176540 Figure 88

68 BODYWORK
.553612. Refitting
.765233. Replacing the window switch

.765233. Removal
10. Remove the handle trim (1) by forcing with an appropriate
tool.
11. Remove the push-button assembly (2) by acting on the retain-
ers (3) and forcing with an appropriate tool to lift the push-
button assembly (2) from the snap-in fixtures.
12. Finally disconnect the electrical connections (4), (5), (6, 7)
from the push button panel (2) and remove the window regu-
lator switches.
176541 Figure 89
.765233. Refitting
.766191. Replacing the door module control unit

.766191. Removal
14. Remove the loudspeaker cover (1) by forcing with a suitable
tool.
15. Remove the loudspeaker by acting on the four retainers.
16. Disconnect the electric connectors (5) from the loudspeaker.
17. Remove the retainer (2) from the control unit (3).
18. Remove the electric connectors (4), then remove the control
unit (3).
176542 Figure 90
.766191. Refitting

BODYWORK 69
.550750. Replacing the interior door trim

.550750. Removal
20. Remove the handle (1) by loosening the retainer (2).
21. Remove the reflector (4) by forcing with a suitable tool.
22. Remove the two main retainers (3) of the door trim (7).
23. Remove the screw caps (5) by lifting them away with a suitable
tool.
24. Remove trim retaining screws (6) along the entire perimeter of
the trim (7).
25. Remove the Door Module control unit. ( ➠ Page 68)
26. Remove the door trim (7).
176543 Figure 91
.550750. Refitting
.550740. Replacing the winding window

.550740. Removal
28. Remove sound deadening guard (1) from the door (2).
73271 Figure 92
29. Extract the outside and inside bottom seals (1) from the win-
dow compartment.
73272 Figure 93

70 BODYWORK
30. Extract the window guide seal (1).
73273 Figure 94
31. Disconnect the electric window regulator device (2) from the
window (1) by removing the clamp (3).
73274 Figure 95
32. Lift the window (1) and remove it from the top of the door
(see arrow).
73275 Figure 96
.550740. Refitting

BODYWORK 71
.550730. REPLACING THE WINDOW WINDER

.550730. Removal
34. Dismantle the descending window as described in the operation
Removal .
36. Remove the screws (1), (3) and (4) retaining the electric win-
dow regulator device (2) on the door.
90067 Figure 97
37. Extract the electric window regulator device (1) from the door.
73277 Figure 98
.550730. Refitting

72 BODYWORK
.550714. Replacing the door lock

.550714. Removal
39. Unhook the clip (2) from the tie rod (3) and disconnect this
from the transfer box (1).
40. Disconnect the electrical connections (4) and (5) from the lock
(6).
176546 Figure 99
41. Disconnect the tie rod (1) from the lever (2) of the outside
handle (3).
176547 Figure 100
42. Unhook the clip (3) from the tie rod (4) and disconnect this from the lever (5) of the inside handle .
43. Remove the screws (1) and detach the lock (2) form the door.
.550714. Refitting
.550717. Replacing the outside handle of the door

.550717. Removal
from the transfer box (1) of the lock (4).
176548 Figure 101

BODYWORK 73
46. Disconnect the tie rod (1) from the lever (2) of the outside
handle (4).
176549 Figure 102
47. Take off the covers (1) and (2) the nuts (3) retaining outer
handle (4) and detach this from the door.
48. Remove the tie rod (3 ) (previous figure) from handle (4).
176550 Figure 103
.550717. Refitting
.550718. Replacing the inside handle

.550718. Removal
50. Remove the trim as described in operation Removal .
from the lever (5) of the inside handle (4).
52. Remove the screws (3) and detach the handle (4) form the
door.
73284 Figure 104

74 BODYWORK
.550718. Refitting
.552910. REPLACING THE SIDE MIRRORS

.552910. Removal
54. Unscrew the screws (1) and (2) remove the plastic guards (3)
and (4).
108622 Figure 105
55. Disconnect the electrical connections (1),(2) and (3).

56. Take out the screws (4) and (5) remove the assembly from the
vehicle.
108877 Figure 106
.552910. Refitting
Tightening torque
Rearview mirror lower retainers 8 N⋅m
Rearview mirror upper retainers 17 N⋅m

BODYWORK 75
.552917. Replacing the upper rearview mirror

.552917. Removal the upper rearview mirror
58. Tilt the mirror (1) and pull it carefully to avoid possible break-
age, freeing it from the support (2).
59. Undo the electrical connections (if present) from the mirror
(1).
131741 Figure 107
.552917. Refitting the upper rearview mirror

60. To refit the mirror just connect the electrical connections (if present) to the mirror and hook the mirror on the support (1).
.552915. Replacing lower rearview mirror

.552915. Removal of the lower rearview mirror
61. Tilt the mirror (1) and pull it carefully to avoid possible break-
age, freeing it from the support (2).
62. Undo the electrical connections (if present) from the mirror
(1).
131742 Figure 108
.552915. Refitting the lower rearview mirror

63. To refit the mirror just connect the electrical connections (if present) to the mirror(1) and hook the mirror on the support
(2).

76 BODYWORK
.550748. Replacing the fixed window

.550748. Removal
64. Take off the side mirror mounting as described in operation
REPLACING THE SIDE MIRRORS ( ➠ Page 74).
65. Remove the inner door trim as described in operation Removal
( ➠ Page 69).
73287 Figure 109
66. Extract the external gasket (1), apply the suction cups (2).
Suction cups 99378031
Note Before starting to cut, you need to protect the paintwork with adhesive tape to prevent any damage.
67. Insert a suitable tool through the sealant by a corner (arrow) of the window.
68. Make the cut all along the perimeter. Remove the window with a suction cup handle (2).
Note Do not use any lubricant during cutting.
The blades must always be sharp.
.550748. Preparing the window compartment

69. Using an appropriate knife, cut and level the sealant of the window compartment so as to leave a thickness of between 0.25
and 1 mm to prevent chipping the paintwork.
Tool / Material
Blade
70. Get rid of the remaining dust and degrease the window compartment with suitable detergent towelette contained in the
IVECO PARTS kit.
Tool / Material
Note The film of sealant remaining on the windscreen will be a support for subsequent gluing
Note If the window bay has been painted after repair work, treat it with the COMBI primer 5061 contained in the kit and
wait for 15 minutes.
.550748. Preparing the window

71. Using an appropriate knife, cut and level the sealant of the window compartment so as to leave a thickness of between 0.25
and 1 mm to prevent chipping the paintwork.
Tool / Material
Blade
72. Get rid of the remaining dust and degrease the window compartment with suitable detergent towelette contained in the
IVECO PARTS kit.

BODYWORK 77
Tool / Material
73. Degrease the screen-printed portion of the windscreen with

the detergent towelette contained in the kit.
Tool / Material
Note If using a new window, it is still necessary to degrease

the screen-printed portion with the specific deterging
cloth.
74. Apply the glass adhesion promoter to the serigraphed area
using the applicator contained in the kit. It is not necessary to
use it on the remaining sealant.
Tool / Material
COMBI primer 5061
75. Wait 15 minutes before continuing with the operations to allow 33928 Figure 110
the adhesion promoter solvent to evaporate.
Tool / Material
COMBI primer 5061
.550748. Refitting
76. Mount the seals on the inside of the door, without touching the area where the adhesion promoter (primer) has been ap-
plied.
77. Mount the rubber seal on the window.
78. Perform a trial assembly and centre the window exactly.
79. After centring the window, mark the reciprocal position between the window and its seat with strips of adhesive tape.
Tool / Material
Adhesive tape
80. Cut the strips of adhesive tape and remove the window.
81. Using an air gun, apply a bead of polyurethane adhesive along

the perimeter of the window as evenly as possible.
Tool / Material
Tyre gun
Polyurethane adhesive BETASEAL 1703 SPRINT
82. Start this process from the middle of the bottom side and pro-
ceed without stopping all around the perimeter of the window.
83. Cut off the tip of the adhesive cartridge so that the
cross-section of the adhesive bead is triangular in shape with a
base of 5÷7 mm and a height of 12 mm.
33929 Figure 111

78 BODYWORK
84. Place the windscreen in its seat with the suction cup handle (2).
85. Align the window with its housing bay, using the adhesive tape
applied beforehand as a reference.
Note The window must be positioned within 15 minutes of
applying the adhesive.
73287 Figure 112
86. Keep the window under pressure with two wooden plugs (1)
and (2) positioned as shown in the figure.
Note Keep the window under pressure for at least 1 hour.
87. Before refitting the elements removed previously, check that
there are no penetration points.
88. Apply soapy water using a sponge to the outer perimeter and
blow through with compressed air from the inside in order to
identify any penetration.
Tool / Material
Soapy water
Sponge
Compressed air
73288 Figure 113
89. If there are any bubbles, degrease the area involved and fill it
using adhesive.
90. Any excess sealant on the inside can be removed once the
sealant has hardened, by cutting it with a blade and detaching
it with a pair of pliers.
Tool / Material
Blade
Pliers
Note Take care not to damage the serigraphed area of the

window with the blade.
91. Refit the elements removed and clean the window.
Note Do not move or deliver the vehicle before 90 minutes
have elapsed at 23 °C and 50% RU (Relative Humidity)
climatic conditions.
If the temperature or humidity are lower you need to
increase the waiting time.

BODYWORK 79
SEATS
5550 SEATS
77150 Figure 114

Driver's seat
Component layout
1 Backrest 9 Seat lowering
2 Cushion 10 Vertical shock absorber adjustment
3 Seat tilt adjustment 11 Seat height adjustment
4 Cushion depth adjustment 12 IPS pneumatic back support
5 Bellows 13 Seat heating
6 Horizontal spring 14 Backrest adjustment
7 Horizontal adjustment 15 Trim
8 Guides

80 BODYWORK
SEATS
77150 Figure 114

BODYWORK 81
SEATS
Driver's seat pneumatic diagram
90034 Figure 115

82 BODYWORK
SEATS
90035 Figure 116

Driver's seat pneumatic diagram
A Height adjustment valve E Gear selector
B Pneumatic suspension F Outlet air
C Quick lowering magnetic valve G Intake air
D IPS valves

BODYWORK 83
SEATS
Passenger's seat pneumatic diagram
90036 Figure 117

84 BODYWORK
SEAT REPAIR OPERATIONS
90037 Figure 118

Passenger's seat pneumatic diagram
A Height adjustment valve D Fast lowering switch
B Pneumatic suspension E Outlet air
C IPS valves F Intake air
.5550. SEAT REPAIR OPERATIONS
Main action
.555010. Removing - Refitting the driver seat

BODYWORK 85
77149 Figure 119

.555010. Removal
1. Open the door (5) of the utility compartment (4).
2. Unscrew the retaining screws (6) and remove the utility compartment (4) from the vehicle.
3. Operate the lever (7) and bring the seat (8) into the all forward position.
4. Operate the lever (2) and tilt the back (1).
5. Undo the quick couplings (10) and remove air pipes (11).

86 BODYWORK
77149 Figure 119

6. Disconnect the electric system connector (12).
7. Unscrew the nuts (3) and the retaining screws (9) and remove the seat (8) from the vehicle.
.555010. Refitting
8. Refit by reversing the order of the operations described for the removal.

BODYWORK 87
.555017. Removing the cushion

9. Lift the lever (2) for adjusting the cushion depth.
10. Arrange the cushion (1) in its head position.
11. Unscrew the screws (5) fixing the seat tilt adjustment lever (4).
12. Keeping the lever (2) in the top position push in the direction
of the arrow (A).
13. Move the cushion (1) of the seat forward and lift it.
14. Disconnect the electrical connection (6) of the seat.
15. Detach the cushion (1) from the seat.
90025 Figure 120

88 BODYWORK
.555017. Installing the cushion

16. Bowden flexible cable (10) must be positioned between lever
(9) and sitting cushion base plate.
17. Press cushion with key holes (7) on rear sliding blocks.
18. Draw lever (2) upwards (do not displace cushion).
19. Press cushion front key holes (8) on front sliding blocks. Push
cushion downwards and at the same time push up to the stop
towards the seat back.
20. Now, check that all the four sliding blocks are still anchored in
cushion base plate (cushion vertical movements must not be
possible).
21. Press lever (2) according to the direction of arrow (B) and
push the cushion towards the backrest until the lever (2) is
engaged.
22. Check that the cushion is well fixed in a horizontal and vertical
direction.
90025 Figure 121

BODYWORK 89
.555017. Cushion sliding block disassembly

23. Disassemble the cushion as described in the related operation.
24. Take plug (2) out and push the sliding block (3) out.
77152 Figure 122
.555017. Cushion sliding block assembly

25. Fit the sliding block (3) to the seat frame (4).
26. Insert the plug (2) in the seat of the sliding block (3).
.555910. Seatbelt removal

27. Detach the seat cushion as described in the related operation.
28. Unscrew the fasteners (1) and remove the rear upholstery (2)
of the back.
77153 Figure 123

90 BODYWORK
29. Lift the back adjustment lever (4) and unscrew the screw (3)
fixing the seatbelt hook.
30. Unscrew the screw (9) fixing the top of the seatbelt and take
off the facing (1).
31. Unhook the sections (5) and lift the back upholstery off the
fixing tapes (2) (velcro).
32. Remove the retainer (6) of the plastic guide (10) acting in the
direction of the arrows.
33. Unscrew the screw (7) fixing the reel and remove the seatbelt
(8) from the seat.
77494 Figure 124
.555910. Attaching the seat belt

34. For fitting, carry out the steps performed for removal in reverse order.
.555061. Removing - refitting seatbelt connection and right-hand side upholstery

35. Position the cushion (5) forwards.
36. Unscrew the screws (4) retaining the trim (6) and press-on
caps (1).
37. Unscrew the screw (2) and remove the belt connection (3)
and the side trim (6).
77495 Figure 125

BODYWORK 91
.555061. Refitting seatbelt connection and right-hand side upholstery

.555061. Removing the left side trim, IPS valve and heating switch
39. Remove the seat cushion as described in the related operation.
40. Undo the screws (1), (2) and (3).
41. Fold the back fully forwards and unscrew the screw (4).
42. Remove the side upholstery (5) from the seat framework.
43. Unscrew one screw (6) and two screws (7).
44. Lift the safety hook (8) in secure mode and remove the air pipe
(9) from the connector (10) see details A, B.
45. Separate the electric connector (11).
46. Push the valve (12) and the switch (13) outside the trim (5).
47. Disconnect the hoses (14) from the valve (12).
Note Mark the hoses to facilitate assembly.
77496 Figure 126
.555061. Refitting the left side trim, IPS valve and heating switch

92 BODYWORK
.555026. Removing the backrest

49. Remove the seat cushion as described above.
50. Adjust inclination at the highest position.
51. Take off the side trim.
52. Disconnect the connector (3) and three air hoses (4) if applic-
able.
53. Remove the safety lock (1).
54. Unscrew the screw (5) retaining the seatbelt reel and the
screw (6) retaining the seatbelt (7).
55. Unscrew the screws (2) fixing the backrest (8).
56. Remove the backrest (8) from the seat.
77497 Figure 127
.555026. Assembling the backrest

.555067. Backrest adjustment lever disassembly

58. Remove the seat cushion and the left-hand side trim as de-
scribed above.
59. Remove the safety washer (1).
60. Remove the spring (2) from the lever (3).
61. Remove the spring (4) from the pin (5).
62. Remove the lever (3).
90026 Figure 128

BODYWORK 93
.555067. Backrest adjustment lever assembly

Note Before putting in the springs, thread end (A) of spring (4) into the opening (B) of spring (2).
.555092. Height adjustment device disassembly

65. Adjust inclination at the highest position.
66. Unscrew the retaining screws (1) loosen the nut (2) and re-
move the flexible cable (3) from the retainer (4).
67. Free the threaded coupling of the cable (5) from the lever (6).
68. Push the flexible cable out of the mount (7) and extract
through the opening (8).
77499 Figure 129
.555092. Height adjustment device assembly

.555067. Removing refitting the seat angle adjustment device

70. Remove the seat cushion and the left-hand side trim as de-
scribed in the related operation.
71. Remove the height adjustment lever (4) as described above.
72. Free the pin (1) from the lever (2). 4
73. Remove the lever mount (3) from the seat framework.
74. Loosen the flexible cable from the lever (2).
75. Remove the seat adjustment device (5) from the seat. 3
1 2
90027 Figure 130
.555067. Assembling the seat angle adjustment device


94 BODYWORK
.555010. Shock absorber adjustment device flexible cable disassembly

78. Remove the supporting washer (1) and the flexible cable (2) of
the lever from the retainer system (3).
79. Undo the screws (4).
80. Extract the pin (5) from the lever (6).
81. Extract the flexible cable (2) from the seat framework.
77501 Figure 131
.555010. Shock absorber adjustment device flexible cable assembly

Note Before fitting the seat cushion, loosen the locking nut (7), adjust the flexible cable (2) so that in the lowest position of
the adjustment lever, the stiffest vertical damping is reached, then retighten the locking nut.
.555010. Backrest adjustment lever segment disassembly

83. Remove the seat cushion, the left-hand side trim and the back-
rest as described in the related operation.
84. Loosen spring (1) from pin (2) of lever (3).
85. Unscrew the nuts (4) and remove the plate (5), the toothed
segment (6) and the lever (3).
77502 Figure 132
.555010. Backrest adjustment lever assembly


BODYWORK 95
.555097. Air spring removal

88. Remove the lower bellow fastener.
89. Secure suspension assembly (1) on the highest position, use
special spacer (3) with dimensions shown in figure.
90. Put in spacer (3) between frame (2) and seat suspension (1).
77503 Figure 133
91. Lift the fixing hook (1) safely and remove the air pipe (2) as
shown in the box.
92. Unscrew the screw (3), loosen the shock-absorber fixing and
move the air spring toward the front.
93. Turn the air spring (4) by 90 degrees and remove it from the
lower mount (5).
90029 Figure 134
.555097. Air spring assembly

Note After assembling a new suspension, projection (6) must engage with the fixing hole of suspension upper support.
.555013. Shock absorber disassembly

96. Remove the lower bellow fastener.
97. Move the suspension assembly into its lowest position.
98. Unscrew nut (1), take out screw (2) and remove bush (3).
99. Position suspension assembly in the highest position (use spacer
(3) figure above).
100. Position suspension assembly in the highest position (use spacer
(3) figure above).
101. Unscrew the bottom shock absorber fastener (4).
102. Remove the supporting washer (5) and the flexible cable of the
lever (6) out of the fastener (7).
77505 Figure 135

96 BODYWORK
.555013. Shock absorber assembly

Note Before fitting the seat cushion, loosen the fixing nut (8), adjust the flexible cable (6) so that in the lowest position of
the adjustment lever, the stiffest vertical damping is reached, then retighten the locking nut (8).
.555092. Removing the height adjustment valve

105. Unscrew the nut (1), remove the flexible cable (2) from the
retainer (3) and pull the cable with the threaded coupling (4)
out of the valve lever (5).
106. Lift the fixing hooks (6) safely and remove the air pipes (7) see
box A.
107. Unhook the spring (8), extract the lower bellow fastener, un-
screw the screw (9) and turn the bracket (10) upward.
108. Turn the valve (11) on the supporting pipe and pull it above the
end of the supporting pipe (12).
77506 Figure 136
.555092. Assembling the height adjustment valve

Note After fitting the new valve, the highest tooth of the toothed segment (13) must adapt to the width of the highest
space of the toothed segment of the valve (14).
.555091. Height lock system disassembly

111. Remove the height adjustment valve.
112. Unscrew support washer (1) and remove toothed segment
(2).
113. Unscrew support washer (3) and remove toothed segment
(4).
114. Unscrew support washer (5) unscrew the screws (6) and re-
move the lever (7).
77507 Figure 137
.555091. Assembling the height lock system

Note After fitting the new parts, the highest tooth of the toothed segment (2) must adapt to the width of the highest space
of the toothed segment of the valve (4).

BODYWORK 97
.555010. Horizontal lever suspension flexible cable disassembly

117. Unscrew the screws (1).
118. Unhook the cable (2) from the lever (3).
119. Extract the flexible cable (2) together with the lever (4) from
the opening (5).
90030 Figure 138
.555010. Horizontal lever suspension flexible cable assembly

.555010. Fast lowering magnetic valve disassembly

122. Loosen the plastic covering (1) as described in the relative op-
eration.
123. Disconnect the hoses (2) and (3) from the valve (4), the hose
(5) from the union (6) and the hose (7) from the union (8)
inside the plastic covering (1) boxes (A, B).
124. Extract the fixing arm (9) of the magnetic valve (10) from the
transverse pipe (11) and lift the valve (10).
126. Remove the magnetic valve (10) for fast lowering from its seat.
77509 Figure 139

98 BODYWORK
.555010. Fast lowering magnetic valve assembly

.555010. Fast lowering switch disassembly

129. Loosen the plastic covering (6) as described in the relative op-
eration.
130. Undo the screws (7).
131. Disconnect the hoses (3) (4) from the union (5).
132. Unscrew the fixing screws (1) and disconnect the switch (2)
for fast lowering from its seat.
90031 Figure 140
.555010. Fast lowering switch assembly


BODYWORK 99
.555095. Removing lumbar support device

134. Partially remove the back trim.
135. Unscrew screws (3) and take the foam off seat back frame.
136. Disconnect the hoses (1).
137. Remove the lumbar support device (2).
90032 Figure 141
.555095. Lumbar support device assembly


100 BODYWORK
.555069. Removing the backrest upholstery

140. Take off the three hoses and electric connection (1).
141. Unhook C-frames (1), box (A).
142. Lift the lever (2) and unscrew the screw (3) fixing the seatbelt.
143. Take off the facing (6).
144. Lift the back upholstery (7) upwards off the fixing tapes (4)
(velcro).
145. Extract the seat belt through the opening (5).
146. Remove the upholstery (7) from the seat.
90033 Figure 142
.555069. Backrest trim fitting

.555068. Removing the cushion upholstery

149. Free the upholstery of the cushion of the seat (1) from the
edging (2) passing along the perimeter of the seat bottom.
77513 Figure 143

BODYWORK 101
CAB AIR-CONDITIONING
.555068. Installing the cushion upholstery

5532 CAB AIR-CONDITIONING
176925 Figure 144
Principles
The purpose of the air-conditioning system is to make the cab comfortable as regards the following parameters:
● temperature and relative humidity of outside air;

● temperature and relative humidity in the cab.
The system subjects the air to thermodynamic transformations that affect its temperature, relative humidity and purity. This is
achieved by:
● ventilation, or introducing air taken from the outside (therefore with the temperature and humidity of the surrounding
environment) into the cab;
● air-conditioning, or cooling and de-humidifying the air, with the possibility of heating it afterwards as preferred so as to
change the temperature and humidity in the cab.

102 BODYWORK
Ventilation
Ventilation is the function of drawing in fresh air from the outside, filtered of pollen and dust by the air filter, or recycling the air in
the cab.
This system is composed of a channel, housing the electric fan unit, air ducts, fresh air intake and recycled air intake.
The electric fan has several speeds to draw in and circulate large masses of air.
Climate control
This air conditioning is achieved by integrating an air-conditioning and a heating system.
This integration makes it possible to change the temperature and humidity in the cab.
air-conditioning
Air-conditioning is accomplished by taking advantage of the high capacity of some gases called «refrigerant», to lower temperat-
ure considerably in their phase of expansion, thereby making it possible to absorb heat from the cab.
This condition is obtained by two different levels of pressure (high, when the refrigerant fluid is in its liquid state, and low, when the
fluid is in its gaseous state) that are established and maintained during operation of the system.
heating
Heating is accomplished by a radiator, in the heater unit, in which the engine coolant circulates.
Special vents allow air to pass through the radiator only when the heating function is activated.
The main components of the air-conditioning and heating system are:
● compressor;
● condenser;
● the drier filter (incorporated in the condenser);
● three-level pressure switch;
● expansion valve;
● evaporator;
● heater/fan unit;
● pollen filter.
Manual air-conditioning controls assembly
176924 Figure 145

BODYWORK 103
Heating and ventilation

● Air temperature control knob, with extreme positions to cut in the HI and LO functions (max and min air temperature / turn
to the left for fresh air - turn to the right for warm air).
● Electric fan knob with relative working speeds and operation selection:
■ switched off (0)
■ manual operation (1-2-3-4).
● Air inlet control knob:
■ face zone air;
■ face and feet zone air;
■ feet zone air;
■ feet and windshield zone air;
■ windshield zone air.
● Switch to turn on air recirculation: it prevents air flowing in from the outside.
● Switch to turn on the air-conditioner.

104 BODYWORK
Climate control unit components
85703 Figure 146

42045 Temperature transmitter 84019 Compressor
82000 Heater assembly 86116 Body Computer
42608 Coolant pressure switches 72021 Diagnostics connector
25332 Compressor engagement contactor

BODYWORK 105
Heating unit components (Versions with manual climate control)
177592 Figure 147

A Recirculation gear motor (Ric) C Expansion valve
B Additional resistor

106 BODYWORK
Side view of heater assembly components
174564 Figure 148

1. Heater 4. Control hose for windscreen defrost panel.
2. Water outlet pipe 5. Air conditioning control panel
3. Water inlet pipe 6. Control hose for air temperature adjustment

BODYWORK 107
Heater components
Gear motors
77572 Figure 149

The recirculation reduction unit is located on Heater/Conditioner unit.
Note If the reduction unit is being replaced, it is NECESSARY to RESET the system.
Compressor
The compressor is situated in the engine bay between the radiator
fan and the alternator.
106393 Figure 150

108 BODYWORK
Condenser and safety pressure switches
77245 Figure 151

The dehumidifier filter is integrated in the condenser that is found on the front of the vehicle.
The refrigeration system uses R134a fluid highlighted on the plate on its casing.
74247 Figure 152

The safety pressure switch assembly with four levels is fitted on the condenser outlet pipe.

BODYWORK 109
characteristics and data
Two NC and NA type pressure switches, keep the pressure inside

the system constant at a minimum of 2,5 bar (NA) to a maximum of
25 bar (NC). If these values are exceeded, the system shuts down.
Whereas, the two pressure switches of the N/O type are used to
disconnect the engine cooling fan coil when the system pressure is
within the interval to bar:
Technical data
Coil removal pressure 18 bar to22 bar
77560 Figure 153
Expansion valve
The expansion valve is block-type; its task is to lower liquid pressure
from the condenser (A) (and therefore of the filter) to a preset
value so that, by circulating inside the evaporator (B), the coolant can
be sucked as a gas by the compressor.
The valve is fitted on the Heater/Air-conditioner assembly near the
blower control module.
77575 Figure 154

Climate control system characteristics and data
Cooling fluid type R 134 A
Amount of system refrigerant fluid 750g
AMOUNT OF AMOUNT OF OIL TO
R134 COOLANT RE- COOLANT IN THE TOTAL AMOUNT OF BE ADDED INTO
COMPRESSOR QUIRED IN THE SYS- PIPES (150 cm COOLANT TO BE SET SYSTEM AT EACH
TEM length) USED FOR ON CHARGING TOOL CHARGING, TYPE
RECHARGING SP10
g 60 for low pressure pipe,
DENSO 10 PA 17 750g 800g 200 cm 3 (+20.0)
g 60 for high pressure pipe
COMPRESSOR NIPPONDENSO
type 10 PA 17
Number of cylinders 10
Bore mm 29.5

110 BODYWORK
CLIMATE CONTROL SYSTEM REPAIR INTERVENTIONS
Climate control system characteristics and data

Stroke mm 26.5
Revs number:
maximum rpm 7000
minimum rpm 6000
Refrigerant R 134 a (ecology)
Oil type SP10
ELECTROMAGNETIC CLUTCH
Rpm:
maximum rpm 7000
minimum rpm 6000
Disengaging torque Nm ≥ 43
Rated voltage V 24
Minimum engagement voltage V 16
Clearance between front disc and pulley mm 0.35 ÷ 0.6
SUPPLEMENTARY HEATER
Air-type heater with burner Eberspächer
type D3L
Rated voltage 24V
Calorific yield:
full capacity kW(kcal/h) 3.2
reduced capacity kW(kcal/h) 1.0
Permitted max. temperature at heater air inlet +40 °C
Heating air flow rate at 0.5 mbar:
full capacity m3/h 160
reduced capacity m3/h 65
.5532. CLIMATE CONTROL SYSTEM REPAIR INTERVENTIONS

Main action
1. Make sure that the spares (filter, condenser, evaporator, hoses and fittings) are complete with caps against dirt and humidity.
These caps must be removed only when the part is ready to be connected.
2. Compressors (sometimes exchangers and filters too) are delivered with some internal pressurisation, to prevent moisture
penetration.
3. Verify that gas escapes when the protection cap is opened, this will prove that the component has been stored correctly.
4. Make sure that pipe unions, between pipes and with other components, are performed as to ensure perfect system water
tightness; refrigerant leaks not only stop the system but also cause rapid compressor wear. Therefore, check that the seal ring
is installed on the male end of the fitting; dampen with system oil (keeping it mind that it varies in relation to type of refriger-
ant) and be sure to avoid all union burrs and cuts between the union surfaces that cause gas leaks.
5. Therefore, when acting on the pipes, follow the instructions given below.

BODYWORK 111
6. Fit the male part into the female hole of the fitting by hand
very carefully until the collar (2) comes into contact with the
corresponding metal seat in the female part.
7. This contact ensures mechanical union with the pipe; the seal
ring (1) pressed between the internal cylindrical part and the
hole provides water tightness.
8. Do not use ring seals having an oversized diameter, or double
seals, which effect the wet seal on the moment but prevent
contact between the metal seats that cause the fitting to loosen
after a short amount of time and gas leaks.
Note When the system pipes are disconnected, plug the
pipes, the component inlets and outlets as well as the
coolant passages (if any), so as to avoid possible mois-
ture formation or dirt penetration. These may affect 86739 Figure 155
correct operation of the system itself.
.553217. REPLACEMENT OF HEATER CONTROLS COMPLETE WITH BOWDEN CABLES
Note This operation may only be performed after completely removing the dashboard from the vehicle.

112 BODYWORK
Main action
.553217. Removal of heater controls complete with bowden cables
7
6
1
5
2
5
4 2
171960 Figure 156

1. Remove the dashboard (7) (553710 Passenger side dashboard removal ( ➠ Page 37)) from the vehicle and place it on a spe-
cific stand.
2. Remove the plastic trip (7) for access to the bowden cables in the heater control unit (1).

BODYWORK 113
173790 Figure 157

3. Remove the heater control unit (1) acting on the retainers (2).
4. Remove the three bowden cables (3) by acting on the fasteners (4) and remove the rings (6) of the bowden cables (3) from
the plastic fasteners (5).
5. Remove the heater control unit (1) complete with bowden cables (3).
.553217. Refitting the heater controls complete with bowden cables

.553210. Heater Removal and Refitting
Main action
.553210. Heater removal
1. Remove the dashboard as described in the relevant chapter (operation 553710Passenger side dashboard removal
( ➠ Page 37)).

114 BODYWORK
2. Unscrew the screws (1) fastening the air ducts (2) to the
heater (3).
3. Disconnect the air ducts (2) from the heater (3).
174354 Figure 158
4. Unscrew the screws (2) fixing the heater (3) to the cross
member on the cab.
5. Detach the clamps (1) of the wiring bundles.
6. Detach the heater (3) from the vehicle.
174355 Figure 159
.553210. Heater refitting

7. To refit, carry out the operations described in the removal process in reverse order, being sure to tighten the nuts or screws
8. Ensure that the engine coolant is at the right level.
9. Ensure that the system and components involved in the described procedure work properly.
10. Refill the air conditioning system (if present), as described in the respective chapter.

BODYWORK 115
.553253. Removing - Refitting the air recirculation door control motor
Main action
.553253. Removing the air recirculation door control motor
1. Remove the glovebox, undo the fastening screws, remove the
Body Control and set aside.
2. Disconnect the power supply connector (2).
3. Undo the retaining screws (1).
4. Remove the air recirculation door control motor (3).
77131 Figure 160
.553253. Refitting the air recirculation door control motor

.553212. Electrical fan Removal - Refitting
Main action
.553212. Electric fan removal
1. Disconnect the connector (3), and the resistor connector (2).
2. Remove the retaining clips (1) and undo the screws (4) and
remove the covers (5) and (6).
174356 Figure 161

116 BODYWORK
3. Remove the electric fan (1) from its seat.
77136 Figure 162
.553212. Electric fan refitting

.553215. Heater radiator Removal - Refitting
Main action
.553215. Heater radiator removal
1. Remove the dashboard as described in the relevant chapter (operation 553710Passenger side dashboard removal
( ➠ Page 37)).
2. Unscrew the retaining screw (2) securing the U-bolt (1), and
release the heater water pipes (3).
77138 Figure 163

BODYWORK 117
3. Unscrew the screws (1), remove the pressure button (5) and
the retaining strap (6) and remove the air duct pipes (2).
4. Detach the clips and remove the pipes (3).
5. Loosen the screws (4) fixing the radiator to the heater.
77139 Figure 164
6. Extract the heater radiator (1) carefully.
77141 Figure 165
.553215. Heater radiator refitting

8. Check that the engine coolant is at the right level.

118 BODYWORK
.553216. Cock Removal and Refitting
Main action
.553216. Cock removal
1. Operating through the lower battery compartment and dash-
board trim, unscrew the retaining screw (2) securing the U-bolt
(1), and release the heater water pipes (3).
77138 Figure 166
2. Unscrew the screws (1), remove the pressure button and cut
the retaining strap (3) and remove the air duct pipes (2).
90040 Figure 167
3. Lift fastener (2) and disconnect piping (3) from radiator (1). By
special pliers, press fins (5) and disconnect tie rod (4). Remove
screws and take cock (6) off the heater.
90041 Figure 168
.553216. Cock refitting


BODYWORK 119
5. Check that the engine coolant is at the right level.

.553261. Pollen filter removal - refitting
Main action
.553261. Pollen filter removal
1. Lift the grille, take off the cover (1) and remove the pollen filter
(2).
77142 Figure 169
.553261. Pollen filter refitting

.553232. Air conditioner condenser removal-refitting
Main action
.553232. Air conditioning condenser removal
1. Lift the grille and discharge the climate control system observing
the procedure described in relating chapter.
2. Unscrew the nut (6) and remove the condenser pipes (5).
3. Unscrew the nut (4) fixing the pipe bracket (3).
4. Unscrew the retaining screws (1) and remove the vehicle con-
denser (2).
77146 Figure 170

120 BODYWORK
.553232. Air conditioner condenser refitting

6. Replace the sealing gasket.
7. Tighten retaining screws and adapters to the specified torque.
8. Fill the air conditioning system as described in the relevant chapter.
.553230. Emptying and refilling of conditioning systems with coolant R 134 a
Work material
Refrigerant R 134 a
Main action
.553230. Safety regulations
Note The device for discharging and charging refrigerant (station) is exclusively for professionally trained operators who must be
familiar with refrigerating systems, refrigerant gasses and the damage pressurised equipment can cause, therefore perform
the following instructions.
1. Always wear gloves and safety glasses when working with refrigerant gasses. Contact of coolant with the eyes can cause blind-
ness.
2. Avoid any contact with skin (low boiling point -30 °C can cause frostbite).
3. Do not inhale refrigerant gas.
4. Before connecting the station to the system, or to an external container, make sure all valves are closed.
5. Before disconnecting the station, check that the cycle has completed and that all valves are closed, this prevents refrigerant gas
escaping into the atmosphere.
6. Do not expose or operate the unit in acid and wet areas or close to open containers of flammable material.
7. The unit must operate in a well-ventilated area.
8. Do not tamper with the safety valve and control system settings.
9. Do not use cylinders or other containers which are not type-approved or equipped with safety valves.
10. Never fill any container above 80% of its maximum capacity.
11. Do not leave the unit powered up if you do not intend to use it immediately. Cut off the mains power supply when it is not
planned to use the equipment.
.553230. Connection method

Note Before starting to disconnect the pipes from the air-conditioner, check whether it is possible to make the repairs without
discharging the gas. If this is not possible, the following operations must be carried out.

BODYWORK 121
12. Use a suitable station for air-conditioning systems with refriger-

ant:
Tool / Material
Refrigerant R 134 a
13. Locate the high and low pressure sockets; RED = high pressure,
BLUE = low pressure.
14. Connect the corresponding pipe fittings (red = high, blue =
low) of the R 134 a refrigerant discharging and charging device.
Tool / Material
Refrigerant R 134 a
Caution! 89890 Figure 171

Refrigerant fluid Standards for the disposal
▶ Avoid dispersing the refrigerant contained in the
system in the air.
15. Recover the refrigerant from the vehicle's system.

Note For the method of connecting up and recovering the
refrigerant in the air-conditioning system, meticulously
follow the instructions given in the publication attached
to the station.
.553230. Leak detector for air conditioning systems with HFC R 134 a
Work material
Refrigerant R 134 a
Technical data
Leak detector operating temperature 0 ℃ to52 ℃
Note Use a suitable instrument capable of identifying leakage of R 134 a fluid.

122 BODYWORK
Main action
1. The leak detector TIF RX-I A is used to locate leaks of R 134 a
fluid in the order of 3,3 g a year.
Tool / Material
Refrigerant R 134 a
2. This instrument requires no calibrations, the operator only

needs to select the desired sensitivity.
3. The instrument warns the operator of any gas leakage with a
buzzer and a LED that flashes in proportion to the concentra-
tion of gas.
4. In addition, the LED indicates the battery is flat if it goes out.
5. Operating temperature is between:
Technical data
117535 Figure 172
Leak detector operating temperature 0 ℃ to52 ℃
6. The instrument is equipped with a flexible probe to reach par-

ticularly difficult fittings or parts.
7. The two levels of sensitivity are:
Technical data
Low sensitivity = 14 g./year.
High sensitivity = 3.3 g./year.
Note Before checking vehicles, wait for the engine to cool,

the hot parts can falsify the test.
DIAGNOSTICS
System does not work

1 Inefficient electric system. Cause confirmed ▶ Check the electrical system.
2 Compressor pulling belt not in normal work- Cause confirmed ▶ Check the belt: if it is too loose or
ing conditions and inefficient. stretched, adjust it or, if necessary,
replace it.
3 Inefficient electromagnetic clutch coil. Cause confirmed ▶ Check whether the coil receives cur-
rent, replace the coil if necessary.
4 Inefficient system fittings and pipes. Cause confirmed ▶ Check and replace defective parts as
necessary. Incorrect distance (play)
between front disc and electromag-
netic clutch.
5 Incorrect distance (play) between front disc Cause confirmed ▶ Check the gap (clearance). If neces-
and electromagnetic clutch. sary, remove the compressor and ad-
just the distance.

BODYWORK 123

6 Compressor inefficient. Cause confirmed ▶ Drain the system as described in the
relevant chapter; disconnect the com-
pressor and replace it.
System noisy

1 Compressor fluid level too low. Cause confirmed ▶ Drain and refill the system as de-
scribed in the relevant chapter.
2 Insufficient coolant in the system. Cause confirmed ▶ Drain and refill the system as de-
3 Incorrect distance (play) between front disc Cause confirmed ▶ Check the gap (clearance). If neces-
and electromagnetic clutch. sary, remove the compressor and ad-
just the distance.
4 Low amount of coolant in the system (green Cause confirmed ▶ Drain and refill the system as de-
sight glass) scribed in the relevant chapter.
5 The system is not sealed. Cause confirmed ▶ Use leak-detector to check the system
and the compressor, and eliminate
refrigerant fluid leaks (if any).
6 The electromagnetic clutch is not operating Cause confirmed ▶ Check the clutch electric connections;
correctly. replace the electromagnetic clutch, if
necessary.
7 Humidity in the system. Cause confirmed ▶ Drain and refill the system as de-
Unusual noise with clutch engaged

1 Loose compressor fasteners Cause confirmed ▶ Check and tighten to torque the
screws and bolts fastening the
compressor.
2 Inefficient electromagnetic clutch. Cause confirmed ▶ Verify whether the fault is due to
mechanical or electrical faults and take
suitable action accordingly.
3 Compressor fluid level too low. Cause confirmed ▶ Drain and refill the system as de-
4 Compressor inefficient. Cause confirmed ▶ Discharge the system and replace the
compressor.

124 BODYWORK

4 Compressor inefficient. Cause not confirmed ▶ Contact the Service Network.
Strange noise with friction disconnected or vibrations

1 Incorrect distance (clearance) between front Cause confirmed ▶ Check the gap (clearance). If neces-
disc and electromagnetic clutch. sary, remove the compressor and ad-
just the distance.
2 Electromagnetic clutch electrical supply sys- Cause confirmed ▶ Check the electric system.
tem inefficient. Cause not confirmed ▶ Contact the Service Network.
Insufficient cooling

1 Humidity in the system. Cause confirmed ▶ Drain and refill the system as de-
2 High discharge pressure and normal sucking Cause confirmed ▶ Drain the refrigerant, replace the drier
pressure due to presence of air in the sys- filter, desecrate the system, then refill,
tem. as described in the relevant chapter.
3 High discharge pressure and low sucking Cause confirmed ▶ As described in the relevant chapter,
pressure with presence of water or ice on drain the refrigerant, eliminate the
the drier filter or the pipes from the con- throttling or replace the faulty com-
denser outlet to the expansion valve. ponent; deaerate the system, then re-
fill.
4 Normal discharge pressure and low/high Cause confirmed ▶ Replace the Trinary pressure gauge.
sucking pressure due to incorrect electro-
magnetic clutch engagement/disengagement

CHASSIS 125
Contents
Contents
characteristics and data . . . . . . . . . . . . . . . . . . . 127
Frame inspections . . . . . . . . . . . . . . . . . . . . . . 127
Frame repairs . . . . . . . . . . . . . . . . . . . . . . . . . 131

126 CHASSIS

CHASSIS 127
CHASSIS
500101 characteristics and data
Double bottle neck high resistance steel chassis.
Dimensions
Inner distance between side members: 1,016 mm
(front)
836
(central)
756 mm
(rear)
Side member section inner height: 289 mm
(front)
199 mm
(rear)
6.7 mm Standard models
Side member thickness:
7.7 mm HM (Heavy Mission) models and 6x2 FP / FS - GV models
Note The indicated distances are independent of thickness.
.500101. Frame inspections
Work material
Hammer
Ruler
Square
Technical data
Maximum vertical curve "b" 10 mm
Lateral curve "a" 3 mm
Vertical curve "b" 1 mm
Torsion "b" (x each side) 1 mm
Main action
1. Inspect the chassis, checking its alignment.
2. If even at this stage you detect any deformation you then need to free the relevant part of the chassis to help make an exact
measurement.
3. Before the inspection you need to check all the parts that, with their imperfections, affect the exact measurements (for ex-
ample: tyre pressure, weak or broken leaf springs, etc.).

128 CHASSIS
Frame inspections
4. Check the rivets by striking their heads with a mallet and touch-
ing the opposite side with your fingers.
Tool / Material
Hammer
5. Mark any loose rivets with paint to help identify them during the
repair work.
17344 Figure 173
6. Carefully check for any peeling or cracking all over the chassis,
paying special attention to the connection points under great
strain, such as: chassis cross members, brackets, mounts of leaf
springs and chassis structural members.
7. Mark any cracked points immediately.
17345 Figure 174
8. Check that the permissible lateral curvature of the chassis

matches the value below.
Technical data
Lateral curve "a" 3 mm
17347 Figure 175
9. Check that the permissible vertical curvature of the chassis

matches the values below.
Technical data
Vertical curve "b" 1 mm
Maximum vertical curve "b" 10 mm 17348 Figure 176
10. Check that the differences between the values (a,b) and (c,d)
match the values below.
Technical data
Permissible difference between "a" and "b" = 3 mm.
Permissible difference with diagonal measurement between "c" and "d" = 6
mm.
17349 Figure 177

CHASSIS 129
Frame inspections
.500101. Measuring the bend of the chassis downwards or upwards

11. Check that the permissible torsion on the chassis matches the
value below.
Technical data
Torsion "b" (x each side) 1 mm
17350 Figure 178
.500101. Measuring the chassis lateral curvature

12. To measure the chassis lateral curvature, the contact surfaces
must be plumbed starting from the two longitudinal members
of the chassis at intervals of approximately 1 m.
13. The points of the plum must be marked accurately on the floor.
17351 Figure 179
14. Stretch a string so that it passes through points marked in line

on the floor.
15. The points outside the line indicate the start and extent of the
actual deformation (a).
17352 Figure 180
16. Procure two equal spacers (1) of such dimensions that a string
can be stretched along the entire length of the rectilinear por-
tion of the lower or upper belt, over the longitudinal member
of the chassis.
17. Measure the distance of the structural member from the string
at 1-metre intervals. A different string distance indicates the
position and extent of an actual bend in the side member.
17353 Figure 181

130 CHASSIS
Frame inspections
.500101. Measuring the chassis displacement

18. Chassis displacement can be measured using a set square. To
this purpose, place the set square at 90° with respect to the
longitudinal member of the chassis check the orthogonality of
the chassis cross member.
Tool / Material
Square
17354 Figure 182
19. Any movement of the axes can be checked by making a diag-

onal measurement. To do this, plumb the centre of the front
mounting of the front suspension and the centre of the front
support of the rear leaf spring on the flat supporting surface, on
both sides.
17355 Figure 183
20. First check the spacing of points a and b. Then make a diagonal
measurement (c, d) from point (2) on the front to the right of
point (2) behind to the left and vice versa.
17356 Figure 184
.500101. Measuring the torsion of the chassis

Note A slight torsion can only be measured with the chassis freed of the cab and mechanical assemblies.

CHASSIS 131
Frame repairs
21. Place the chassis onto two stands.

22. Using two clamps, secure one side of the chassis frame to the
stand.
23. Position the other side of the chassis, in a central position under
the rear cross member, on the knee of an L-shaped iron (1).
24. Set a rule crosswise and put a spirit level (2) on this checking
the reading.
Tool / Material
Ruler
Note The same reading should be obtained at every check

point; if not, the chassis is deformed.
17357 Figure 185
.500101. Frame repairs

Technical data
Reconditioned temperature 600 ℃ to680 ℃
Main action
.500101. Precautions
1. During welding, drilling and grinding operations, and also when
making cuts near the braking system pipes, especially if made of
plastic or electrical cables, make sure that the components are
protected, removing them from the vehicle if necessary. All the
reconditioned chassis parts shall be protected against oxidation
and corrosion.
2. The protection and painting operations must be carried out
accurately on all the concerned parts, in accordance with any
instructions, methods and procedures provided by the paint
manufacturer.
17358 Figure 186
3. The chassis is reconditioned by wedge heating the relevant part

with a blowpipe.
4. During the operation, the metal should turn cherry red, which
indicates a temperature of:
Technical data
Reconditioned temperature 600 ℃ to680 ℃
5. The points previously heated shall not be heated any further.

6. Allow the treated points to cool slowly without using water,
compressed air or other similar methods. 17359 Figure 187

132 CHASSIS
Frame repairs
7. Straighten the chassis side bend with heat wedges in the upper
and lower belt of the respective chassis part.
8. The heat wedge tip should be placed in the desired direction of
bending.
9. If base (a) of the two heat wedges is found on the upper plate
of the side member, the plate must also be heated after the
wedge.
17360 Figure 188
10. Correct the vertical curvature of the chassis with heat wedges
in the high plate of the longitudinal member. In the case of
downward bending, the base (a) of the thermal wedge is at
the bottom. In the case of upward bending, do the opposite.
11. The respective lower or upper belt of the longitudinal member
must be heated last in the area of the heat wedge base.
17361
17361 Figure 189
.500101. Welds on the chassis

Note The welds must only be made by qualified, trained personnel with suitable equipment, and always to professional stand-
ards.
12. Before starting the operations, detach the battery negative ter-
minal and connect the welder ground directly to the part being
welded. The plastic piping must be protected or removed.
17362 Figure 190

CHASSIS 133
Frame repairs
13. Remove the paint and traces of oxidation from the parts to
be welded. At the point of breakage, on the inside of the side
member and along the entire length of the relevant section,
make a V bevel of 60°.
Note No cuts are permitted on the side members at areas of
changes in profile or at points with a high concentration
of stresses; additionally, the line of separation must not
concern the holes already in the side member.
17363 Figure 191
14. Heat all around the area to be welded (except for the QST E
420 material); arch weld in successive steps using alkaline elec-
trodes that have been properly dried, or MIG - MAG proced-
ures with appropriate repair material. Avoid power overloads;
the weld must be free of margin cuts and impurities.
15. Repeat in the other direction and make the weld as specified in
the previous step.
16. Allow the longitudinal members to cool slowly and uniformly.
Note Do NOT use jets of air or other means.
17. Grind off the excess material.
17364 Figure 192
18. Mount internal steel corner stiffeners, which have the same
characteristics as those used on the chassis; the minimum sizes
are listed in the figures above.
19. These reinforcements shall be secured only at the vertical side
member rib; welding beads, false spots, screws or rivets can be
used to this purpose.
20. The welding bead section and length, as well as the number and
arrangement of false spots, screws or rivets, must be suitable to
transmit the bending and cutting moments of the section.
21. On completing the work, the part involved in welding must be
effectively protected with rust proofing.
17365 Figure 193

134 CHASSIS

682 ‒ Scheduled maintenance
Contents 1
Contents
SCHEDULED MAINTENANCE OF VEHICLES WITH

CURSOR 9 EURO III ENGINES . . . . . . . . . . . . . . . 3
MAINTENANCE OF VEHICLES WITH CURSOR 9

ENGINE EURO 4 . . . . . . . . . . . . . . . . . . . . . . . 43
MAINTENANCE OF VEHICLES WITH CURSOR 13

ENGINE (F3B) . . . . . . . . . . . . . . . . . . . . . . . . . 51

2 Contents

SCHEDULED MAINTENANCE OF VEHICLES WITH CURSOR 9 EURO III ENGINES 3
Contents
Contents Checking the fastening of the engine mounts . . . . 18

Visual check of front leaves and leaf spring
SERVICE M0 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Visual check of the rear leaves and leaf spring
MAINTENANCE SERVICES SCHEDULE . . . . . . . . . . 5
U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STANDARD SERVICE OPERATIONS . . . . . . . . . . . 6 Checking the fastening of the steering system
levers and rods . . . . . . . . . . . . . . . . . . . . . . . 19
EXTRA PLAN OPERATIONS . . . . . . . . . . . . . . . . . 7 Checking the fastening of bracket supports and leaf
spring retaining bars . . . . . . . . . . . . . . . . . . . . 20
TIMED OPERATIONS . . . . . . . . . . . . . . . . . . . . . 7
Functional road test . . . . . . . . . . . . . . . . . . . . 20
M1 SERVICE OPERATIONS . . . . . . . . . . . . . . . . . . 8
M2 SERVICE OPERATIONS . . . . . . . . . . . . . . . . . 20
Engine oil change . . . . . . . . . . . . . . . . . . . . . . . 8
Change filter and clean horizontal air filter
Replacing the vehicle fuel filter (F2C Engines) . . . . . 9 casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel pre-filter replacement . . . . . . . . . . . . . . . . . 9 Change filter and clean vertical air filter
Replacement or cleaning of hydraulic steering casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
system filter . . . . . . . . . . . . . . . . . . . . . . . . . 10 Air system drying filter replacement . . . . . . . . . . 22
Checking the engine coolant level . . . . . . . . . . . 10 Manual transmission oil change . . . . . . . . . . . . . 23
Checking the steering hydraulic system oil Transmission and intermediate axle oil
level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 replacement . . . . . . . . . . . . . . . . . . . . . . . . . 24
Checking the hydraulic clutch system fluid Replacement of the side reduction gear oil . . . . . . 24
level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking the headlight alignment . . . . . . . . . . . . 25
Checking the cab tilting system oil level . . . . . . . . 12
Checking the fastening of the battery box . . . . . . 26
Checking the instruments and indicator lights . . . . 12
Checking the fastening of the gearbox
Checking the air conditioner compressor belt . . . . 13 mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Checking the water pump/generator drive Checking the brake shoes . . . . . . . . . . . . . . . . 27
belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Checking the fastening of the steering box and
Checking the tightness of the collars and the support. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
condition of the air intake sleeves . . . . . . . . . . . 14
Clean manual gearbox oil bleeder . . . . . . . . . . . 29
Checking the tyre pressures and condition, adjust
the pressures if necessary. . . . . . . . . . . . . . . . . 14 Clean oil breather on axles . . . . . . . . . . . . . . . 29
Checking the seal of the cab tilting system Checking the EDC failure memory with diagnostics
pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Drain condensation water from pneumatic system Checking the functioning of the windscreen
tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Checking the functioning of the direction M3 SERVICE OPERATIONS . . . . . . . . . . . . . . . . . 30
indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacement of the water pump/alternator drive
Checking the functioning of the external belt on the vehicle . . . . . . . . . . . . . . . . . . . . . 30
lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking the seal of the mechanical unit drive belt on the vehicle . . . . . . . . . . . . . . . . . 30
fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking the seal of the engine cooling
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Intake and exhaust rocker arm clearance
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking the seal of the pneumatic system . . . . . 17
Checking the efficiency of the engine breather and
Checking the braking system pipes . . . . . . . . . . . 17 ventilation valve . . . . . . . . . . . . . . . . . . . . . . 36

4 SCHEDULED MAINTENANCE OF VEHICLES WITH CURSOR 9 EURO III ENGINES
Contents
EP1 SERVICE OPERATIONS . . . . . . . . . . . . . . . . 36

Chassis general greasing . . . . . . . . . . . . . . . . . 36

Replacement of the engine oil filter . . . . . . . . . . 36
Check cleanliness of engine air filter (dry filter
element) . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
T1 SERVICE OPERATIONS . . . . . . . . . . . . . . . . . 38
Remove/refit and check pollen filters . . . . . . . . . 38
Wash radiator protective grille . . . . . . . . . . . . . 38
Checking the antifreeze concentration in the
engine coolant . . . . . . . . . . . . . . . . . . . . . . . 38
Changing the cooling system coolant . . . . . . . . . 39

SERVICE M0
SCHEDULED MAINTENANCE OF VEHICLES WITH CURSOR 9 EURO III ENGINES

M SERVICE M0
To be carried out within the first 3,000 km (or 60 hours) of driving
● Axle oil change
● Rear axle(s) wheel reduction unit oil change
M MAINTENANCE SERVICES SCHEDULE

The Scheduled Maintenance is made up of the "Standard" services, plus a series of operations called "Extra Plan" and others called
"Times". Usually, no different plans are specified in relation to type of vehicle use. If there is a classification in regards to "mission
type", the number of plans provided equals the number of missions. The systematic use of recommended lubricants allows for
lengthy intervals of time between replacements at relatively limited costs.
The "standard" services are indicated with M =Maintenance". They must be performed at regular mileage intervals which are
normally regular (multiples).
Extra plan operations are indicated as EP = “Extra Plan”. These are complementary operations to "standard" services and must
be performed at intervals not compatible with standard services.
Time operations are indicated with T = Time. These are specific operations linked solely to time intervals and, generally, are per-
formed during specific seasonal conditions.
To minimize the number of downtimes for maintenance, it is advisable to plan the downtimes, based on the annual average dis-
tance, making them coincide, to the extent possible with the predefined kilometric intervals.
To schedule the work, observe the following chart:
Maintenance services schedule

EXTRA PLAN
STANDARD SERVICES TIMED OPERATIONS
Use type Engine oil OPERATIONS
M1 M2 M3 EP1 EP2 T1 T2 T3
Every
Road vehicles every
Every every 10,000 km Every
travelling medium and 160,000
40,000 km 80,000 km or 20,000 km
long distances km
1 year
ACEA E5/E7
Every Every every 6 Every 2
Urania LD7 Every Every year
Quarry and Every 120,000 10,000 km Every months years
15W40 60,000 km
construction vehicles 30,000 km km or 15,000 km
or
(Cement mixers, or or 200 hours or
1,200
Tipper trucks) 600 hours 2,400 or 300 hours
hours
hours 6 months
Note If using ACEA E4/ E7 (Urania FE) lubricant, the timing for changing the engine oil and oil filter can be doubled.
If using fuel with a sulphur percentage greater than 0.035 %, the timing for replacing the engine oil and filter must be
halved.
If using low quality fuel (due to water, pollution) the timing for replacing the fuel filters must be halved.
For very low annual mileage the engine oil and filter must be changed at least once a year.
In the event of low annual mileage, the axle and gearbox oil must be replaced at least every 2 years.
The air system drying filter must be changed every year.

STANDARD SERVICE OPERATIONS

SCHEDULED MAINTENANCE OPERATIONS
M1 M2 M3
LUBRICATION, OIL AND FILTER CHANGE AND FLUID CHECK
Change engine oil (1)
• • •
Replacement of the fuel filter cartridge • • •
Replacement of the fuel filter additional cartridge • • •
Change the fuel pre-filter cartridge • • •
Replace engine air filter (dry filter element) (2)
• •
Change pneumatic system drier filter (1)
• •
Replacement or cleaning of hydraulic steering system filter • • •
Checking the engine coolant level • • •
Checking the steering hydraulic system oil level • • •
Checking the hydraulic clutch system fluid level • • •
Checking the cab tilting system oil level • • •
Mechanical transmission oil change (3)
• •
Change rear axle oil (3)
• •
Rear axle(s) wheel reduction unit oil change • •
CAB CHECKS
Checking the functioning of the windscreen wipers and headlight wipers • •
Checking the instruments and indicator lights • • •
ENGINE COMPARTMENT CHECKS
Checking the condition of various drive belts • •
Replacement of the water pump belt and generator (4)
•
Replacement of the air conditioner compressor drive belt (4)
•
Replacement of the alternator movable belt tensioner •
Checking the tappet clearances and adjusting if necessary •
Checking the tightness of the collars and the condition of the air intake sleeves • • •
Checking the engine breather pipe and ventilation valve •
EXTERNAL CHECKS
Checking the headlight alignment • •
Checking the condition and pressure of tyres • • •
Checking the fastening and condition of the battery box • •
Checking the functioning of the direction indicators. • • •
Checking the functioning of the external lights • • •
Checking the seal of the cab tilting system pipes • • •
Drain condensation water from pneumatic system tanks • • •
UNDER VEHICLE CHECKS
Checking the seal of the mechanical unit fluids • • •
Checking the seal of the engine cooling system • • •
Checking the seal of the pneumatic system • • •
Checking the braking system pipes • • •
Visual check of leaves and leaf spring U-bolts • • •
Checking the fastening of bracket supports and leaf spring retaining bars • • •

EXTRA PLAN OPERATIONS

M1 M2 M3
Checking brake shoe wear • •
Checking the fastening of the steering system levers and rods • • •
Checking the fastening of the steering box and support. • •
Checking the manual transmission oil breather efficiency • •
Checking the rear axle breather efficiency • •
Checking the fastening of the engine mounts • • •
Checking the fastening of the gearbox mounts • •
DIAGNOSTICS
Checking the EDC failure memory with diagnostics tool • •
MISCELLANEOUS
Functional road test • • •
1. To be done every year in any case
2. Early filter clog is generally due to environmental conditions. Therefore it must be changed when signalled by the special sensor regardless of the indications,
which must in any case be observed when no specific instructions are provided.
3. To be carried out every 2 years in any case.
4. The mileage for replacement must be halved when using the vehicle in severe conditions (dust and/or heat).

Interval
Road vehicles Quarry and
OPERATIONS
travelling medium construction
and long distances vehicles
Every 10,000 km
● Chassis general greasing Every 10,000 km or
● Check the rear axle oil level EP1 or 200 hours
● Check the intermediate axle oil level 1 year or
6 months
Every 15,000 km
● Change engine oil filter/s (1)
EP2 Every 20,000 km or
● Clean the engine air filter cartridge and casing
300 hours
TIMED OPERATIONS
OPERATIONS
Interval
● R-I and antipollen filter control

T1 Every 6 months
● Wash radiator protective grille
● Checking the coolant density T2 Every year before winter
● Engine coolant change (1)
T3 Every 2 years
● Change the oil and bleed the hydraulic clutch control
1. Paraflu 11 must be diluted 50% with water

M1 SERVICE OPERATIONS
.543070. Engine oil change
Tightening torques
Oil drain plug 95 ±10 N⋅m
Main action
1. Lift the front grille and pull out the oil dipstick (1).
2. From underneath the vehicle, remove the soundproofing guard.
3. Unscrew the plug (2) from the oil sump and drain the engine
oil off into a specific container.
4. Re-screw the plug under the pan and tighten it at the pre-
scribed torque.
Tightening torque
215752 Figure 1
5. Alternative 1 of 2 ‒ Operating with cab in drive position;

▶ Fill in with the prescribed oil quantity and quality from the
filler (1) on the flywheel casing.
215754 Figure 2
5. Alternative 2 of 2 ‒ Operating with cab tipped.
▶ Fill in with the prescribed oil quantity and quality from the
filler (1) on the rocker arm cover.
215753 Figure 3

.542011. Replacing the vehicle fuel filter (F2C Engines)

Main action
tightening torque.
(operation 542011);
119972 Figure 4
.773110. Fuel pre-filter replacement

Main action
2. Position a collection container under the filter (1).
3. Unscrew the filter (1) from the support (3) and replace it.
4. Before refitting the new cartridge, moisten the seal with diesel
or engine oil.
5. Tighten the cartridge (1) by hand until it is in contact with the
mount (3) and then tighten through 3/4 of the turn to the spe-
cified torque.
6. Reconnect the bottom electrical connection (2).
Note When replacing the cartridge, it must not have been
pre-filled.
This is to prevent impurities getting into circulation that
could damage injector/pump system components.
Bleed the air from the fuel circuit as described in the 215756 Figure 5
relevant part in the relative chapter.

.501462. Replacement or cleaning of hydraulic steering system filter

Main action
1. Before taking off the cover (1), thoroughly clean the tank.
Note This will prevent foreign impurities from coming into
contact with the oil of the hydraulic system.
2. Take the cover (1) off the tank and take out the oil filter.
3. Remove the coupling device from the oil filter and replace the
filter.
4. After replacing the filter, in order to check the level of power
steering oil, remove the plug (1), release the transmitter and
check with the engine running and with the wheels facing
straight forward that the oil reaches the required level.
202770 Figure 6
.506010. Checking the engine coolant level
Main action
1. Check that the engine coolant level is between the minimum
and maximum level marks on the expansion tank (2).
2. If necessary top up from the cap (1) of the expansion tank (2).
178183 Figure 7

.501462. Checking the steering hydraulic system oil level
Main action
▶ After the engine is stopped and with the wheels in forward
alignment, the oil level should exceed the upper level on the
dipstick by 1 to 2 cm; remove the cover and top up the level if
necessary (1).
202770 Figure 8
.505260. Checking the hydraulic clutch system fluid level
Main action
Caution!
Danger of injury. The clutch fluid is toxic and corrosive.
▶ Always wear protective gloves. In the event of accidental contact immediately wash with water and neutral soap.
▶ The fluid used is corrosive on painted surfaces with which it comes into contact.

▶ Check the level of the clutch fluid in the tank (→); top it up if it
is too low.
98879 Figure 9
.554250. Checking the cab tilting system oil level
Main action
▶ Follow instructions in the corresponding paragraph of Section, “BODY WORK” for this type of operation Check oil level
( ➠ Page 61).
.765210. Checking the instruments and indicator lights
Main action
▶ From the driving seat, run a general check on the operation of the instruments and warning lights.

.543910. Checking the air conditioner compressor belt
Main action
▶ Visually check that the belt (1) is not worn or deteriorated; if
necessary replace it as described.
173819 Figure 10
.543411. Checking the water pump/generator drive belt
Main action
216002 Figure 11

.505130. Checking the tightness of the collars and the condition of the air intake sleeves
Main action
▶ Visually check all intake sleeves (1, 2, 3, 4). If any leaks are
found, tighten the collars and clamps to torque or replace
cracked components.
215757 Figure 12
.502510. Checking the tyre pressures and condition, adjust the pressures if necessary.
Main action
▶ Tyre pressures must be checked when the tyres are 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 will not be distrib-
uted over the whole tread but be concentrated at either side, causing premature wear of these areas and also damaging the
internal structure of the tyre. Unequal pressures between tyres affect the driving stability of the vehicle and impairs operating
safety. abnormal tyre wear can occur in different areas of the tread.
Note The tyre pressure must be checked WHEN THE TYRES ARE COLD.
It is STRICTLY FORBIDDEN to deflate the tyres when they are hot.

.554257. Checking the seal of the cab tilting system pipes
Main action
▶ Thoroughly check the cab tilting system pipes. Repair any leaks
by tightening all unions or by replacing damaged components.
215758 Figure 13
.798315. Drain condensation water from pneumatic system tanks
Main action
▶ Drain the condensate water in the air tanks by means of the
relevant manual bleeding valves (1).
215759 Figure 14

.763230. Checking the functioning of the direction indicators.
Main action
▶ Engage the driver side controls to check the working condition of the light assemblies and turn signals.
.765225. Checking the functioning of the external lights
Main action
.M. Checking the seal of the mechanical unit fluids
Main action
▶ Check that the mechanical unit fluids show no signs of any leaks. If leaks are found, repair or replace the damaged or worn
parts.
.506042. Checking the seal of the engine cooling system
Main action
1. Make an accurate visual inspection of all the pipelines and related components of the cooling system.
2. Any stains left by cooling liquid leaks are signs of a fault on the circuit being examined. Where found, tighten the collars and
straps to torque or replace cracked components.

.799510. Checking the seal of the pneumatic system
Main action
▶ Ensure that the pipes are in perfect condition, with no cracks
or cuts. Check that there are no leaks from the various connec-
tions, tightening or replacing them as necessary.
215760 Figure 15
.799510. Checking the braking system pipes
Main action
▶ Perform a thorough visual inspection on all pneumatic braking
system pipes (1). Replace any damaged parts in case of leaks.
215761 Figure 16

.505710. Checking the fastening of the engine mounts
Main action
▶ Check that the fastening nuts and screws (1) of the engine
mounts are tightened to the specified torque.
215767 Figure 17
.500411. Visual check of front leaves and leaf spring U-bolts
Main action
▶ Perform a thorough visual check of the leaves and leaf spring
retainer U-bolts.
215764 Figure 18

.500430. Visual check of the rear leaves and leaf spring U-bolts
Main action
retainer U-bolts.
215765 Figure 19
.520630. Checking the fastening of the steering system levers and rods
Main action
▶ Check the fasteners of the steering system levers and rods.
Retighten if necessary.
215768 Figure 20

.500150. Checking the fastening of bracket supports and leaf spring retaining bars
Main action
▶ Check the fasteners of the suspension system levers and rods.
215765 Figure 21
Functional road test

Main action
1. Check the correct operation of steering.
2. Check the correct operation of service brakes.
3. Check operation of emergency and parking brakes.
M2 service includes the M1 service to which must be added the following operations.


Main action
174177 Figure 22


Main action
casing (1).
grime build-up.
wards.
200104 Figure 23
.798850. Air system drying filter replacement

Main action
1. Discharge pressure in the compressed air system.
2. By means of the specific tool, remove the drier filter (1) from
its mounting and fit the new part.
3. Tighten manually until coming into contact with the support and
then tighten half a rotation.
Note If on removal you find there is too much oil in the drier
or in the intake pipe, check the conditions of the com-
pressed air as described under the relevant heading.
215751 Figure 24

.530210. Manual transmission oil change

Main action
1. Unscrew the plug (1) from under the vehicle and drain the oil
into a suitable container.
215772 Figure 25
2. Undo the side cap (2).

3. Fill with new oil through the sealed hole on the cap (1) until oil
pours from the side cap (2).
178186 Figure 26

.525110. Transmission and intermediate axle oil replacement

Main action
1. With the axle warm, unscrew the plugs (1) and (2) drain off
the spent oil into a specific container.
2. Screw the caps back on and refill with new oil through the holes
closed by the caps (3) and (4).
3. Clean the oil vapour breather.
4. Tighten the plugs to the recommended torque.
215773 Figure 27
.522870. Replacement of the side reduction gear oil

Main action
1. Position the plug (1) and the oil drain hole (2) as shown in the
figure.
2. Place a suitable container under the rear axle side reducer,
unscrew the plug and drain the oil through the opening (2).
3. Tighten the oil-drain cap (2).
Note To avoid unwanted oil leakage from the cap, apply
sealant on the surface of the seal.
4. Refill the side reducer from the hole closed by the cap (1) with
oil in the quantity and quality specified.
216001 Figure 28

.763010. Checking the headlight alignment
Main action
1. Place the vehicle, without load and with the tyres inflated to
the prescribed pressure, on a flat surface in front of a lightly
coloured wall at a distance of 10 m.
2. Mark two crosses on the wall corresponding to the centres of
the two headlamps.
3. By using control (1), position headlights with inclination zero.
Inclination can be displayed on CLUSTER display unit.
191908 Figure 29

4. Tilt the cab and turn on the low beam; the distance between
the crosses and P points, which correspond to the angle of the
headlights, should be 15 cm.
5. Adjust light beam according to horizontal and vertical directions
by operating on screws (1, 2).
215774 Figure 30
.551910. Checking the fastening of the battery box
Main action
▶ Check the tightening of the battery case to the frame and
retighten if necessary.
178187 Figure 31

.505813. Checking the fastening of the gearbox mounts
Main action
▶ Check that the gearbox mount fastening nuts and screws (1)
are correctly tightened; retighten if necessary.
227432 Figure 32
.527232. Checking the brake shoes
Main action
1. Check the wear on the drums (1) to decide whether they can
be re-used.
2. Measure the drum diameters with a gauge without bending the
arms.
3. Measure the drum diameter in several spots to determine oval-
ity and wear. Also examine depth of scoring on the braking sur-
face.
4. Max. permitted ovality and/or eccentricity tolerance is 0.25 mm.
If the braking surface scoring or wear cannot be repaired by
turning, or if there are evident signs of overheating, replace the
drum.
185048 Figure 33

5. Check the conditions of the brake shoes (2), if they are cracked
replace them.
6. If the brake lining surface is oily, trace the cause and repair the
fault. The minimum brake lining thickness is 6.7 mm.
7. If this is not so, even if only slightly above or below the specified
value, replace them.
8. Check the integrity and/or efficiency of the brake lining wear
indicator cable.
9. Check the integrity and/or efficiency of the shoe return springs
(1).
10. Clean all mating faces of the brake pads.
11. Clean the seat of the adjustment mechanism.
185068 Figure 34
.501430. Checking the fastening of the steering box and support.
Main action
1. Check that the nuts and screws (3) fastening the box (2) to
the support are tightened to the specified torque, otherwise
2. Verify that the nut (5) fastening the steering lever (4) is cor-
rectly tightened.
3. Check that the steering column support (1) retainer nuts and
screws (6) and are correctly tightened: retighten if necessary.
174277 Figure 35

.530210. Clean manual gearbox oil bleeder

Tightening torques
Gearbox oil breather 10 N⋅m
Main action
▶ Remove the oil vapour breather and clean it thoroughly, then fit it back on, checking it is in the right position, and tighten it to
Tightening torque
.525013. Clean oil breather on axles

Main action
▶ Remove the oil breathers (1) from the intermediate axle and
(2) the rear axle and clean them thoroughly; fit them back on,
checking they are in the right position, and tighten to the re-
quired torque.
72576 Figure 36
Checking the EDC failure memory with diagnostics tool
Main action
1. Connect the E.A.SY. tool to the diagnostics socket (1) and
check the faults memory of the engine control unit.
2. If there are any faults, make the repair suggested by the instru-
ment.
3. Perform the check following the instructions of the fault dia-
gnosis instrument used.
215771 Figure 37

.766510. Checking the functioning of the windscreen wipers
Main action
▶ Check the windscreen wiper operation from the driver's seat.
The M3 service includes the operations of the M1 + M2 services excluding the point "Checking condition of various drive belts" to
which the following operations must be added.
.543411. Replacement of the water pump/alternator drive belt on the vehicle

Main action
1. Remove the air compressor belt as described in the relevant chapter (Replacement of the air conditioner compressor drive
belt on the vehicle ( ➠ Page 30) operation 543910).
2. Using a suitable tool (3) turn the automatic belt tensioner (2)
in the direction of the arrow (→)and remove the drive belt (1)
of the water pump, alternator and fan and replace it with a new
one.
3. Refit the air conditioner compressor belt as described in the
relevant chapter (Operation 543910 Replacement of the air
conditioner compressor drive belt on the vehicle ( ➠ Page 30)).
215766 Figure 38
Work material

Main action
radiator.
217703 Figure 39

not be used again.
173819 Figure 40
Caution!


code
code

code

Caution!

Tightening torques
Screws securing belt tensioner 40 N⋅m to50 N⋅m
Main action
1. Remove the water pump/alternator drive belt (1) as described
in the relevant chapter (543411 Replacement of the water
2. Use a wrench (3) to unscrew the fastening screw of the auto-
matic belt tensioner (2) .
3. Replace the automatic belt tensioner and tighten the fastening
screw to the specified torque.
Tightening torque
4. Refit the water pump/alternator drive belt as described in

the relevant chapter (543411 Replacement of the water
173820 Figure 42

Work material
Box wrench
very carefully.

Main action
187916 Figure 43


6, 2 - 5 and 3 - 4.
nut (1).
Tool / Material
Box wrench
114287 Figure 44
tion.
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle degree [°]
120
5 2
Angle degree [°]
120
1 6
Angle degree [°]
120
4 3
Angle degree [°]
120
2 5
Angle degree [°]

EP1 SERVICE OPERATIONS
.540480. Checking the efficiency of the engine breather and ventilation valve
Main action
▶ Remove and thoroughly clean the breather (1) and the ventila-
tion valve.
178189 Figure 45

.500101. Chassis general greasing
Main action
▶ Perform general greasing of the mobile parts of the chassis (stub axles, fifth wheel, etc...).

.543070. Replacement of the engine oil filter
Tightening torques
Engine oil filter 60 ±5 N⋅m
Main action
Caution!
Filter replacement Precautions
▶ Position a suitable container to collect the oil.
▶ Avoid skin contact with the engine oil: in case of contact, wash thoroughly with water.
▶ The engine oil is highly pollutant: it must be disposed of according to applicable laws.

1. Unscrew the drain plug (1) and drain the engine oil contained in
the filter.
2. Unscrew the body (2) completely and replace the cartridge.
3. Insert the cartridge into the body and fit the centring flanges on
the top cap with the relative seats.
resting bases.
Tightening torque
7. Tighten the drain plug (1) in the cartridge body.

Tightening torque
191322 Figure 46
.505111. Check cleanliness of engine air filter (dry filter element)
Main action
1. Remove the engine air filter and operate as described in the chapter Replace the dry air filter cartridge and clean of its con-
tainer and clean it using low pressure compressed air.
2. Thoroughly clean the air filter container and refit the filter in its seat.

T1 SERVICE OPERATIONS
.553261. Remove/refit and check pollen filters
Main action
1. Lift the front grille and the door (1).
2. Check the clogging condition of pollen filter (2).
Note Excessive clogging of the pollen filters can cause a re-
duction in the flow rate of air into the cab and there-
fore less ventilation.
This will result in a significant reduction in the efficiency
of defrosting the windscreen.
98890 Figure 47
.506010. Wash radiator protective grille

Main action
▶ Lift the cab radiator cowling and carefully clean the radiator grille.
.506010. Checking the antifreeze concentration in the engine coolant
Work material
Hydrometer (densimeter) for checking density of anti- 99395858
freeze liquid
Main action
Caution!
Expansion tank caps Precautions when checking coolants
▶ The plug (1) must not be removed for any reason whatsoever.
▶ With the engine warm, the cooling system is in overpressure, therefore take care when removing the cap (2).

1. Remove the cap (2) and draw off a sample of coolant from the
expansion tank (3) with the densimeter.
code
Hydrometer (densimeter) for checking density of antifreeze 99395858
liquid
2. Depending on the temperature of the fluid, check the percent-

age of antifreeze in the fluid on the reading scale of the instru-
ment.
Note The percentage should be higher than 40% and must
not exceed 50%.
3. If necessary, restore the percentage of antifreeze, keeping in
mind the frequency specified for "Changing the coolant". 98881 Figure 48
Note For vehicles fitted with a supplementary heater, the
percentage of antifreeze must under no circumstances
exceed 50%.
.506010. Changing the cooling system coolant
Technical data
Engine operating temperature ≈ 90 ℃
Main action
.506010. Cooling system filling
Conditions
● For vehicles fitted with just the standard cab heating system or manual air-conditioning system:
▶ fully open the heating fluid tap on the instrument panel.
Conditions
▶ take the heater off-line.
1. Place a sheet of cardboard between the coolant radiator and the intercooler radiator in order to shorten the time needed to
reach the engine's operating temperature.
Technical data

Caution!
Cooling system Precautions during filling
▶ Only top up the fluids when the engine is cold.
▶ To prevent air pockets in the system, the fluid has to be poured slowly (approximate flow rate 8 litres/min).
▶ For vehicles equipped with an additional heater: the percentage of glycols in the coolant must not exceed 50%.
2. After having strictly observed the above mentioned

warnings, proceed as follows.
3. Remove the cap (2) from the expansion tank (3).
4. pour the coolant into the expansion tank (3) until it is com-
pletely full.
87198 Figure 49

Caution!
engine cold.
Conditions
than before.
Restart the engine.

Technical data

42 MAINTENANCE OF VEHICLES WITH CURSOR 9 ENGINE EURO 4

MAINTENANCE OF VEHICLES WITH CURSOR 9 ENGINE EURO 4 43
Contents
Contents
SERVICE M0 . . . . . . . . . . . . . . . . . . . . . . . . . . 45
MAINTENANCE SERVICES SCHEDULE . . . . . . . . . 45
STANDARD SERVICE OPERATIONS . . . . . . . . . . 46
EXTRA PLAN OPERATIONS . . . . . . . . . . . . . . . . 47
TIMED OPERATIONS . . . . . . . . . . . . . . . . . . . . 47
T3 SERVICE OPERATIONS FOR EURO 4

ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacing the AdBlue filter . . . . . . . . . . . . . . . . 48
Replacing the AdBlue prefilter . . . . . . . . . . . . . 49
AdBlue system test with E.A.SY. . . . . . . . . . . . . 50


SERVICE M0
MAINTENANCE OF VEHICLES WITH CURSOR 9 ENGINE EURO 4

For all operations described see the procedures in the maintenance plan for vehicles with engine Cursor 9 -
Euro 3.
M SERVICE M0
● Axle oil change


EXTRA PLAN
Every
Road vehicles every
40,000 km 80,000 km or 20,000 km
long distances km
1 year
ACEA E5/E7
15W40 60,000 km
or
1,200
hours
hours 6 months
halved.


M1 M2 M3
• • •
• •
• •
• •
• •
Rear axle(s) wheel reduction unit oil change • •
CAB CHECKS
•
•
EXTERNAL CHECKS


M1 M2 M3
DIAGNOSTICS
MISCELLANEOUS

Interval
OPERATIONS
Every 10,000 km
6 months
Every 15,000 km
● Change engine oil filter/s (1)
300 hours
TIMED OPERATIONS
OPERATIONS
Interval

T1 every 6 months
T3 Every 2 years
● Change filter and prefilter/s of AdBlue system
● AdBlue system test (E.A.SY. )

T3 SERVICE OPERATIONS FOR EURO 4 ENGINES

.507413. Replacing the AdBlue filter
Main action
2. Tilt the cab.
fasteners (6).
217722 Figure 50

tank (1).
217725 Figure 51

8. Remove the filter (1) from the AdBlue level indicator (2) and
replace with a new filter.
217731 Figure 52
.507414. Replacing the AdBlue prefilter

Main action
1. Remove the cap (1) from the AdBlue reservoir (2).
2. Remove the fixing screws (3) of the fastening collar (4).
217732 Figure 53
3. Remove the fastening collar (1) from reservoir (2).
217733 Figure 54

4. Remove the AdBlue pre-filter (1) from the AdBlue tank (2).
5. Replace the AdBlue filter (1) with a new one.
217734 Figure 55
.295458. AdBlue system test with E.A.SY.
Main action
▶ Connect the E.A.SY. tool to the diagnostics socket (1) and run
the check test on the Ad-Blue system using EASY.
215771 Figure 56

MAINTENANCE OF VEHICLES WITH CURSOR 13 ENGINE (F3B) 51
Contents
Contents Checking the braking system pipes . . . . . . . . . . . 65

Checking the fastening of the engine mounts . . . . 66
SERVICE M0 . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Visual check of front leaves and leaf spring
U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
MAINTENANCE SERVICES SCHEDULE . . . . . . . . . 53
Visual check of the rear leaves and leaf spring
STANDARD SERVICE OPERATIONS . . . . . . . . . . 54 U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Checking the fastening of the steering system
EXTRA PLAN OPERATIONS . . . . . . . . . . . . . . . . 55 levers and rods . . . . . . . . . . . . . . . . . . . . . . . 67
TIMED OPERATIONS . . . . . . . . . . . . . . . . . . . . 55 Checking the fastening of bracket supports and leaf
spring retaining bars . . . . . . . . . . . . . . . . . . . . 68
M1 SERVICE OPERATIONS . . . . . . . . . . . . . . . . . 56 Functional road test . . . . . . . . . . . . . . . . . . . . 68
Engine oil change . . . . . . . . . . . . . . . . . . . . . . 56
M2 SERVICE OPERATIONS . . . . . . . . . . . . . . . . . 68
Replacement of the engine oil filter . . . . . . . . . . 56
Change filter and clean horizontal air filter
Replacing the vehicle fuel filter (F3B Engines) . . . . 57 casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fuel pre-filter replacement . . . . . . . . . . . . . . . . 58 Change filter and clean vertical air filter
Replacement or cleaning of hydraulic steering casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
system filter . . . . . . . . . . . . . . . . . . . . . . . . . 58 Air system drying filter replacement . . . . . . . . . . 70
Checking the engine coolant level . . . . . . . . . . . 59 Manual transmission oil change . . . . . . . . . . . . . 71
Checking the steering hydraulic system oil Transmission and intermediate axle oil
level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 replacement . . . . . . . . . . . . . . . . . . . . . . . . . 72
Checking the hydraulic clutch system fluid Replacement of the side reduction gear oil . . . . . . 72
level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Checking the headlight alignment . . . . . . . . . . . . 73
Checking the cab tilting system oil level . . . . . . . . 60
Checking the fastening of the battery box . . . . . . 74
Checking the instruments and indicator lights . . . . 61
Checking the fastening of the gearbox
Checking the air conditioner compressor belt . . . . 61 mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Checking the water pump/generator drive Checking the brake shoes . . . . . . . . . . . . . . . . 75
belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Checking the fastening of the steering box and
Checking the tightness of the collars and the support. . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
condition of the air intake sleeves . . . . . . . . . . . 62
Clean manual gearbox oil bleeder . . . . . . . . . . . 77
Checking the tyre pressures and condition, adjust
the pressures if necessary. . . . . . . . . . . . . . . . . 62 Clean oil breather on axles . . . . . . . . . . . . . . . 77
Checking the seal of the cab tilting system Checking the EDC failure memory with diagnostics
pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Drain condensation water from pneumatic system Checking the functioning of the windscreen
tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Checking the functioning of the direction M3 SERVICE OPERATIONS . . . . . . . . . . . . . . . . . 78
indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Replacement of the water pump/alternator drive
Checking the functioning of the external belt on the vehicle . . . . . . . . . . . . . . . . . . . . . 78
lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Checking the seal of the mechanical unit drive belt on the vehicle . . . . . . . . . . . . . . . . . 78
fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Checking the seal of the engine cooling
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Checking the seal of the pneumatic system . . . . . 65

52 MAINTENANCE OF VEHICLES WITH CURSOR 13 ENGINE (F3B)
Contents

Intake and exhaust rocker arm clearance
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 81
Checking the efficiency of the engine breather and
ventilation valve . . . . . . . . . . . . . . . . . . . . . . 84

Chassis general greasing . . . . . . . . . . . . . . . . . 84

Replacement of the blow-by filter on the
vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Check cleanliness of engine air filter (dry filter
element) . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Remove/refit and check pollen filters . . . . . . . . . 86
Wash radiator protective grille . . . . . . . . . . . . . 86
Checking the antifreeze concentration in the
engine coolant . . . . . . . . . . . . . . . . . . . . . . . 86
Changing the cooling system coolant . . . . . . . . . 87

SERVICE M0
MAINTENANCE OF VEHICLES WITH CURSOR 13 ENGINE (F3B)

M SERVICE M0
● Axle oil change


EXTRA PLAN
Every
Road vehicles every
40,000 km 80,000 km or 20,000 km
long distances km
1 year
ACEA E5/E7
15W40 60,000 km
or
1,200
hours
hours 6 months
halved.


M1 M2 M3
• • •
Change engine oil filter/s (1)
• • •
• •
• •
• •
• •
Rear axle wheel reduction unit oil replacement • •
CAB CHECKS
•
•
EXTERNAL CHECKS


M1 M2 M3
DIAGNOSTICS
MISCELLANEOUS

Interval
OPERATIONS
Every 10,000 km
6 months
Every 15,000 km
● Replacement of filter/s Blow-By (1)
300 hours
TIMED OPERATIONS
OPERATIONS
Interval

T1 Every 6 months
T3 Every 2 years

.543070. Engine oil change
Tightening torques
Main action
1. Lift the front grille and pull out the oil dipstick (1).
2. From underneath the vehicle, remove the soundproofing guard.
3. Unscrew the plug (2) from the oil sump and drain the engine
oil off into a specific container.
4. Re-screw the plug under the pan and tighten it at the pre-
scribed torque.
Tightening torque
215752 Figure 57
5. Fill in with the prescribed oil quantity and quality from the filler
(1) on the rocker arm cover.
215755 Figure 58
.543070. Replacement of the engine oil filter

Tightening torques
Main action
Caution!
Filter replacement Precautions
▶ Position a suitable container to collect the oil.
▶ Avoid skin contact with the engine oil: in case of contact, wash thoroughly with water.
▶ The engine oil is highly pollutant: it must be disposed of according to applicable laws.

1. Unscrew the drain plug (1) and drain the engine oil contained in
the filter.
2. Unscrew the body (2) completely and replace the cartridge.
3. Insert the cartridge into the body and fit the centring flanges on
the top cap with the relative seats.
resting bases.
Tightening torque
7. Tighten the drain plug (1) in the cartridge body.

Tightening torque
191322 Figure 59
.542011. Replacing the vehicle fuel filter (F3B Engines)

Main action
tightening torque.
(operation 542011);
216003 Figure 60

.773110. Fuel pre-filter replacement

Main action
2. Position a collection container under the filter (1).
3. Unscrew the filter (1) from the support (3) and replace it.
4. Before refitting the new cartridge, moisten the seal with diesel
or engine oil.
5. Tighten the cartridge (1) by hand until it is in contact with the
mount (3) and then tighten through 3/4 of the turn to the spe-
cified torque.
6. Reconnect the bottom electrical connection (2).
Note When replacing the cartridge, it must not have been
pre-filled.
This is to prevent impurities getting into circulation that
could damage injector/pump system components.
Bleed the air from the fuel circuit as described in the 215756 Figure 61
relevant part in the relative chapter.
.501462. Replacement or cleaning of hydraulic steering system filter

Main action
1. Before taking off the cover (1), thoroughly clean the tank.
Note This will prevent foreign impurities from coming into
contact with the oil of the hydraulic system.
2. Take the cover (1) off the tank and take out the oil filter.
3. Remove the coupling device from the oil filter and replace the
filter.
4. After replacing the filter, in order to check the level of power
steering oil, remove the plug (1), release the transmitter and
check with the engine running and with the wheels facing
straight forward that the oil reaches the required level.
202770 Figure 62

.506010. Checking the engine coolant level
Main action
1. Check that the engine coolant level is between the minimum
and maximum level marks on the expansion tank (2).
2. If necessary top up from the cap (1) of the expansion tank (2).
178183 Figure 63
.501462. Checking the steering hydraulic system oil level
Main action
▶ After the engine is stopped and with the wheels in forward
alignment, the oil level should exceed the upper level on the
dipstick by 1 to 2 cm; remove the cover and top up the level if
necessary (1).
202770 Figure 64

.505260. Checking the hydraulic clutch system fluid level
Main action
Caution!
Danger of injury. The clutch fluid is toxic and corrosive.
▶ Always wear protective gloves. In the event of accidental contact immediately wash with water and neutral soap.
▶ The fluid used is corrosive on painted surfaces with which it comes into contact.
▶ Check the level of the clutch fluid in the tank (→); top it up if it
is too low.
98879 Figure 65
.554250. Checking the cab tilting system oil level
Main action
▶ Follow instructions in the corresponding paragraph of Section, “BODY WORK” for this type of operation Check oil level
( ➠ Page 61).

.765210. Checking the instruments and indicator lights
Main action
▶ From the driving seat, run a general check on the operation of the instruments and warning lights.
.543910. Checking the air conditioner compressor belt
Main action
173819 Figure 66
.543411. Checking the water pump/generator drive belt
Main action
106223 Figure 67

.505130. Checking the tightness of the collars and the condition of the air intake sleeves
Main action
▶ Visually check all intake sleeves (1, 2, 3, 4). If any leaks are
found, tighten the collars and clamps to torque or replace
cracked components.
215757 Figure 68
.502510. Checking the tyre pressures and condition, adjust the pressures if necessary.
Main action
▶ Tyre pressures must be checked when the tyres are 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 will not be distrib-
uted over the whole tread but be concentrated at either side, causing premature wear of these areas and also damaging the
internal structure of the tyre. Unequal pressures between tyres affect the driving stability of the vehicle and impairs operating
safety. abnormal tyre wear can occur in different areas of the tread.
Note The tyre pressure must be checked WHEN THE TYRES ARE COLD.
It is STRICTLY FORBIDDEN to deflate the tyres when they are hot.

.554257. Checking the seal of the cab tilting system pipes
Main action
▶ Thoroughly check the cab tilting system pipes. Repair any leaks
by tightening all unions or by replacing damaged components.
215758 Figure 69
.798315. Drain condensation water from pneumatic system tanks
Main action
▶ Drain the condensate water in the air tanks by means of the
relevant manual bleeding valves (1).
215759 Figure 70

.763230. Checking the functioning of the direction indicators.
Main action
.765225. Checking the functioning of the external lights
Main action
.M. Checking the seal of the mechanical unit fluids
Main action
▶ Check that the mechanical unit fluids show no signs of any leaks. If leaks are found, repair or replace the damaged or worn
parts.
.506042. Checking the seal of the engine cooling system
Main action
1. Make an accurate visual inspection of all the pipelines and related components of the cooling system.
2. Any stains left by cooling liquid leaks are signs of a fault on the circuit being examined. Where found, tighten the collars and
straps to torque or replace cracked components.

.799510. Checking the seal of the pneumatic system
Main action
▶ Ensure that the pipes are in perfect condition, with no cracks
or cuts. Check that there are no leaks from the various connec-
tions, tightening or replacing them as necessary.
215760 Figure 71
.799510. Checking the braking system pipes
Main action
▶ Perform a thorough visual inspection on all pneumatic braking
system pipes (1). Replace any damaged parts in case of leaks.
215761 Figure 72

.505710. Checking the fastening of the engine mounts
Main action
▶ Check that the fastening nuts and screws (1) of the engine
mounts are tightened to the specified torque.
215767 Figure 73
.500411. Visual check of front leaves and leaf spring U-bolts
Main action
retainer U-bolts.
215764 Figure 74

.500420. Visual check of the rear leaves and leaf spring U-bolts
Main action
retainer U-bolts.
215765 Figure 75
.520630. Checking the fastening of the steering system levers and rods
Main action
▶ Check the fasteners of the steering system levers and rods.
215768 Figure 76

.500150. Checking the fastening of bracket supports and leaf spring retaining bars
Main action
▶ Check the fasteners of the suspension system levers and rods.
215765 Figure 77
Functional road test

Main action
1. Check the correct operation of steering.
2. Check the correct operation of service brakes.
3. Check operation of emergency and parking brakes.
M2 service includes the M1 service to which must be added the following operations.


Main action
174177 Figure 78


Main action
casing (1).
grime build-up.
wards.
200104 Figure 79
.798850. Air system drying filter replacement

Main action
1. Discharge pressure in the compressed air system.
2. By means of the specific tool, remove the drier filter (1) from
its mounting and fit the new part.
3. Tighten manually until coming into contact with the support and
then tighten half a rotation.
Note If on removal you find there is too much oil in the drier
or in the intake pipe, check the conditions of the com-
pressed air as described under the relevant heading.
215751 Figure 80

.530210. Manual transmission oil change

Main action
1. Unscrew the plug (1) from under the vehicle and drain the oil
into a suitable container.
215772 Figure 81
2. Undo the side cap (2).

3. Fill with new oil through the sealed hole on the cap (1) until oil
pours from the side cap (2).
178186 Figure 82

.525110. Transmission and intermediate axle oil replacement

Main action
1. With the axle warm, unscrew the plugs (1) and (2) drain off
the spent oil into a specific container.
2. Screw the caps back on and refill with new oil through the holes
closed by the caps (3) and (4).
3. Clean the oil vapour breather.
4. Tighten the plugs to the recommended torque.
215773 Figure 83
.522870. Replacement of the side reduction gear oil

Main action
1. Position the plug (1) and the oil drain hole (2) as shown in the
figure.
2. Place a suitable container under the rear axle side reducer,
unscrew the plug and drain the oil through the opening (2).
3. Tighten the oil-drain cap (2).
4. Refill the side reducer from the hole closed by the cap (1) with
oil in the quantity and quality specified.
216001 Figure 84

.763010. Checking the headlight alignment
Main action
1. Place the vehicle, without load and with the tyres inflated to
the prescribed pressure, on a flat surface in front of a lightly
coloured wall at a distance of 10 m.
2. Mark two crosses on the wall corresponding to the centres of
the two headlamps.
3. By using control (1), position headlights with inclination zero.
Inclination can be displayed on CLUSTER display unit.
191908 Figure 85

4. Tilt the cab and turn on the low beam; the distance between
the crosses and P points, which correspond to the angle of the
headlights, should be 15 cm.
5. Adjust light beam according to horizontal and vertical directions
by operating on screws (1, 2).
215774 Figure 86
.551910. Checking the fastening of the battery box
Main action
▶ Check the tightening of the battery case to the frame and
178187 Figure 87

.505813. Checking the fastening of the gearbox mounts
Main action
▶ Check that the gearbox mount fastening nuts and screws (1)
are correctly tightened; retighten if necessary.
227432 Figure 88
.527232. Checking the brake shoes
Main action
1. Check the wear on the drums (1) to decide whether they can
be re-used.
2. Measure the drum diameters with a gauge without bending the
arms.
3. Measure the drum diameter in several spots to determine oval-
ity and wear. Also examine depth of scoring on the braking sur-
face.
4. Max. permitted ovality and/or eccentricity tolerance is 0.25 mm.
If the braking surface scoring or wear cannot be repaired by
turning, or if there are evident signs of overheating, replace the
drum.
185048 Figure 89

5. Check the conditions of the brake shoes (2), if they are cracked
replace them.
6. If the brake lining surface is oily, trace the cause and repair the
fault. The minimum brake lining thickness is 6.7 mm.
7. If this is not so, even if only slightly above or below the specified
value, replace them.
8. Check the integrity and/or efficiency of the brake lining wear
indicator cable.
9. Check the integrity and/or efficiency of the shoe return springs
(1).
10. Clean all mating faces of the brake pads.
11. Clean the seat of the adjustment mechanism.
185068 Figure 90
.501430. Checking the fastening of the steering box and support.
Main action
1. Check that the nuts and screws (3) fastening the box (2) to
the support are tightened to the specified torque, otherwise
2. Verify that the nut (5) fastening the steering lever (4) is cor-
rectly tightened.
3. Check that the steering column support (1) retainer nuts and
screws (6) and are correctly tightened: retighten if necessary.
174277 Figure 91

.530210. Clean manual gearbox oil bleeder

Tightening torques
Main action
▶ Remove the oil vapour breather and clean it thoroughly, then fit it back on, checking it is in the right position, and tighten it to
Tightening torque
.525013. Clean oil breather on axles

Main action
▶ Remove the oil breathers (1) from the intermediate axle and
(2) the rear axle and clean them thoroughly; fit them back on,
checking they are in the right position, and tighten to the re-
quired torque.
72576 Figure 92
Checking the EDC failure memory with diagnostics tool
Main action
1. Connect the E.A.SY. tool to the diagnostics socket (1) and
check the faults memory of the engine control unit.
2. If there are any faults, make the repair suggested by the instru-
ment.
3. Perform the check following the instructions of the fault dia-
gnosis instrument used.
215771 Figure 93

.766510. Checking the functioning of the windscreen wipers
Main action
▶ Check the windscreen wiper operation from the driver's seat.
The M3 service includes the operations of the M1 + M2 services excluding the point "Checking condition of various drive belts" to
which the following operations must be added.
.543411. Replacement of the water pump/alternator drive belt on the vehicle

Main action
1. Remove the air compressor belt as described in the chapter (Replacement of the air conditioner compressor drive belt on
the vehicle ( ➠ Page 78) Operation 543910).
2. Using a suitable tool (3) turn the automatic belt tensioner (2)
in the direction of the arrow (→)and remove the drive belt (1)
of the water pump, alternator and fan and replace it with a new
one.
3. Refit the air conditioner compressor belt as described in the
relevant chapter (Operation 543910 Replacement of the air
conditioner compressor drive belt on the vehicle ( ➠ Page 78)).
106223 Figure 94
Work material

Main action
radiator.
217703 Figure 95

not be used again.
173819 Figure 96
Caution!


code
code

code

Caution!

Tightening torques
Main action
1. Remove the water pump/alternator drive belt (1) as described
in the relevant chapter (543411 Replacement of the water
2. Use a wrench (3) to unscrew the fastening screw of the auto-
matic belt tensioner (2) .
3. Replace the automatic belt tensioner and tighten the fastening
screw to the specified torque.
Tightening torque
4. Refit the water pump/alternator drive belt as described in

the relevant chapter (543411 Replacement of the water
173820 Figure 98

Work material
Box wrench
very carefully.

Main action
187916 Figure 99


6, 2 - 5 and 3 - 4.
nut (1).
Tool / Material
Box wrench
114287 Figure 100
tion.
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle degree [°]
120
5 2
Angle degree [°]
120
1 6
Angle degree [°]
120
4 3
Angle degree [°]
120
2 5
Angle degree [°]

.540480. Checking the efficiency of the engine breather and ventilation valve
Main action
▶ Remove and thoroughly clean the breather (1) and the ventila-
tion valve.
215770 Figure 101

.500101. Chassis general greasing
Main action
▶ Perform general greasing of the mobile parts of the chassis (stub axles, fifth wheel, etc...).


.540486. Replacement of the blow-by filter on the vehicle
Main action
2. Unscrew the screws (4), remove the centrifugal filter below
(3) and replace it.
217711 Figure 102
.505111. Check cleanliness of engine air filter (dry filter element)
Main action
1. Remove the engine air filter and operate as described in the chapter Replace the dry air filter cartridge and clean of its con-
tainer and clean it using low pressure compressed air.
2. Thoroughly clean the air filter container and refit the filter in its seat.

.553261. Remove/refit and check pollen filters
Main action
1. Lift the front grille and the door (1).
2. Check the clogging condition of pollen filter (2).
Note Excessive clogging of the pollen filters can cause a re-
duction in the flow rate of air into the cab and there-
fore less ventilation.
This will result in a significant reduction in the efficiency
of defrosting the windscreen.
98890 Figure 103
.506010. Wash radiator protective grille

Main action
▶ Lift the cab radiator cowling and carefully clean the radiator grille.
.506010. Checking the antifreeze concentration in the engine coolant
Work material
Hydrometer (densimeter) for checking density of anti- 99395858
freeze liquid
Main action
Caution!
Expansion tank caps Precautions when checking coolants
▶ With the engine warm, the cooling system is in overpressure, therefore take care when removing the cap (2).

1. Remove the cap (2) and draw off a sample of coolant from the
expansion tank (3) with the densimeter.
code
Hydrometer (densimeter) for checking density of antifreeze 99395858
liquid
2. Depending on the temperature of the fluid, check the percent-

age of antifreeze in the fluid on the reading scale of the instru-
ment.
Note The percentage should be higher than 40% and must
not exceed 50%.
3. If necessary, restore the percentage of antifreeze, keeping in
mind the frequency specified for "Changing the coolant". 98881 Figure 104
Note For vehicles fitted with a supplementary heater, the
percentage of antifreeze must under no circumstances
exceed 50%.
.506010. Changing the cooling system coolant
Technical data
Main action
.506010. Cooling system filling
Conditions
● For vehicles fitted with just the standard cab heating system or manual air-conditioning system:
▶ fully open the heating fluid tap on the instrument panel.
Conditions
▶ take the heater off-line.
1. Place a sheet of cardboard between the coolant radiator and the intercooler radiator in order to shorten the time needed to
reach the engine's operating temperature.
Technical data

Caution!
Cooling system Precautions during filling
▶ Only top up the fluids when the engine is cold.
▶ To prevent air pockets in the system, the fluid has to be poured slowly (approximate flow rate 8 litres/min).
▶ For vehicles equipped with an additional heater: the percentage of glycols in the coolant must not exceed 50%.
2. After having strictly observed the above mentioned

warnings, proceed as follows.
3. Remove the cap (2) from the expansion tank (3).
4. pour the coolant into the expansion tank (3) until it is com-
pletely full.
87198 Figure 105

Caution!
engine cold.
Conditions
than before.
Restart the engine.

Technical data


682 ‒ Electric/electronic system
Contents 1
Contents
ELECTRIC/ELECTRONIC SYSTEM . . . . . . . . . . . . . 3
CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . 165
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 335

2 Contents

ELECTRIC/ELECTRONIC SYSTEM 3
Contents
Contents Rear view mirror adjustment / power window control

/equipment compartment open control . . . . . . . . . . 56
CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
"LH" STEERING COLUMN SWITCH 6-FUNCTION
VDB (Vehicle Data Bus) communication Line . . . . . 6 STEERING COLUMN SWITCH UNIT - [54033] . . . . 57
ECB (Engine Control Bus) communication line (Euro
4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 "RH" STEERING COLUMN SWITCH 4-FUNCTION
STEERING COLUMN SWITCH UNIT - [54030] . . . . 59
POWER NETWORK . . . . . . . . . . . . . . . . . . . . . . 7 Right multifunction lever . . . . . . . . . . . . . . . . . 60
GROUNDING POINTS . . . . . . . . . . . . . . . . . . . 10 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ELECTRICAL EQUIPOTENTIAL BRAID . . . . . . . 11 Optical indicators on cluster . . . . . . . . . . . . . . 63
MITSUBISHI 28V-90A ALTERNATOR . . . . . . . . . . 16 Indicators on display unit (failure) . . . . . . . . . . . 65
Mitsubishi 28-90A . . . . . . . . . . . . . . . . . . . . . 16 Cluster (pin-out) . . . . . . . . . . . . . . . . . . . . . . 69
Characteristics . . . . . . . . . . . . . . . . . . . . . . . 17 MTCO TACHOGRAPH [40011] . . . . . . . . . . . . . . 70
STARTER MOTOR "DENSO" 24V - 4.5kW . . . . . . . 18 VOLTAGE REDUCER[85031] . . . . . . . . . . . . . . . 71
Denso 4.5 kW . . . . . . . . . . . . . . . . . . . . . . . 18
INTERCONNECTION CONTROL UNIT
Characteristics . . . . . . . . . . . . . . . . . . . . . . . 19
[75000] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DELCOREMY ALTERNATOR 28V-90A (CURSOR
LOCATION OF CONTROL UNITS . . . . . . . . . . . 87
13) SELF-RECTIFYING ALTERNATOR WITH
BUILT-IN VOLTAGE REGULATOR - [03000] . . . . . 20
BODY CONTROLLER (IBC2) [86116] . . . . . . . . . . 88
DELCOREMY ALTERNATOR . . . . . . . . . . . . . 20
Characteristics . . . . . . . . . . . . . . . . . . . . . . . 21 REAR VIEW MIRROR CONTROL UNIT
[86021] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
STARTER MOTOR "Bosch" 24V − 4.5kW (CURSOR
13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CENTRAL LOCKING CONTROL UNIT
[86029] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Bosch starter motor . . . . . . . . . . . . . . . . . . . 22
DIAGNOSTICS CONNECTORS . . . . . . . . . . . . . 96
JUNCTION CONNECTORS . . . . . . . . . . . . . . . . 23
List of connectors . . . . . . . . . . . . . . . . . . . . . 24 EDC SYSTEM FUNCTIONS (Cursor 9) . . . . . . . . . 98
Electro-injectors [78247] . . . . . . . . . . . . . . . 109
Tail headlights cable box . . . . . . . . . . . . . . . . . . . 37
Rail pressure sensor (RPS) PRESSURE
Tail headlights connections . . . . . . . . . . . . . . . 37 ADJUSTMENT SENSOR - [85157] . . . . . . . . . 110
20-pin connector for bodybuilders (cab) [61071] . . . . 39 High pressure pump CP3.3 (pressure
regulator) . . . . . . . . . . . . . . . . . . . . . . . . . 111
4-pin connector for bodybuilders (cab) . . . . . . . . . . 40 Fuel temperature sensor FUEL TEMPERATURE
SENSOR - [47042] . . . . . . . . . . . . . . . . . . . 112
7-poles current outlet for trailer electric
Engine coolant temperature sensor COOLANT
connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TEMPERATURE SENSOR FOR EDC -
BULKHEAD CONNECTOR . . . . . . . . . . . . . . . . 42 [85153] . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Flywheel pulse transmitter ENGINE RPM
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 48 SENSOR - [48035] . . . . . . . . . . . . . . . . . . . 116
CENTRAL DASHBOARD . . . . . . . . . . . . . . . . . . 50
Cab interior lights . . . . . . . . . . . . . . . . . . . . . . . 52

4 ELECTRIC/ELECTRONIC SYSTEM
Contents
Timing system pulse transmitter ENGINE SPEED HYDRONIC M-II WATER HEATER . . . . . . . . . . . 159
SENSOR ON TIMING SYSTEM - [48042] . . . . . 118 Component location . . . . . . . . . . . . . . . . . . 159
Air temperature and pressure sensor TURBO Additional heater water circuit diagram . . . . . . . 160
BLOWER AIR PRESSURE AND TEMPERATURE
SENSOR FOR EDC - [85156] . . . . . . . . . . . . . 119 HYDRONIC M-II HEATER . . . . . . . . . . . . . . 161
Oil pressure and temperature sensor AIRTRONIC AIR HEATER (EBERSPACKER) . . . . . 163
TRANSMITTER FOR ENGINE OIL PRESSURE
GAUGE/TRANSMITTER FOR THERMOMETER Component location . . . . . . . . . . . . . . . . . . 163
SIGNALLING THE ENGINE OIL TEMPERATURE Heater control unit connector . . . . . . . . . . . . 164
- [42030/47032] . . . . . . . . . . . . . . . . . . . . . 121
EDC SYSTEM (Cursor 13) . . . . . . . . . . . . . . . . . 124

CURSOR 13 engine cable . . . . . . . . . . . . . . . 131
Electro-injectors [78247] . . . . . . . . . . . . . . . 132
Rail pressure sensor (RPS) PRESSURE
ADJUSTMENT SENSOR - [85157] . . . . . . . . . 133
Fuel metering valve PRESSURE REGULATOR
SOLENOID VALVE - [78013] . . . . . . . . . . . . . 134
Fuel temperature sensor FUEL TEMPERATURE
SENSOR - [47042] . . . . . . . . . . . . . . . . . . . 135
Engine coolant temperature sensor COOLANT
TEMPERATURE SENSOR FOR EDC -
[85153] . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Flywheel pulse transmitter ENGINE RPM
SENSOR - [48035] . . . . . . . . . . . . . . . . . . . 138
Timing system pulse transmitter ENGINE SPEED
SENSOR ON TIMING SYSTEM - [48042] . . . . . 140
Pre/post heating element . . . . . . . . . . . . . . . . 141
Air temperature and pressure sensor TURBO
BLOWER AIR PRESSURE AND TEMPERATURE
SENSOR FOR EDC - [85156] . . . . . . . . . . . . . 142
Oil pressure and temperature sensor
TRANSMITTER FOR ENGINE OIL PRESSURE
GAUGE/TRANSMITTER FOR THERMOMETER
SIGNALLING THE ENGINE OIL TEMPERATURE
- [42030/47032] . . . . . . . . . . . . . . . . . . . . . 144
SCR SYSTEM (SELECTIVE CATALYTIC

REDUCTION) (Euro 4) . . . . . . . . . . . . . . . . . . 146
AdBlue metering module . . . . . . . . . . . . . . . . 151
DCU (Dosing Control Unit) . . . . . . . . . . . . . 152
SCR system interconnection control unit . . . . . 154
«ABS - EBL» SYSTEM (ANTI-LOCK BRAKE

SYSTEM) - (ELECTRONIC BRAKE LIMITER) . . . . . 155
ABS control unit CONTROL UNIT FOR ABS
SYSTEM - [88000] . . . . . . . . . . . . . . . . . . . . 157

CAN LINE
ELECTRIC/ELECTRONIC SYSTEM
76 CAN LINE
The term CAN means Controller Area Network. It consists of dedicated wiring that connects the control units (ECU) of a vehicle,
creating a structure similar to a nervous system.
This system allows the instantaneous exchange of large quantities of data between the various electrical systems on board the
vehicle.
It represents a mode of TWO-WAY communication that is increasingly used and accepted in the vehicle industry, thanks to the
reduction of conductors and interference.
Information travels respecting a protocol that defines the communication modes:
● Synchronization of information.
● Methods of call and response between the various systems.
Identification and correction of any transmission errors.
A B
73652
73652 Figure 1
A. Sleeve (grey) B. Twisted wires (white/green)
CAN line set-up

The cable used for the "CAN" line on the vehicle is a twisted cable.
It has this characteristic so as to eliminate any electrical disturbances on the signals.
Its covering is grey.
Efficiency tests on the CAN line

To check the state of efficiency of the CAN line on the vehicle, some measures have to be taken. To be able to make these meas-
urements, connect pins 22 and 21 of the 30 pole diagnostics connector and take the following measurements.
Values to be detected during measuring (VDB)

0Ω ≈ 60 Ω ≈ 120 Ω O.L.
CAN line in short circuit CAN line OK One resistor interrupted: CAN LINE interrupted

CAN LINE
76 VDB (Vehicle Data Bus) communication Line
217802 Figure 2
Characteristics
Data transmission speed: 250,000 (BIT/SEC)
Cable colour: Black.
List of control units

Ref. Description Component code
TACHO. Tachograph 40011
IC Instruments Cluster 50003
IBC2 Body Controller 86116
ABS ABS control unit 88000
MIRROR Mirror control unit 86021
Diagnostic Connector /30 30-pole diagnosis connector 72021
OBD II Connector 16-pole connector for OBD (on-board diagnostics) 72069
Telematic Connector /7 7-pole diagnosis connector 72XXX
EDC Engine Management control unit 85150

POWER NETWORK
76 ECB (Engine Control Bus) communication line (Euro 4)
218397 Figure 3
technical specifications
Technical data
Data transmission speed 250,000 bit/s
List of control units

Ref. Description
EDC Engine Management control unit
DCU SCR pump module control unit
UDS Metering module
NOx NOx sensor control unit
76 POWER NETWORK
The aim of the electrical system is to generate, regulate, store and distribute the power needed for vehicle components to work.
Caution!
▶ Never disconnect the batteries from the system with the engine running. Before connecting the batteries to the
system, make sure that the system is suitably insulated.
▶ The batteries must be disconnected from the system when they are to be recharged.
For this reason the supply of the base electric system is ensured by a generator (24V - 90A alternator) and two batteries, each with
12V 165Ah each, connected in series.
Power cable section:
● direct cable from battery (DGC) = 70 mm2

● starter motor cable = 70 mm 2
● alternator cable = 16 mm 2
● positive pin cable = 16 mm 2
● cable to UCI = 10 mm 2
● cable to fuses = 4 mm 2
Operate according to what is detected on the vehicle for the remaining sections.
Negative network

POWER NETWORK
The batteries are connected at M9 ground on the rear part of the gearbox unit with a brown 70 mm2 cable. From the same point
a cable is connected to the chassis ground point on the left side crossmember.
The cab has the same electrically negative equipotentiality as the chassis thanks to a braided cable connected onto the cab front
(T1) and the right front side member (T2).
Power supply batteries
173708 Figure 4
Positive pin
173709 Figure 5

POWER NETWORK
173710 Figure 6
Ground point of batteries on gearbox and left side member

GROUNDING POINTS
76 GROUNDING POINTS
173711 Figure 7
M1/M2Cab interior left side ground M8 Ground on the lower right side of the engine
M3/M3/1
Cab interior right side ground M9 Ground of batteries on gearbox and left side member
M4 Right side cab interior ground (signal ground) ground
M5 Roof panel ground M10 Ground rear right side member
M7 External ground at the front right side of the cab T1/T2 Electrically negative equipotentiality braided cable

GROUNDING POINTS
76 ELECTRICAL EQUIPOTENTIAL BRAID

The electronic components, though generally protected against the influence of on-board equipment voltage, nevertheless remain
particularly sensitive to electromagnetic compatibility issues.
These can be of various nature:
● generated by the vehicle

● external.
A suitable size flexible electrolytic copper braid has been provided on the vehicles to minimise these phenomena and return main
cab and chassis structures to the equipotential state.
Check that the braid is properly attached to the chassis and the cab, in the event of defective cab grounding.
173712 Figure 8

GROUNDING POINTS
173713 Figure 9
Ground point behind the cluster

GROUNDING POINTS
173714 Figure 10
Ground point behind the body controller
Roof panel ground point
173715 Figure 11

GROUNDING POINTS
173716 Figure 12
Cab exterior right side ground
173717 Figure 13
Ground point on the lower right side of the engine

GROUNDING POINTS
173718 Figure 14
Ground point of batteries on gearbox and left side member ground
Ground point of batteries on rear right side member
173719 Figure 15

MITSUBISHI 28V-90A ALTERNATOR
760310 MITSUBISHI 28V-90A ALTERNATOR

Mitsubishi 28-90A
30±2 96.8 32.15
± 0.7
22
40 °
M8X1.25
82°± 2°
028
50 9-3.56
± 0.1
R9
0
35°
15.4MIN
.
19
2- R
062
066
025
0142+2
-1
12
.5
34
55
90
°
45
°
°
017
40
31
3
0.
5±
0+10
0.
028
028
01
2-
±
58 32.150.7 36.2
A (165.15)
(A) B C
100 ( 23°C)
90
80 ( 80°C)
70
60
50
40
30
20
10
0
1 2 3 4 5 6 ( x1000 rpm)
D E S
IG
L
(B+)
224877 Figure 16
A Technical view D Wiring Diagram
B Alternator current delivery curve E Electric connections
C Perspective view

MITSUBISHI 28V-90A ALTERNATOR
Characteristics
Supplier: MITSUBISHI
Technical data
Rated voltage 27 V
Rated current delivery 92 A
Environmental temperature 20 ℃
Current delivery at 1500 rpm (at ambient temperature and rated voltage) 36 A
Belt tension 730 N
Weight 6.9 kg
Direction of rotation: clockwise (seen from pulley side)
Tightening torque
Tightening torque on terminal B+ 12.5 ±2 N⋅m
Pin - out connector / Positive terminal (B+)

Ref. Function Cable colour code
L Failed battery recharge signal (to chassis control unit) 7009
15 (IG) Positive signal+15 (from vehicle fuse) 8876
S Battery positive signal (jumper with terminal B+) 7777
Positive +30 (from starter motor) 7777
B+ Positive +30 (jumper with terminal S) 7777
Positive +30 (to external pin cab positive) 7777

STARTER MOTOR "DENSO" 24V - 4.5kW
760810 STARTER MOTOR "DENSO" 24V - 4.5kW

Denso 4.5 kW
15±1
Ø9 9-0.5
-1.5
69±2
79±0.5
(1 5
°)
17°
±2°
±2
59
51
.5±
1.5
10
79 + ±3
±1
26
- 21
1
3±
57MA X
38
°±
1° 38°±1°
30 50
224879 Figure 17
B Graph curves characteristics E Electrical connections (terminals)
C Perspective view

STARTER MOTOR "DENSO" 24V - 4.5kW
Characteristics
Supplier: DENSO
Technical data
Nominal power 4.5 kW
Rated voltage 24 V
Operating voltage (max) 16 V
Rated time 30 s
Weight 8.4 kg
Coupling system: Positive advance control

Direction of rotation: clockwise (seen from pinion side)
Tightening torque
Tightening torque on terminal 30 17.6 N⋅m to24.5 N⋅m
Tightening torque on terminal 50 2.6 N⋅m to4.6 N⋅m
Specific power
Load Test conditions Characteristics
90 A
No load 23 V MAX
(3,500 rpm)
530 A
17 V
Load MAX
(39.2 N⋅m)
(950 rpm)
900 A
Stall 6V MAX
(49.0 N⋅m)
Motor terminals
Ref. Function Cable colour code
Positive +30 for starter motor power supply, from battery positive terminal (via Main Current Contactor) 7777
30 +30 positive to the alternator 7777
+30 positive to contactor for engine preheat activation consent 7777
50 Positive +50 from key switch 8888

DELCOREMY ALTERNATOR 28V-90A (CURSOR 13) SELF-RECTIFYING ALTERNATOR WITH BUILT-IN
760310 DELCOREMY ALTERNATOR 28V-90A (CURSOR 13) SELF-RECTIFYING ALTERN-

ATOR WITH BUILT-IN VOLTAGE REGULATOR - [03000]
DELCOREMY ALTERNATOR
A
B C
D E
S
IG
L
217850 Figure 18
A Technical view D Voltage regulator
B Characteristic curves E Electric connections
C Perspective view

DELCOREMY ALTERNATOR 28V-90A (CURSOR 13) SELF-RECTIFYING ALTERNATOR WITH BUILT-IN
Characteristics
Supplier: DELCOREMY 28V 90A
Technical data
Rated voltage 28.3 ±0.5 V(20 ℃)
Nominal current supply 90 A
Operating speed 5,000 rpm
Direction of rotation: Clockwise, viewed from pulley
Technical data
Weight 7.7 kg
Tightening torque
Tightening torque on terminal B+ 12.5 ±2.5 N⋅m

STARTER MOTOR "Bosch" 24V − 4.5kW (CURSOR 13)
760810 STARTER MOTOR "Bosch" 24V − 4.5kW (CURSOR 13)

Bosch starter motor
217849 Figure 19
A Technical view B Characteristic curves

JUNCTION CONNECTORS
C Wiring Diagram D Power supplies
Nominal power 4.5 kW
Rated voltage 24 V
Coupling system Positive approach control
Adjusted time 30 sec.
Direction of rotation Clockwise seen from pinion end
Operating voltage 16 V MAX
Weight approx. 8.4 kg
Tightening torque for terminal +30 20 - 24 Nm (M10X1.5)
7691 JUNCTION CONNECTORS
X56/3/A
X56/3/B
ST82000A
ST82000B
ST82000C
173720 Figure 20
The location of the connectors present (cab - chassis) could be subject to change due to wiring requirements.

JUNCTION CONNECTORS
List of connectors
Name Description
ST 01 Ignition switch
ST 02A Connection for steering column
ST 06A Connection for roof panel wings devices on the driver side
ST 06B Connection for tachograph
ST 08A Connection for driver side door
ST 08B Connection for driver side door
ST 09A Connection for passenger side door
ST 15 Connection for couplings in the high roof
ST 16 Connection for pneumatic horn
ST 31A Connection for cab rear
ST 79A Connection for external cab front
ST 79B Connection for windsscreen washer and warning horn unit
ST Y1 Connection for right headlights cable
ST Y2 Connection for left headlights cable
ST 82000A Connection for air conditioner with manual control
ST 82000B Connection for air conditioner with manual control
ST 82000C Connection for air conditioner with manual control
X56/3/A Connection for rear chassis wiring
X56/3/B Connection for trailer setup
Junction connector ST01 (black) - ignition key
1 2 3 1 2 3
107169 Figure 21
Pin Function Cable colour code

1 Positive +30 for key switch 7777
2 Terminal 15, ignition switch 8887

JUNCTION CONNECTORS
ST02A (grey) - connection for steering column
101564 Figure 22

1 Horn control 1116
2 Windscreen wiper (single swipe) 8886
3 Right turn signal light 1123
4 Left turn signal light 1129
5 Full beam headlights on 2200
6 Light flasher 2204
7 Windscreen wiper (intermittent) 8822
8 Windscreen wiper (slow speed) 8882
9 Windscreen wiper (maximum speed) 8881
10 ground 0000
11 Cruise Control (Resume / CC OFF) 8154
12 Cruise Control (Set-) 8157
13 Cruise Control (Set+) 8156
14 Speed limiter signal 9968
15 Spare −
16 Engine brake control 8159
17 Spare −
20 Positive +30 for key switch 7777

JUNCTION CONNECTORS
ST06A junction connector (yellow) - roof panel wings devices on the driver side
101564 Figure 23

1 Positive for left speaker (roof) 1188
2 Negative for left speaker (roof) 1186
3 Positive for right speaker (roof) 1184
4 Negative for right speaker (roof) 1183
5 Electric roof opening control power supply 7010
6 Electric roof closing control power supply 7011
7 Battery direct positive (+Batt) for voltage reducer 7704
8 Positive for 12V power socket 7770
9 Positive for bunk lights (12 V) 7770
10 Spare −
11 Positive for internal side lights (bunk lights) 4111
12 Positive for step light 4408
13 Positive for internal lights (spot lights) 4440
14 Positive right front side marker 3314
15 Positive left front side marker 3304
16 Spare −
17 Spare −
18 Spare −
19 Spare −
20 Spare −

JUNCTION CONNECTORS
ST06B junction connector (black) - tachograph
101564 Figure 24

1 Spare −
2 Spare −
3 Spare −
4 Spare −
5 Spare −
6 Speed sensor power supply (pin 1) 5514 (XXX1)
7 Ground for speed sensor power supply (pin 2) 0058 (XXX2)
8 Sensor speed signal (pin 3) 5517 (XXX3)
9 Setup (Inverted signal from speed sensor) 5516 (XXX4)
10 Lighting ideograms 4442
11 Spare −
12 Battery direct positive (+Batt) 7768
13 Spare −
14 Spare −
15 Positive +15 8879
16 Spare −
17 Spare −
18 Spare −
19 CAN “H” line White
20 CAN "L" line Green
Junction connector ST08A (blue) - driver side door
101554 Figure 25

1 Positive for power window switches 8861

JUNCTION CONNECTORS
101554 Figure 25

2 Connection 1 between side power window switches 8861
4 Ground for power window switches 0000
5 Positive for speaker (left door) 1188
6 Negative for speaker (left door) 1186
7 Central locking control (lock door) 0065
8 Central locking control (unlock door) 0064
9 Centralised closing engine power supply (door closing) 9965
10 Centralised closing engine power supply (door opening) 9964
11 Signal from left door button 0003
12 Ground for left door button 0066
Junction connector ST09A (blue) - passenger side door
101554 Figure 26

1 Positive for power window switch 8861
4 Positive for speaker (right door) 1184
5 Negative for speaker (right door) 1183
8 Centralised closing engine power supply (door closing) 9965
9 Centralised closing engine power supply (door opening) 9964
10 Signal from right door button 0003
11 Ground for right door button 0066
12 Spare −

JUNCTION CONNECTORS
Junction connector ST09B (blue) - passenger side door
101554 Figure 27

1 Right mirror heating power supply 8830
2 ground 0000
3 Right main rear-view mirror control (vertical) 8858
4 Right rear-view mirror control (return) 8857
5 Main right rear view mirror control (horizontal) 8859
6 Right wide angle rear view mirror control (horizontal) 8852
7 Right wide angle rear view mirror control (vertical) 8853
8 Spare −
9 Spare −
10 Spare −
11 Spare −
12 Spare −
ST15 junction connector (yellow) - Connection for couplings in the high roof
107538 Figure 28

1 Positive for left speaker (roof) 1188
2 Negative for left speaker (roof) 1186
3 Positive for right speaker (roof) 1184
4 Negative for right speaker (roof) 1183
5 Positive for internal side lights (bunk lights) 4111
6 ground 0000
7 Electric roof opening control power supply 7010
8 Electric roof closing control power supply 7011
9 Spare −

JUNCTION CONNECTORS
107538 Figure 28

10 Spare −
11 Spare −
12 Spare −
ST16 junction connector - connection for pneumatic horn
101531 Figure 29

1 Positive for pneumatic warning horn 1133
2 ground 0000
ST31A junction connector (green) - Cab rear
101554 Figure 30

1 Positive for bunk lights (12 V) 7770
2 ground 0000
3 Positive for switch for lighting tool compartment 7772
4 Positive for instrument lighting 4442
5 Ground for tool compartment light / lighting control switch 0000
6 Ground for refrigerator 0000
7 Positive for refrigerator 7772

JUNCTION CONNECTORS

8 Spare −
9 Spare −
10 Spare −
11 Spare −
12 Spare −
ST79A junction connector (yellow) - external cab front
107545 Figure 31

1 Positive for horns 1116
2 Ground for horns 0000
3 Spare −
4 Spare −
5 Stop light signal 1117
6 Positive from secondary brake pedal switch 8158
7 Positive for friction sensor / Brake pedal switch on duplex 8362
8 Positive to coolant pressure indicator switch (air conditioning) 8871
10 Windscreen wiper motor (31B) 8873
11 Windscreen wiper motor (53 - Slow) 8882
12 Windscreen wiper motor (53B - Fast) 8861
13 Positive from coolant pressure indicator switch (air conditioning) 8871
14 Clutch switch signal 0160
15 Spare −

JUNCTION CONNECTORS
Junction connector ST79B (yellow) - windshield washer and warning horn unit
107531 Figure 32

1 Front brake air pressure sensor signal 5562
2 Front brake air pressure sensor positive 5560
3 Air pressure sensor of rear brakes positive 5560
4 Rear brake air pressure sensor signal 5561
5 Ground for front brake system air pressure sensor 0000
6 Rear brake air pressure sensor ground 0000
7 Spare −
8 Spare −
9 Spare −
Junction connector STY1 - right headlights cable
101551 Figure 33

1 ground 0000
2 Right turn indicator light power supply 1123
3 Right side lights power supply 3314
4 Right low beam light power supply 2223
5 Right high beam light power supply 2221
6 Right fog light power supply 2228
7 Spare −

JUNCTION CONNECTORS
Junction connector STY2 - left headlights cable
101551 Figure 34

1 ground 0000
2 Left turn indicator light power supply 1123
3 Left side lights power supply 3304
4 Left low beam light power supply 2223
5 Left high beam light power supply 2221
6 Left fog light power supply 2228
7 Spare −
Connector for junction ST82000A - manually controlled air conditioning
176001 Figure 35

1 Positive for ideogram lighting 4442
2 Positive +15 8879
3 ground 0000
4 − −
5 − −

JUNCTION CONNECTORS
Connector for junction ST82000B - manually controlled air conditioning
176001 Figure 36

1 − −
2 − −
3 − −
4 Air condition engagement control 8871
5 − −
Connector for junction ST82000C - manually controlled air conditioning
107545 Figure 37

1 − −
2 − −
3 Positive +15 7550
4 − −
5 − −
6 − −
7 − −
8 Air condition engagement control 8871
9 ground 0000
12 − −
13 − −
14 − −
15 − −

JUNCTION CONNECTORS
Connector for junction X56/3/A - rear chassis wiring
176002 Figure 38
Pin Cable colour code Function Cable colour code

1 2286 Positive for rear fog light EBD
2 5552 Fuel level gauge DFC
3 1177 Positive for left stop light BA
4 2226 Positive for reverse lights BC
5 3315 Positive for rear right side lights EA02
6 1129 Positive for left turn indicators GF
7 1123 Positive for right turn indicators GA
8 1172 Positive for right stop light A
9 3308 Positive for rear right side markers B
10 6620 Signal from switch for signalling transversal differential lock LKA1
11 9325 Power supply to rear transverse differential locking solenoid valve EAC
12 6643 Longitudinal lock engaged signal LKC
13 9324 Power supply for rear longitudinal differential lock solenoid valve BAC
14 − Spare −
15 3308 Positive for rear left side markers C
16 2224 Fifth wheel light positive BKC
17 3307 Right licence plate lights D
18 0652 Fuel level gauge ground FC
19 3305 Positive for rear left side lights EF02
20 9144 Dumper tipping indicator EA01
21 − Spare −

JUNCTION CONNECTORS
Connector for junction X56/3/B - trailer setup
113250 Figure 39
Pin Cable colour code Function Cable colour code

1 3305 Left positioning light positive for trailer EF
2 1180 Left direction indicator light postive for trailer GF
3 1179 Trailer stop light positive BA
4 1185 Right direction indicator lights positive for trailer GA
5 3315 Positive for trailer right side lights EA
6 2270 Trailer rear fog light positive 2270
7 − Spare −
8 2226 Trailer reverse light positive BC

Tail headlights cable box
7691 Tail headlights cable box

Tail headlights connections
X12
M10
STY3 STY4
X12 X12 X12 X12 X12 X12 X12 X12 X12 X12 X12
X12
217820 Figure 40
M10 Ground point of batteries on rear right side member STY3 Stop light and side markers connector (right headlight)
X12 Tail headlights connector plate STY4 Stop light and side markers connector (left headlight)
X12/2 connector (In)

1 Spare −
2 Spare −
3 Spare −
4 Spare −
5 ground L

Tail headlights cable box
X12/4 connector (Out)

1 Positive for rear fog light EBD
2 Spare −
3 Spare −
4 Spare −
5 Spare −

2 Spare −
3 Spare −
4 Spare −
5 Spare −

2 Positive for right turn indicators GA
3 Positive for rear right side lights EA02
4 Spare −
5 ground L

1 Positive for reverse lights BC
2 Positive for right turn indicators GA
3 Positive for rear right side lights EA02
4 Spare −
5 ground L

2 Spare −
3 Spare −
4 Spare −
5 ground L

2 Positive for left turn indicators GF
3 Positive for rear left side lights EF02

20-pin connector for bodybuilders (cab) [61071]

4 Positive for left stop light BA
5 ground L

2 Positive for left turn indicators GF
3 Positive for rear left side lights EF02
4 Positive for left stop light BA
5 ground L
STY3 connector
A Positive for right stop light A
B Positive for rear right side markers B
STY4 connector
C Positive for rear left side markers C
D Right licence plate lights D
7691 20-pin connector for bodybuilders (cab) [61071]
222598 Figure 41
Connector 61071 pin-out
1 Positive for accelerator pedal position sensor 5158
2 Signal from accelerator pedal position sensor 5157
3 Ground for accelerator pedal position sensor 0157
4 Negative for pressed accelerator switch 0158
5 Accelerator switch pressed signal 0159
11 Power supply for secondary accelerator 8350

4-pin connector for bodybuilders (cab)
222598 Figure 41

12 Signal from secondary accelerator 5330
13 Signal from secondary accelerator selector 0330
14 Spare −
15 Spare −
16 Speed signal from tachograph 5542
17 Spare −
19 Signal for secondary accelerator selector 0131
7691 4-pin connector for bodybuilders (cab)
101538 Figure 42
Connector Pin - out for bodybuilders
1 Positive +30 7772
2 Ground 0000
3 CAN - H line White
4 CAN - L line Green

7-poles current outlet for trailer electric connection
7672 7-poles current outlet for trailer electric connection
113252 Figure 43
CONNECTOR VIEW (CABLE SIDE)
72000 - standard 7-poles current outlet for trailer electric connection

1 ground 0000
2 Positive for trailer right side lights 3315
3 Left direction indicator light postive for trailer 1180
4 Trailer stop light positive 1179
5 Right direction indicator lights positive for trailer 1185
6 Left positioning light positive for trailer 3305
7 Trailer reverse light positive 2226
72001 - auxiliary 7-poles current outlet for trailer electric connection

1 ground 0000
2 Spare −
3 Trailer rear fog light positive 2270
4 Spare −
5 Spare −
6 Spare −
7 Spare −
72006 - 7-poles current outlet for trailer ABS electric connection

1 Positive +30 for trailer ABS 7777
3 ABS trailer ground 0000
5 Trailer ABS failure warning light 6671
6 Spare −
7 Spare −

BULKHEAD CONNECTOR
7672 BULKHEAD CONNECTOR
173721 Figure 44
A White connector D Blue connector
B Brown connector F Green connector
C Yellow connector
Note There may be the letter E rather than the letter F printed above the green connector as shown in the figure.
Connector Pin-out "A" (white)

1 Positive for "EV" solenoid valve (unloading), front left wheel 9921
2 Positive for "AV" solenoid valve (loading), front left wheel 9919
3 ABS speed sensor front left wheel 5570
5 ABS speed sensor front right wheel 5571
7 Positive controlling "AV" solenoid valve (loading), front right wheel 9918
8 Positive for "EV" solenoid valve (unloading), front right wheel 9920
9 Positive for "AV" (loaded) solenoid valve command, rear left wheel 9929
10 Positive "EV" (unloaded) solenoid valve command, rear left wheel 9931
11 ABS speed sensor rear left wheel 5572

BULKHEAD CONNECTOR

13 ABS speed sensor rear right wheel 5573
15 Positive "EV" (unloaded) solenoid valve command, rear right wheel 9930
16 Positive "AV" (loaded) solenoid valve command, rear right wheel 9928
17 Front left ABS solenoid valve ground 0000
18 Front right ABS solenoid valve ground 0000
19 Rear left ABS solenoid valve ground 0000
20 Rear right ABS solenoid valve ground 0000
22 Trailer ABS failure warning light 6671
23 ground 0000
24 − −
25 − −
26 − −
27 − −
28 − −
29 − −
30 − −
31 − −
32 − −
33 − −
34 − −
35 − −
36 − −
37 − −
38 − −
Connector "B" pin-out (brown)

1 Positive for front side lights and side markers (left) 3304
2 Positive for front side lights and side markers (right) 3314
3 Positive for hight beam headlamp (left) 2219
4 Positive for high beam headlamp (right) 2221
5 Positive for low beam headlamp (left) 2231
6 Positive for low beam headlamp (right) 2223
7 Positive for front turn indicators (left) 1129
8 Positive for front turn indicators (right) 1123
9 Positive for fog lights (left and right) 2228
10 Positive for pneumatic warning horn 1133
11 Spare −
12 Spare −

BULKHEAD CONNECTOR

13 Spare −
14 Spare −
15 Positive for electric windscreen washer pump (Euro 4) 8886
16 Spare −
17 Spare −
18 Spare −
19 Spare −
20 Signal for headlamp position adjuster 9934
21 Positive for headlamp position adjuster 8820
22 Spare −
23 Spare −
24 Spare −
25 Spare −
26 Spare −
27 Spare −
28 Spare −
29 Spare −
30 Spare −
31 Spare −
32 Spare −
33 Spare −
34 Spare −
35 Spare −
36 Spare −
37 Spare −
38 Spare −
39 Spare −
40 Spare −
Connector "C" Pin-Out (yellow)

1 Front differential lock engaged signal 6659
2 Power supply for front transverse differential lock solenoid valve 9325
3 Power supply for hydraulic pump for servo cab tilting 7029
4 Spare −
5 Spare −
6 Positive from hydraulic cab disengagement consent switch 0029
7 Spare −
8 Spare −
9 Battery direct positive (+Batt) for refrigerator 7777
10 PTO 1 engaged signal 6131
11 PTO 2 engaged signal 6132
12 PTO 1 solenoid valve power supply 9131

BULKHEAD CONNECTOR

13 Spare −
14 Spare −
15 Spare −
16 Spare −
17 Spare −
18 Spare −
19 Spare −
20 Spare −
21 Spare −
22 Spare −
23 Spare −
24 Spare −
25 Spare −
26 Spare −
27 Spare −
28 Spare −
29 Spare −
30 Spare −
31 Spare −
32 Spare −
33 Spare −
34 Power supply for engine water recirculation solenoid valve 9506
35 Ground for additional water heater for fuel pump 0000
36 Ground for additional water heater 0000
37 Power supply for additional water heater 7772
38 Control signal for additional water heater 1210
39 Fuel pump ground for additional water heater 0000
40 Fuel pump power supply for additional air heater 7783
Pin - out connector “D” (blue)

1 Speed sensor power supply 5514 (XXX1)
2 Speed sensor ground 0058 (XXX2)
3 Speed sensor signal 5517 (XXX3)
4 Licence plate lights 3307
5 Reverse light positive 2226
6 Power supply for diesel heater heating element in tank 7036
7 Trailer rear fog light positive 2270
8 Ground from reverse engagement indicator switch 2268
9 Transmission in neutral signal switch 7050
10 Positive for rear right side lights 3315
11 Positive for rear left side lights 3305
12 Positive for rear side markers 3308

BULKHEAD CONNECTOR

13 Positive for left stop light 1177
14 Positive for right stop light 1172
15 Positive for rear fog light 2286
16 Positive +15 (brake air drier) 8840
21 Positive for trailer right side lights / Positive for external light switch for bodybuilders connector 3315
22 − −
23 − −
24 Fuel level gauge 5552
25 Fuel level gauge ground 0652
26 Dumper tipping indicator 9144
27 Positive for right turn indicators 1123
28 Air filter clogged sensor 6663
29 Slow gears engaged light (signal) 9976
30 Positive for cab release indicator switch 8879
31 Signal from cab release indicator switch 6666
32 Ground for cab release indicator switch 0000
33 Positive from DGC for EDC deactivation contactor 7777
34 Power supply to rear transverse differential locking solenoid valve 9325
35 Signal from switch for signalling transversal differential lock 6620
36 Positive for left turn indicators 1129
37 Power supply for rear longitudinal differential lock solenoid valve 9324
38 Longitudinal lock engaged signal 6643
40 Fifth wheel light positive 2224
Pin - out connector “F” (green)

1 CAN H line White
2 CAN L line Green
3 Ignition signal “+50” 8888
4 Positive +30 for fuel heater element 7733
5 Positive +30 for EDC 8150
6 K line for 30-pole diagnostic connector (pin 2) 2298
7 Negative from engine stop button inside engine bay −
8 Negative from engine ignition button inside engine bay 9907

BULKHEAD CONNECTOR

14 Positive +15 from key switch for EDC 8051
15 Spare −
16 Speed signal EDC (setup) 5321
Economy Power Switch (Euro 3) 0171
17
Spare (Euro 4) −
Spare (Euro 3) −
18
19
Battery direct positive for UREA system power supply (Euro 4) 7606
22 Hydraulic power steering oil level signal 5525
23 Spare −
24 Spare −
Spare (Euro 3) −
25
Positive +15 for sensor for detecting water in diesel filter (Euro 4) 8879
Water present in fuel filter signal (Euro 3) 5530
26
Spare (Euro 4) −
Spare (Euro 3) −
27
Power steering oil level signal (Euro 4) 5525
Positive for electric windscreen washer pump (Euro 3) 8886
28
Water present in fuel filter signal (Euro 4) 5530
Positive +15 for sensor for detecting water in diesel filter (Euro 3) 8879
29
PTO request signal for UREA control unit (Euro 4) 5563
Spare (Euro 3) −
30
32 Signal for low battery charge light 7780
33 Alternator "+15" 8876
34 Air conditioning control 8004
35 Stop light signal (setup) 1117
36 Power supply for secondary accelerator 8350
37 Spare −
38 Positive from Body Controller for EDC 8876
39 Signal from secondary accelerator 5330

INSTRUMENT PANEL
553710 INSTRUMENT PANEL
11 12 13 14 15 16 17 18 19
20
21
22
23
24
10 9 8 7 6 5 4 3 2 1 25
217803 Figure 45

1 Rev counter 48001 (50003)
2 Coolant thermometer 47001 (50003)
3 Fuel level gauge 44001 (50003)
4 speedometer 40011 (50003)
5 Additional water heater control panel Hydronic (Euro 4) (if fitted) 84006
6 Tank internal fuel heater switch (Euro 4) 52223
7 Switch for additional water heater (Euro 4) 52003
8 Seat heating ON/OFF switch (Euro 4) 52YYY
9 Windscreen heating ON/OFF switch (Euro 4) 52036
10 Headlight levelling control switch 52312
11 External light switch 52307
12 Warning light cluster (50003)
14 Instruments Cluster 50005
15 Display (50003)
17 Display menu activation switch 53403
18 Display menu output switch 53402

INSTRUMENT PANEL

19 Menu switch + 53400
20 Menu switch - 53401
21 ABS shut-off switch 52057
22 Fog light switch 52321
23 Rear fog light switch 52007
24 Side spot light switch (bunk lights) 53509
25 Emergency light actuation switch 52302

CENTRAL DASHBOARD
553710 CENTRAL DASHBOARD
9b 5b
1 2 3 4 5
6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 5b 6 7 8 9 9b 10
217804 Figure 46

1 Engine brake actuation switch 52324
2 Central spot light switch 52094
3 Loading platform light actuation switch 52009
4 Switch for electric or pneumatic horns 52200
5 Eco Power Switch 53310
5b Control for electric hatch 53306
6 Rear transversal differential locking switch 53039
7 Longitudinal differential lock switch 52045

CENTRAL DASHBOARD

8 Rear view mirrors heating 52004
9 Power take-off switch 1. 52071
9b Front transverse differential lock switch 53022
10 Cab tilting enable switch 53061
11 Hand brake (53512)
12 Heating/ventilation or air conditioner controls 82000
13 Radio 68000
14 Cigarette lighter 85000
15 Additional air heater control panel Airtronic (Euro 4) (if fitted) 84006
16 12V socket 72054

Cab interior lights
5501 Cab interior lights
173724 Figure 47
Component
Ref. Description
code
1 Overhead light for left step lighting 39003<
2 Tachograph / tachograph simulator 40011
3 Central spot ceiling lights (left) 39022<
4 Central spot ceiling lights (right) 39022>

Cab interior lights
Component
Ref. Description
code
5 Overhead light for right step lighting 39003>
6 Lateral spot ceiling lights (bunk lights - right) 39027>
7 Lateral spot ceiling lights (bunk lights - left) 39027<
8 Courtesy light for reading lights 39009


Rear view mirror adjustment / power window control /equipment compartment open control

Rear view mirror adjustment / power window control /equipment compartment open control
5501 Rear view mirror adjustment / power window control /equipment compartment open
control
173725 Figure 48
Component
Ref. Description
code

"LH" STEERING COLUMN SWITCH 6-FUNCTION STEERING COLUMN SWITCH UNIT - [54033]
1 Rearview mirror adjuster 85010

2 Mirror selector switch 85011
3 Driver's side electric window switch 53300
4 Passenger's side electric window switch 53302
5 Tool compartment opening control switch 53075
765416 "LH" STEERING COLUMN SWITCH 6-FUNCTION STEERING COLUMN SWITCH

UNIT - [54033]
73985b Figure 49
Ref. Description
1 Windscreen wiper (maximum speed)
2 Windscreen wiper (low speed)
3 Windscreen wiper (intermittent)
4 Windscreen wiper (single swipe)
5 Spare
6 Full beam headlights on
7 Light flasher
8 ground

"LH" STEERING COLUMN SWITCH 6-FUNCTION STEERING COLUMN SWITCH UNIT - [54033]
73985b Figure 49
Ref. Description
9 Windscreen washer electric pump control
10 Spare
11 Spare
12 Spare
13 Spare
14 Spare
15 Right turn signal light
16 Left turn signal light

"RH" STEERING COLUMN SWITCH 4-FUNCTION STEERING COLUMN SWITCH UNIT - [54030]
534271 "RH" STEERING COLUMN SWITCH 4-FUNCTION STEERING COLUMN SWITCH

UNIT - [54030]
108919b Figure 50
Ref. Description
1 Intarder (position 4)
2 Gear shift (down)
3 Cruise Control (set / acceleration)
4 Cruise Control (Resume)
8 Spare
11 Cruise Control (decelerate)
12 Spare
13 Spare
14 Spare

"RH" STEERING COLUMN SWITCH 4-FUNCTION STEERING COLUMN SWITCH UNIT - [54030]
Ref. Description
15 Gear shift (up)
16 Ground (from the SWI)
Right multifunction lever
108920a Figure 51
The multi-function lever is located on the right side of the steering column and allows the engagement of the Intarder engine brake
function when present and gear selection with automatic transmission.
The engine brake function is selected by placing the lever in position 1 and 2 and remains engaged even when the lever is sued to
set the Intarder function (positions 3, 4, 5 and 6 relating to available braking powers).
When the engine brake function is selected, the control lever signal is transmitted to the S.W.I. (Steering Wheel Interface) control
unit.
The SWI activates the engine brake on warning light on Instrument Cluster IC, and via Body Computer B.C. sends the request of
engine brake to the EDC, EBS and automated EuroTronic ECUs (when present).
When the driver manually selects the engine brake, this choice is displayed on the instrument panel by a flashing light which goes
to steady when the engine brake is working. In manual mode, the exhaust brake function is also affected by the position of the
accelerator pedal (pedal released).
In the automatic mode, the engine brake is activated by the EDC centre on receipt of a request from the EBS centre. In this condi-
tion, the EDC centre pilots the engine brake solenoid valve and the VGT actuator to the fully closed position.

Description
5537 Description
217805 Figure 52
This system has the following features and is made up of:
● a speedometer (in both km/h and mph)

● a rev counter
● a fuel level gauge
● an engine coolant temperature gauge
● one display showing faults and user messages
● three sets of warning lights
● four scrolling keys for the various menus (Highline model only)
● a button for adjusting background lighting
● a trip meter reset button (change page on Baseline)
In addition to being connected to the vehicle's CAN line, the Instrument Cluster receives a set of signals directly from several
sensors or relays on the vehicle electric system.
The Instrument Cluster also receives the signals from the four buttons for the various menus. The operating logic for the buttons is
completely standard: the arrows are for changing page; if you select a page with numerous lines, the display allows you to view only
3 lines at a time or a page with a sub-menu. Pressing OK allows you to access the page and you can then use the "arrows".
Button C allows you to return to the previous page.
The display is in black-and-white. The lack of a colour display has been offset by the logic of associating yellow or red warning lights
with symbols to communicate important information to the driver.
Signals are sent directly to the Instrument Cluster (no CAN line is provided) from the:
● Engine oil level

● Fuel level sensor
● Presence of water in the diesel fuel filter sensor
● Air filter clogged signal
● Rear brake converter travel sensor
● Rear brake fluid level sensor
● Immobiliser warning light

Description
217805 Figure 52
● Battery charge indicator
● Trailer ABS failure indicator
All the other signals are received through the CAN line so as to allow the relevant message to be displayed. The Instrument Cluster
does not store error messages; it only displays them.
The systems that can currently be diagnosed are as follows: EDC, ELECTRIC MIRRORS, BODY CONTROLLER.
If the "HIGHLINE" model Cluster is available, a diagnosis of these systems can be shown on the display and this allows you to
identify failure codes.
These codes can be referred to by means of the "MENU" buttons provided on the dashboard.

Description
5537 Optical indicators on cluster
14 13 12 1 2 3 4 5 6 7
8
9
10
11
217806 Figure 53
Ref. Description Colour Symbol
1 External lights Green
2 Supplementary high-beam headlamps Blue
3 High-beam headlamps Blue
4 Hazard lights Red
5 Instrument panel failure Red
6 Fog lights Green
7 Rear fog lights Yellow
8 SLOW gears engaged Yellow
9 Engine preheating Yellow
10 Programmable speed limiter Yellow
11 Heated mirrors Yellow
12 Front transverse differential locked Yellow
13 Longitudinal differential locked. - Transfer box in neutral Yellow
14 Rear transverse differential lock Yellow

Description
17 16 15 20 19 18 22 23
25
26
27
24
21
217807 Figure 54
Ref. Description Colour Symbol
15 Side PTO I ON Yellow
16 Rear PTO II / transfer box ON Yellow
17 Left tractor direction Green
18 Retarder engaged Yellow
19 Engine brake ON Yellow
20 Braking system failure Red
21 Emergency brake ON Red
22 ABS fault Yellow
23 Trailer ABS failure Yellow
24 Special emergency brake ON (for FF vehicles) Red
25 OBDII anomaly Yellow
26 pneumatic suspension low pressure Red
27 Right trailer direction Green

Description
36 35 34 33 32 31 30 29 28
217808 Figure 55
Ref. Description
28 Analogue rev counter
29 Instrument lighting intensity adjustment
30 Major fault indicator
31 Coolant temperature (high temperature warning light)
32 Display
33 Fuel level sensor
34 Minor fault indicator
35 Button for resetting partial km count
36 Analogue speedometer
5537 Indicators on display unit (failure)

When one of the following functions is activated or one of the following malfunctions occurs, the corresponding symbol will appear
on the display.
Yellow symbols appear on the left side of the display, (minor faults and problems) while red symbols appear on the right side (seri-
ous faults).

Description
217809 Figure 56
Description Colour Symbol
Warning light for minor faults and non-serious problems Yellow
Serious fault warning (Stop) Red
Low air pressure, rear axle brake Red
Axle brake linings worn Red
Rear axle brake linings worn Red
Low brake fluid level Red
Rear AoH converter at end of travel Red
Tractor unit EBS fault Red
Tractor unit EBS fault Red
Low engine oil pressure Red
High engine coolant temperature Red
Low engine oil level Red
Radiator water low Red
EDC Red
Gearbox failure Red

Description
High gear fluid temperature Yellow
High retarder temperature Yellow
Retarder failure Yellow
Air suspension fault Red
IBC failure Red
Alternator not charging Red
Second alternator not charging Red
Low power steering fluid level Red
Cab unhooked Red
Tail lift Red
Airbag fault Red
Doors open Red
Vehicle braked by EBS Yellow
ASR enabled (brake control) Yellow
Tractor unit EBS fault Yellow
Tractor unit EBS fault Yellow
EDC fault Yellow
Immobiliser fault/ON Yellow
Immobiliser fault/ON Yellow
Starter disabled Yellow
Gearbox failure Yellow
Gear changes limited on automatic transmission Yellow
Air suspension fault Yellow
Pneumatic suspension not in operating condition Yellow
IBC fault Yellow
External lighting Yellow
Dumper tilted Yellow
Air filter clogged Yellow
Water in diesel pre-filter Yellow
Low windscreen fluid level Yellow

Description
Drive time fault Yellow
Perform maintenance

Trailer connected
EDC in power take-off mode
Seat belts unfastened Red
Instrument panel fault Yellow
Instrument panel failure Red
Low external temperature

CAN network failure Yellow
CAN network failure Red

Description
5537 Cluster (pin-out)
173730 Figure 57
Pin A - Black Cable colour B - Blue Cable colour

1 − − K line (diagnostics connector pin 14) 2994
2 CAN H line 6108 − −
3 CAN L line 6109 Trailer ABS failure warning light 6671
4 − − − −
5 − − − −
6 − − − −
7 − − − −
8 − − − −
9 − − Speed signal EDC (setup) 5321
10 − − Dumper tipping indicator 9144
11 Fuel level gauge ground 5557 Air filter clogged sensor 6663
12 Fuel level gauge 0616 Water in fuel filter sensor 5530
13 − − "UP" menu button 5900
14 − − − −
15 − − "DOWN" menu button 5901
16 − − "OK" menu button 5902
17 − − Signal for low battery charge light 7780
18 Positive +15 8879 − −
19 ground 0000 − −
20 Positive +30 7772 “C” menu button 5903

MTCO TACHOGRAPH [40011]
764020 MTCO TACHOGRAPH [40011]
180 t 5678.9
18:28
X Ø h h Ø X
1 5 1 5 1 5 1 5
2 6 2 6 2 6 2 6
D 3 7 3 7
C B 3 7 3 7
A
D C B A
4 8 4 8 4 8 4 8
217810 Figure 58

2 Lighting ideograms 4442
3 Positive +15 8879
4 CAN “H” line White
A
5 ground 0066
6 ground 0066
7 − −
1 Speed sensor power supply (pin 1) 5514 (XXX1)
2 Ground for speed sensor power supply (pin 2) 0058 (XXX2)
3 Sensor speed signal (pin 3) 5517 (XXX3)
4 Setup (Sensor speed inverted signal - pin 4) 5516 (XXX4)
B
5 − −
6 − −
7 Speed signal for bodybuilders (28-pin diagnostics socket) 5542
8 − −
1 − −
2 − −
3 − −
C
4 − −
5 − −
6 − −

VOLTAGE REDUCER[85031]

7 − −
C
8 − −
1 − −
2 − −
3 − −
4 − −
D
5 − −
6 − −
7 − −
8 − −
766140 VOLTAGE REDUCER[85031]
173732 Figure 59
Characteristics
Technical data
Inlet voltage 18 V to32 V
Outlet voltage 14 V ±3 %
Current absorption Less or equal19 mA
Output current 0 A to20.5 A
Operating temperature range −30 to60
Pin Description Cable colour code

1 NC Not used −
2 +14 User power supply positive 7770
3 31a Not used −
4 +14 User power supply positive 7770
5 Not used (ground) −
6 31b Reducer power ground 0000
7 30 Voltage reducer positive 7704
8 +14 Not used −

INTERCONNECTION CONTROL UNIT [75000]
7661 INTERCONNECTION CONTROL UNIT [75000]
1 2
6 5 4
217811 Figure 60
Ref. Description
1 Fuse holder (70000/3 - /1 - /2)
2 Contactor switches
3 30-pole diagnosis connector
4 OBD diagnostics socket
5 Body Controller
6 Control unit / Contactor

Contactor assembly
(E1) (E3)
F H G
A
B
C
D
E
217812 Figure 61

A Switch for +15 power supply from diagnostics socket 25705
B Fog lights contactor 25003
C Diesel heating contactor 25810
D Heated rear view mirrors contactor 25813
E − −
F(E1) Contactor for KEY-controlled power supply 25213
H − −
G(E3) Contactor for horn control 25805

Supplementary contactors
1 2 3 4 3
5 6 7 8 9 10 11 12 13 14
217813 Figure 62

1 Start-up contactor 25200
2 Contactor for connection of air-conditioning system 25327
3 Contactor for heated windscreen activation (Euro 4) 25818A
4 Contactor for heated windscreen activation (Euro 4) 25818B
5 3 - 1A diodes holder (2 with common anode) 61001
6 Contactor for brief connection of air-conditioning system 25326
7 Contactor for EDC deactivation 25903
8 Contactor for engaging ceiling lights reading 25819
9 Remote reverse light switch 25007
10 Contactor for cab tilting motor 25847
11 Power steering indicator light control switch 25868
12 Contactor for heater seat engagement (Euro 4) 25YYY
13 Tank heating switch (Euro 4) 25356B
14 Tank heating switch (Euro 4) 25356A

Diagram of fuses
70000/3 70000/1 70000/2
70000/3 70000/1 70000/2
217814 Figure 63
Red colour fuse holder (70000/1)
(70000/1)
Ref. Function Capacity (A) Terminal
1 Diagnostics connector 10 +30
2 Cigarette lighter / Spot light 10 +30
3 Fog lights / Electric sun roof 10 +30
4 Rear view mirrors heating 10 +30
5 Reverse lights / Differential locking / Power take-off 10 +15\1
6 Air conditioning / Fifth wheel light 10 +15\1
White colour fuse holder (70000/2)
(70000/2)
1 Auxiliary water heater 20 +30
2 Tool compartment lights 10 +30

70000/3 70000/1 70000/2
70000/3 70000/1 70000/2
217814 Figure 63

3 Trailer ABS 20 +30
4 ABS / Bodybuilders' connector 20 +30
5 ABS 5 +15\1
6 Ignition 20 +30
Green fuse holder (70000/3)
(70000/3)
1 Refrigerator 10 +Batt
2 Cab tilting 30 +30
3 Diesel pre-filter heated 20 +30
4 Cab tilting consent 5 +30
5 − − −
6 − − −
Fuse holder (70051)

(70051)
1 Additional air heater timer 5 +30
Control unit connection fuses (75000)
173737 Figure 64
(75000)
1 Body Controller / Tachograph / Cluster Instrument / Consent signalling power steering fault (8x4) 5 +15\1
Cab unhooked sensor / Diesel filter water sensor / Engine brake prearrangement / Additional
2 5 +15\1
water heater timer
3 Tachograph / Body Controller (Left low beam light - Right high beam light) 10 +Batt
4 Available 10 +30
5 EDC / Urea System (E4) 5 +15\1
6 Trailer socket / Chassis bodybuilders socket 5 15\2
7 Central locking / 24V Radio / 24V/12V Voltage reducer (Bunk lights - Electric socket) 10 +Batt
8 Body Controller (Right low beam light - Left high beam light) / Dashboard lighting 10 +30
9 ABS trailer socket 5 +15\2
10 Body Controller (Left parking lights and stop lights) 10 +30
11 Body Controller (turn indicators - emergency lights) 10 +30

173737 Figure 64

12 Horn 10 10A
13 Power windows 20 +15\2
14 Electric heater for windscreen defrosting / Air conditioning system 20 +15\2
15 Body Controller (windscreen wiper - windscreen washer) 10 +30
16 Brake air drier / Rear view mirror central control 5 +15\1
17 Auxiliary water heater 5 +15/2
18 Instrument Cluster / Telematics 5 +30
19 EDC 20 +30
20 Body Controller (Right parking lights and rear fog lights) 10 +30
21 ÷ 26 − − −

Connector assembly
D A
G 7
E
1 7
H
1 4 B
2
3 8 6 14
1
F
1 10
I
1 6 C
1
9 20 6
5 12
217815 Figure 65
"A" - "B" - "C" connector

A
7
B
2
C
1
174565 Figure 66

1
2
3 Positive +15 for power window switches 8861
A 4 Positive +30 (Body Controller) 7772
5 Positive +15 electric heater 8879
6 Positive +30 (Body Controller) 7772
7 Positive +30 for EDC 8150
1 Positive +15 for headlight alignment adjuster 8820
B
2 Positive +15 (from key switch) 8887
1 Positive direct battery (+Batt) after fuse (Body Controller / Tachograph) 7768
2
C 3
4
5 Positive direct battery (after fuse) roof panel cable junction 7704


C 6
"E" Connector
E
1 7
6 14
174566 Figure 67

1
2
3
4
E 5
6
7


11
E 12
13
14
"F" connector
F
1 10
9 20
174567 Figure 68

1
2 Positive +15 bodybuilders connector 7772
F 4 Positive +15 for EDC 8051
5
6
7


8 Positive +15 (brake air drier) 8840
9
10
12
13
F 14
15 Negative from horn engagement button 1116
16 Battery direct positive (+batt) central locking control unit 7728
17
18 Positive +30 (Instrument Cluster) 7772
19 Positive +30 (Telematic connector) 7772
20 Positive +30 horn control contactor 7777
"G" "H" Connector
H
1 4
3 8
174568 Figure 69


A Positive battery after DGC 7777
G
B Positive battery after DGC 7777
1 − −
2 − −
3 − −
4 − −
H
5 − −
6 Positive +15 (Body Controller / Instrument Cluster / Tachograph) 8879
7 − −
8 − −
"I" Connector
I
1 6
5 12
174569 Figure 70


1 ground 0000
2
3
4
5 Positive +15 Rear view mirror control unit 8879
6
I
7
8 Positive +30 horn control 1116
9 Positive direct battery (+Batt) (Body Controller / Tachograph) 7777
10
11
12

Internal Wiring Diagram
173739 Figure 71

LOCATION OF CONTROL UNITS
76 LOCATION OF CONTROL UNITS
3 2 4 1
217816 Figure 72
Ref. Description
1 ABS
2 Rear view mirror control
3 Central locking control unit
4 Supplementary contactors

BODY CONTROLLER (IBC2) [86116]
766187 BODY CONTROLLER (IBC2) [86116]

Connection connectors
173791 Figure 73
Connector “A” (Black)

1 Positive for fog light contactor 3302
2 Brake air sensor positive 5560


3 Brake air sensor ground 0000
4 Signal from switch for preventing engine start-up with handbrake off 6662
5 Signal from exhaust brake selector 9024
6 Slow gears engaged light (signal) 9976
8 Rear fog light switch 2283
9 Electric windscreen wiper pump control (Steering column switch) 8886
10 Handbrake engaged signal from switch 9907
11
12
13 Rear brake air pressure sensor signal 5562
14
15
16 Engine brake signal (Steering column switch) 8159
17 Speed Limiter signal 9968
18 Signal from fog lamp switch 2228
19
20 Signal from switch for signalling transversal differential lock 6620
21 Front brake air pressure sensor signal 5561
22 Signal from emergency light actuation switch 2507
23 Signal from left door button 0003
24 Windscreen wiper control (Slow) (Steering column switch) 8882
25 Steering column switch (Right turn indicators switch) (Steering column switch) 1123
26 Steering column switch (light flasher button) (Steering column switch) 2204
27 Cruise Control (SET-) (Steering column switch) 8157
28 Cruise Control (Resume / CC OFF) (Steering column switch) 8154
29 Windscreen wiper control (Intermit) (Steering column switch) 8822
30 Windscreen wiper control (Fast) (Steering column switch) 8881
31 Signal from button turning on central ceiling light 0010
33 Signal from right door button 0003
35 LH turn indicators (Steering column switch) 1129
36 High beam lights (Steering column switch) 2200
37 Signal from cab release indicator switch 6666
38 Cruise Control (SET+) (Steering column switch) 8156
39 Ground (front wheel pad wear signal) 0000
40 Ground (rear wheel pad wear signal) 0000
Connector “B” (White)

1 Rear power take-off engaged signal 6131

173791 Figure 73

2 Side power take-off engaged signal 6132
3 Negative from engine ignition button inside engine bay 9907
4 Longitudinal lock engaged signal 6643
5 Spare
6 Front differential lock engaged signal 6659
7 Spare −
8 Hydraulic power steering oil level signal 5525


9 Spare −
10 Spare
11 Transmission in neutral signal switch 7050
12 Spare
13 Spare
14 Spare
15 Spare
16 Control for internal white light 0941
17 EDC positive 8876
18 Spare
Connector “C” (Black)

1 Spare
3 Positive for internal roof lamp 4111
4 Right high beam headlamp 2221
5 Left low beam headlamp 2231
6 Windscreen wiper motor (53B - Fast) 8861
7 Windscreen wiper motor (53 - Slow) 8882
8 Positive for electric windscreen washer pump (setup) 8886
9 Windscreen wiper motor (31B) 8873
10 ground 0000
11 CAN “H” line Green
12 CAN "L" line White
13 Spare
15 Positive for step light 4408
18 Positive for left turn indicators 1129
20 Positive for right turn indicators 1123
Connector “D” (Blue)

2 Spare −
3 Spare −
4 Positive for rear fog light 2286

173791 Figure 73

5 Positive for rear left side lights 3305
6 Positive front left side lights / side markers 3304
7 Positive for rear side markers 3308
9 Positive +30 7772
10 Right low beam headlight / LDR consent 2223
11 Left high beam headlamp 2219

REAR VIEW MIRROR CONTROL UNIT [86021]

14 Licence plate lights 3307
15 Positive for rear right side lights 3315
16 Positive side light / front side marker 3314
17 Positive for trailer right side lights / Positive for external light switch for bodybuilders connector 3315
18 Positive for left stop light 1177
19 Positive for right stop light 1172
Connector “E” (White)

1 Spare
2 Spare
3 Reading light contactor control 4423
4 Positive +15 8879
5 Positive from key switch in ignition phase (+50) 8037
6 Contactor control engine start-up 9032
7 Spare
8 Spare
766152 REAR VIEW MIRROR CONTROL UNIT [86021]
173792 Figure 74
Pin Function Wire code

1 Left wide angle rearview mirror control (Horizontal) 8843

REAR VIEW MIRROR CONTROL UNIT [86021]
173792 Figure 74

2 Right wide angle rear view mirror control (vertical) 8853
3 Right main rear-view mirror control (vertical) 8858
4 Left main rear-view mirror control (vertical) 8808
5 Right rear-view mirror control (return) 8857
6 Spare
7 Negative for rear view mirror selector button 0956
8 Spare
9 Negative from rear view mirror button (movements to the right) 0953
10 Control unit ground 0000
11 Spare
12 Spare
13 Positive for control unit power supply 8879
14 Right wide angle rear view mirror control (horizontal) 8852
15 Main right rear view mirror control (horizontal) 8859
16 Left wide angle rear-view mirror control (Vertical) 8842
17 Left rear-view mirror control (return) 8806
18 Left main rear-view mirror control (horizontal) 8809
19 CAN H Line (BCB) White
20 CAN L Line (BCB) Green
21 Negative from heated mirror control switch 0957
22 Negative from rear view mirror button (movements to the left) 0954
23 Spare
24 Negative from rear view mirror button (downward movements) 0951
25 Negative from rear view mirror button (upward movements) 0952
26 Positive for heated mirror control switch 8819

CENTRAL LOCKING CONTROL UNIT [86029]
766146 CENTRAL LOCKING CONTROL UNIT [86029]
173793 Figure 75

1 (+) Battery direct positive (+Batt) 7728
1 4
Centralised closing engine power supply (door opening) 9964
(M1)
5
Centralised closing engine power supply (door closing) 9965
(M2)
1
2 ground 0066
2 3
4
5

DIAGNOSTICS CONNECTORS
7691 DIAGNOSTICS CONNECTORS

Diagnostics connector - [72021]
16 1 2
15 (+)
26 17 18 3 26 17 18
14 4
25 19 25 19 30 27
13 5
24 20 24 20 29 28
12 23 6 23 22 21
22 21 7 (-) (v)
11
10 9 8
113302 Figure 76
DIAGNOSIS CONNECTOR (FRONT VIEW)
Pins 27, 28, 29, 30 might be printed with different positions from those reported in this picture.
Pin System Function Cable colour code

1 Spare
2 EDC (ECM) K 2298
3 Spare
4 ABS K 2299
5 Spare
6 Spare
7 Spare
8 Spare
9 Spare
10 Spare
11 Power supply for ignition switch ancillaries + 15 8876
12 Spare
13 Spare
14 IC / Tachograph K 2994
15 Spare
16 Spare
17 Spare
18 Spare
19 Spare
20 Spare
21 CAN H (VDB) H White
22 CAN L (VDB) L Green
23 Spare
24 Spare
25 Engine start signal 9907

DIAGNOSTICS CONNECTORS
Pin System Function Cable colour code

26 Signal ground 0000
27 Spare
28 Spare
29 Signal ground 31 0000
30 Positive + 30 7772
OBD diagnostics connector (blue) [72069]
173794 Figure 77

1
2
3
4 ground 0000
5
6 CAN H line (VDB) White
7 K Line 2298
8
9
10
11
12
13
14 CAN L line (VDB) Green
15

EDC SYSTEM FUNCTIONS (Cursor 9)
Telematic connector - 7 pole [72XXX]
173795 Figure 78

1 Positive +30 7772
4 ground 0000
5 K Line 2298
6 Positive +15 8879
7 ground 0000
766161 EDC SYSTEM FUNCTIONS (Cursor 9)

The EDC 7 UC31 control unit manages the following main functions:
Fuel injection
Accessory functions (cruise control, speed limiter, power take-off, etc.)
Self-diagnosis
Recovery
Also permits:
Interface with other on-board electronic systems (if present)
Diagnosis
Fuel dosing
The fuel metering is calculated in relation to:
● accelerator position
● Engine rpm.
● Quantity of air introduced.
The outcome may be corrected in relation to:
● water temperature

or to avoid
● noise.
● Smoke.
● Overloading.
● Overheating.
The delivery can be modified in the case of:
● Engine brake engagement.

● External device intervention (such as the speed limiter, cruise control, etc.).
● Serious trouble decreasing the load or stopping the engine.
After determining the mass of air introduced by measuring its volume and temperature, the control unit calculates the correspond-
ing mass of fuel to inject into the relevant cylinder, also taking into account the temperature of the diesel.
Correcting flow rate according to water temperature
When it is cold, the engine encounters greater resistance to its action: the mechanical friction is high, the oil is still very viscous, the
various operating clearances are not yet optimum.
In addition to this, injected fuel tends to condense on the still cold metallic surfaces.
The fuel supply for a cold engine is therefore greater than for a warm one.
Correction of fuel introduction to prevent noise, smoke emissions or overloading.
The behaviour that could lead to this kind of trouble is well known.
The designer has therefore included special instructions in the control unit to avoid it.
De-rating
In the event of the engine overheating, injection is modified, decreasing the delivery to a varying degree, in proportion to the tem-
perature reached by the coolant.
Injection advance electronic control
The advance (start of delivery, expressed in degrees) may differ from one injection to the next and from one cylinder to another. It
is calculated, in the same way as the flow, in relation to the engine load (accelerator position, engine speed and air introduced).
The advance is appropriately corrected:
● during acceleration.
● according to the water temperature.
And also to obtain:
● lower emissions, noise and overloading.

● better vehicle acceleration.
When starting the engine, a high degree of advance is used based on water temperature.
Feedback from the start of delivery is supplied by the change in impedance of the injector solenoid valve.
Starting the engine
During the first few turns of the engine, the timing and cylinder no. 1 recognition signals (flywheel sensor and camshaft sensor) are
synchronized.
The accelerator pedal signal is ignored upon engine start. Starting delivery is set only according to water temperature, by a special
map.
When the control unit detects enough speed and acceleration in the flywheel to indicate that the engine is started up and no longer
driven by the starter motor, it re-activates the accelerator pedal.

Run Up
Upon activation of the key contact, the control unit transfers the information stored during the last engine stop to the main
memory (see: After run), and runs system diagnostics.
After Run
Whenever the engine is switched off with the key, the control unit stays powered for a few seconds by the main relay.
This enables the microprocessor to transfer certain data from the main memory (volatile) to a non-volatile EEprom, to make it
available for the next starting cycle (see: Run Up).
The data mainly consists of:
● various settings (engine low idle setting, etc.).

● Settings of some components.
● Faults memory.
The process lasts a few seconds, typically from 2 to 7 (depending on the amount of data to be saved), after which the ECU sends a
command to the main relay to disconnect from the battery.
This procedure should never be interrupted, for instance by switching off the engine with the battery isolator or disconnecting the
battery isolator before at least 10 seconds have passed after the engine is switched off.
If this happens, system functionality remains guaranteed until the fifth time it is turned off incorrectly (also non consecutively) after
which an error is stored in the faults memory and upon the following engine start-up, the engine will function with reduced per-
formance while the EDC warning light remains on (if present).
Repeated interruptions of the procedure could in fact lead to damage to the control unit.
Cut - off
It is the function of delivery interruption during deceleration.
Cylinder balancing
The individual balance of the cylinders contributes to improve comfort and driveability.
This function permits individual, customized control over the delivery of fuel and the start of delivery for each cylinder, which can
even differ from one cylinder to another, to compensate for the hydraulic tolerances of the injector.
The differences in flow (delivery specifications) between the various injectors cannot be evaluated directly by the ECU. This in-
formation is supplied by entering the code of each injector at the time of assembly through the diagnostic tool.
Synchronisation search
If the camshaft sensor signal fails, the control unit can still recognise the cylinders into which fuel is to be injected.
If this occurs when the engine is already running, the combustion succession has already been obtained, and therefore the control
unit continues with the sequence on which it is already synchronised.
If this occurs when the engine is off, the control unit energises a single solenoid valve. At the latest by the 2nd engine shaft revolu-
tion, an injection will occur in that cylinder, for which the central unit only has to synchronise itself on the combustion sequence and
start the engine.

Engine components
125717 Figure 79
A Fuel temperature sensor D Fuel regulation valve on high-pressure pump
B Camshaft timing sensor E Starting motor
C EDC control unit 7 F Oil pressure/temperature transmitter

125717 Figure 79
G Alternator M Connector on the engine head for connection with
H Temperature/air pressure sensor electro-injectors
I A/C compressor N Engine speed sensor on flywheel
L Water temperature sensor

EDC 7 UC31 ECU [85150]
115802 Figure 80
1 Injector connector 3 Sensor connector
2 Chassis connector 4 Atmospheric pressure sensor
Electric injector connector 3 (A)

12 16
6 11
1 5
102374 Figure 81
Pin Function
1 Solenoid valve for electric injection, cylinder 5
7
8
9 High-pressure pump
Sensor connector 2 (C)

6 8 16 9 15 22
4
5
1 3 23 30 36 29
102375 Figure 82
Pin Function
1 Variable geometry turbine control solenoid valve
2
3 Variable geometry turbine control solenoid valve
4 Engine brake control solenoid
6÷8
9 Ground for engine speed sensor on timing (timing sensor)
10 Engine rpm signal on timing system (timing sensor)
11
12 Fuel pressure sensor on rail (ground)
13 Fuel pressure sensor on rail (power supply)
14 Fuel pressure sensor on rail (signal)
15 Coolant temperature sensor signal
16
17 Fuel temperature sensor ground
18
19 Engine rpm sensor ground (flywheel sensor)
20 Turbocharger speed sensor ground
21÷22
23 Engine rpm sensor signal (flywheel sensor)
24 Ground for oil pressure/temperature sensor
25 Ground for air pressure/temperature sensor
26 Ground for coolant temperature sensor
27 Oil temperature sensor signal

Pin Function
28 Oil pressure sensor signal
29
30 Turbocharger speed sensor signal
31
32 Power supply for oil pressure/temperature sensor
33 Power supply for air pressure/temperature sensor
34 Air pressure sensor signal
35 Fuel temperature sensor signal
36 Air temperature sensor signal
Chassis connector “B”
71 89 72 54 6 11
1
7
12
53 35 18 36 17
50350 Figure 83

1
2 Positive +30 8150
3 Positive +30 8150
4
5 ground 0000
6 ground 0000
7
8 Positive +30 8150
9 Positive +30 8150
10 ground 0000
11 ground 0000
12 Negative for pre-post heating resistor command relay 0094
13
14
15


16
17
18
19
20
22
23
24
25
26
27
28
30
31
32
33
35 CAN "H" line White
36
37
38
39
42 Water present in fuel filter signal 5530
43
44
45
46
47 Negative from engine stop button inside engine bay 9906
50
51
52
53
54
55 Negative for engine brake solenoid valve 0043
56
57
58 Positive for engine brake solenoid valve 9966


59
60
61
62 Economy Power Switch 8854
63
64
67
68
69
70
71
72
73
74
75 Positive for thermostarter relay 8885
76
80
81
82
83
84
85
86
87
88

775010 Electro-injectors [78247]
192196 Figure 84
This is an N.O. solenoid valve.
They are connected to the EDC ECU on connector A.
The resistance of the coil of each individual injector is 0.56 - 0.57 Ohm.
● actuator - spray nozzle consisting of a pressure rod, a needle and a jet.

● Driving solenoid valve made up of coil and pilot valve.
The solenoid valve checks the lift of the nozzle needle.

BEGINNING OF INJECTION
Upon being supplied with power, the coil moves up the shutter.
The fuel in the control volume flows back towards the return duct resulting in a pressure drop in control volume.
At the same time, the fuel pressure in the pressure chamber moves up the needle resulting into the fuel being injected into the
cylinder.
END OF INJECTION
When power to the coil is cut off, the shutter closes again so as to re-create an equilibrium which moves the needle back into its
closed position and stops the injection process.

774511 Rail pressure sensor (RPS) PRESSURE ADJUSTMENT SENSOR - [85157]

The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection
electronic command.
196904 Figure 85
A Technical view C Recommended assembly position
B Perspective view
Supplier: BOSCH
Technical data
Pressure range 0 bar to2,400 bar
RPS sensor power supply 5V
Tightening torque
RPS sensor 140 N⋅m
Pin - out
Pin Function Cable colour
1 Pressure sensor power supply on rail (+5V) −
2 Pressure signal on rail −
3 Earth −

771010 High pressure pump CP3.3 (pressure regulator)

Pump with 3 radial pistons controlled by the timing gears, requiring no timing adjustment, with rotor type feed pump fitted to the
back.
CP.3 pump components
000912T Figure 86
A Connection between fuel return outlet and filter D Connection between fuel outlet from feed pump and
bracket filter
B Connection for fuel inlet from heat exchanger control E Rail fuel outlet coupling
unit 1 High-pressure pump
C Connection for fuel inlet from fuel filter 2 Fuel pump
3 Pressure regulator (NA solenoid valve regulated by
the control unit by means of PWM signal)

771034 Pressure regulator - solenoid valve [78013]

Situated at the inlet of the high pressure pump, on the low pressure system, this device adjusts the quantity of fuel reaching the high
pressure pump in accordance with the commands received from the control unit.
It mainly consists of the following parts:
● tapered shutter;
● valve control pin;
● pre-load spring;
● coils.
In the absence of a control signal, the flow regulator is normally open, and thus the high pressure pump is in maximum delivery
mode.
The control unit regulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying fuel to the high
pressure pump.
This component cannot be replaced individually and thus should not be dismantled.
The amount of fuel feeding the high pressure pump is metered by a proportional valve on the low pressure system - managed by
the EDC7 control unit.
The delivery pressure to the rail is regulate between 250 and 1400 bar by the control unit acting on the pressure regulator solen-
oid valve.
It is a N.O. solenoid valve.
Its resistance is:
Technical data
Pressure regulator solenoid valve resistance ≈ 3.2 Ω
It is connected to the control unit by pins A9 - A10.
772656 Fuel temperature sensor FUEL TEMPERATURE SENSOR - [47042]

It is a N.T.C. sensor located on the fuel filter at the engine left side.
It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume and adjust the delivery.

Sensor
196902 Figure 87
A Technical view C Wiring Diagram
B Perspective view

Supplier: BOSCH
Tightening torque
maximum tightening torque 25 N⋅m
Pin - out
1 Fuel temperature signal −
2 Earth −
764274 Engine coolant temperature sensor COOLANT TEMPERATURE SENSOR FOR EDC - [85153]
It is a N.T.C. sensor located on the head water output manifold on the engine left side.
It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies the
need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.

Sensor
196902 Figure 88
B Perspective view

Supplier: BOSCH
Tightening torque
Pin - out
1 Engine coolant temperature signal −
2 Earth −
764263 Flywheel pulse transmitter ENGINE RPM SENSOR - [48035]

This sensor is an inductive one and is located on the flywheel.
It generates signals obtained from the magnetic flow lines, which close through the holes obtained on the flywheel.
The electronic control unit uses this signal to detect the various engine ratings and to control the electronic rev counter.
If this signal fails the rev counter will not work.
The sensor gap is NOT ADJUSTABLE.

Sensor
191894 Figure 89
B Perspective view D Connector
Characteristics:
Supplier: BOSCH
Tightening torque
tightening torque 8 ±2 N⋅m
Technical data
resistance 774 Ω to956 Ω

Pin - out
1 Engine speed signal on flywheel −
2 Earth −
764264 Timing system pulse transmitter ENGINE SPEED SENSOR ON TIMING SYSTEM - [48042]
This inductive sensor is located on the camshaft.
It generates signals obtained from changes in magnetic flux created by spaces between the teeth on the phonic wheel fitted to the
crankshaft.
The signal generated by this sensor is used by the control unit as the injection timing signal.
Sensor
191894 Figure 90
A Technical view B Perspective view

C Wiring Diagram D Connector
Characteristics
Supplier: BOSCH
Tightening torque
Technical data
Pin - out
1 Engine speed signal on timing system −
2 Earth −
540752 Air temperature and pressure sensor TURBO BLOWER AIR PRESSURE AND TEMPERATURE
SENSOR FOR EDC - [85156]
This component incorporates a temperature sensor and a pressure sensor.
It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the
exact amount of fuel to be injected at each cycle.
The output voltage is proportional to the pressure (or temperature) measured by the sensor.

Sensor
196905 Figure 91
B Perspective view E Connector
C Recommended assembly position

Supplier: BOSCH
Technical data
Sensor power supply 5V
Storage temperature −40 to130
Pin - out
1 Earth −
2 Air temperature signal −
3 Sensor power supply (+5V) −
4 Air pressure signal −
764251 Oil pressure and temperature sensor TRANSMITTER FOR ENGINE OIL PRESSURE
GAUGE/TRANSMITTER FOR THERMOMETER SIGNALLING THE ENGINE OIL TEMPERAT-
URE - [42030/47032]
The values sent are transmitted to the EDC control unit which, in turn, governs the indicator on the dashboard (indicator/low pres-
sure warning light).
The engine oil temperature is used by the EDC control unit only.

Sensor
196906 Figure 92

Supplier: BOSCH
Technical data
Pin - out
1 Earth −
2 Oil temperature signal −
4 Oil pressure signal −

EDC SYSTEM (Cursor 13)
766161 EDC SYSTEM (Cursor 13)

Engine components
1
3
4
12
5
11
10 9 8 7
13 12
4
11
218390 Figure 93
1 Electro-injectors 7 EDC17 engine control unit
2 Fuel pressure sensor on rail 8 Temperature/air pressure sensor
3 Engine brake solenoid valve 9 Pre/post heating element
4 Fuel temperature sensor 10 starter motor
5 A/C compressor 11 Engine speed sensor (flywheel)
6 Alternator

12 Fuel regulation valve on high-pressure pump 13 High-pressure pump
3 4
218391 Figure 94
1 Connector on the engine head for connection with 2 Water temperature sensor
electro-injectors 3 Oil pressure/temperature transmitter
4 Distribution speed sensor

EDC 17 CV44 ECU [85150] (Cursor 13)
2 1
73
46 60 94
31 45 5 6 72
16 30 3 4
50
1 15 28
1 2
217817 Figure 95
1 Chassis connector 2 Connector - sensors and injectors
Pin - out

2 1
217818 Figure 96
Chassis connector (1)

1 Positive +30 8150
2 ground 0000
3 Positive +30 8150
4 ground 0000
5 Positive +30 8150
6 ground 0000
7
8
9
10
11
12
13
17 Water present in fuel filter signal 5530
18
19
20
21
22
23
24
25 Negative for pre-post heating resistor command relay 0094
26
27
28
29 Positive for engine brake solenoid valve (setup) 9966
30
31 Negative from engine stop button inside engine bay 9906
32
33
34


35
36
37
38
39
40 Positive from Body Controller 8876
42
43
44
46
47 Negative for engine brake solenoid valve (setup) 0043
48
49
50
51
52
53
54 CAN "H" line White
55
56
57
58
60
63
64
65
66
67
69
70
71
72
73
75
77


78
80
81
82
83
84
85
86
89
90 Positive for thermostarter relay 8885
Connector - sensors and injectors (2)

Pin Function
6 −
8 −
9 Power supply for air pressure/temperature sensor
10 −
11 Fuel temperature sensor signal
12 −
13 −
14 −
19 −
20 −
21 −
22 −
23 −
24 Power supply for oil pressure/temperature sensor
27 Air temperature sensor signal

Pin Function
28 Coolant temperature sensor signal
29 Ground for coolant / fuel temperature sensor
30 −
34 −
35 −
36 −
37 Engine rpm sensor ground (flywheel sensor)
39 Engine rpm signal on timing system (timing sensor)
40 −
41 −
42 Ground for air pressure/temperature sensor
43 Air pressure sensor signal
44 Oil temperature sensor signal
49 −
50 −
51 −
52 Engine rpm sensor signal (flywheel sensor)
53 −
54 Ground for engine speed sensor on timing (timing sensor)
55 −
56 −
57 Ground for oil pressure/temperature sensor
58 −
59 Oil pressure sensor signal
60 −

7691 CURSOR 13 engine cable
178249 Figure 97
1 Connector ST-E 6 Injector 4
2 Injector 1 7 Injector 5
3 Rail pressure sensor 8 Exhaust brake control solenoid valve
4 Injector 2 9 Injector 6
5 Injector 3
Pin Function
7 −
11 −

775010 Electro-injectors [78247]
192196 Figure 98
This is an N.O. solenoid valve.
They are connected to the EDC ECU on connector A.
The resistance of the coil of each individual injector is 0.56 - 0.57 Ohm.
● actuator - spray nozzle consisting of a pressure rod, a needle and a jet.

● Driving solenoid valve made up of coil and pilot valve.
The solenoid valve checks the lift of the nozzle needle.

BEGINNING OF INJECTION
Upon being supplied with power, the coil moves up the shutter.
The fuel in the control volume flows back towards the return duct resulting in a pressure drop in control volume.
At the same time, the fuel pressure in the pressure chamber moves up the needle resulting into the fuel being injected into the
cylinder.
END OF INJECTION
When power to the coil is cut off, the shutter closes again so as to re-create an equilibrium which moves the needle back into its
closed position and stops the injection process.

774511 Rail pressure sensor (RPS) PRESSURE ADJUSTMENT SENSOR - [85157]

The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection
electronic command.
196904 Figure 99
A Technical view C Recommended assembly position
B Perspective view
Supplier: BOSCH
Technical data
Pressure range 0 bar to2,400 bar
RPS sensor power supply 5V
Tightening torque
RPS sensor 140 N⋅m
Pin - out
1 Pressure sensor power supply on rail (+5V) −
2 Pressure signal on rail −
3 Earth −

771034 Fuel metering valve PRESSURE REGULATOR SOLENOID VALVE - [78013]
1 2 1 1
2
2
3 3
218392 Figure 100
1 High-pressure pump 3 Engine speed sensor (flywheel)
2 Fuel metering valve
Situated at the inlet of the high pressure pump, on the low pressure system, this device adjusts the quantity of fuel reaching the high
pressure pump in accordance with the commands received from the control unit.
It mainly consists of the following parts:
● tapered shutter
● valve control pin
● Pre-load spring
● Coil
In the absence of a control signal, the pressure regulator is normally open, and thus the high pressure pump is in maximum delivery
mode.
The control unit regulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying fuel to the high
pressure pump.
The amount of fuel feeding the high pressure pump is metered by a proportional valve on the low pressure system that is managed
by the EDC.
Pin - out
1 Power Supply −
2 Earth −

772656 Fuel temperature sensor FUEL TEMPERATURE SENSOR - [47042]

It is a N.T.C. sensor located on the fuel filter at the engine left side.
It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume and adjust the delivery.
Sensor
196902 Figure 101

B Perspective view

Supplier: BOSCH
Tightening torque
Pin - out
1 Fuel temperature signal −
2 Earth −
764274 Engine coolant temperature sensor COOLANT TEMPERATURE SENSOR FOR EDC - [85153]
It is a N.T.C. sensor located on the head water output manifold on the engine left side.
It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies the
need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.

Sensor
196902 Figure 102

B Perspective view

Supplier: BOSCH
Tightening torque
Pin - out
1 Engine coolant temperature signal −
2 Earth −
764263 Flywheel pulse transmitter ENGINE RPM SENSOR - [48035]

This sensor is an inductive one and is located on the HP pump.
It generates signals obtained from the magnetic flow lines, which close through the holes obtained on the phonic wheel.
The electronic control unit uses this signal to detect the various engine ratings and to control the electronic rev counter.
If this signal fails the rev counter will not work.

Sensor
191894 Figure 103

B Perspective view D Connector
Characteristics:
Supplier: BOSCH
Tightening torque
Technical data

Pin - out
1 Engine speed signal on flywheel −
2 Earth −
764264 Timing system pulse transmitter ENGINE SPEED SENSOR ON TIMING SYSTEM - [48042]
This inductive sensor is located on the camshaft.
It generates signals obtained from changes in magnetic flux created by spaces between the teeth on the phonic wheel fitted to the
crankshaft.
The signal generated by this sensor is used by the control unit as the injection timing signal.
Sensor
191894 Figure 104


C Wiring Diagram D Connector
Characteristics
Supplier: BOSCH
Tightening torque
Technical data
Pin - out
1 Engine speed signal on timing system −
2 Earth −
766123 Pre/post heating element

The resistance is located between the cylinder head and the intake manifold used to heat the air in pre - post heating operations.
When the key switch is actuated, if even only one of the temperature sensors (water, air, diesel) detects less than 10 °C, the elec-
tronic control unit activates pre/post-heating and turns on the relevant dashboard warning light for a time depending on the tem-
perature.
Once this time expires, the warning light starts flashing, thus telling the driver that he can now start the engine.
The warning light goes off after engine start while the resistance continues to be supplied for a variable period of time performing
post - heating.
If the engine is not started within 20 to 25 seconds after the warning light starts flashing, the operation is cancelled so as to prevent
battery discharge.
When reference temperature is above 10°C, actuating the ignition key makes the warning light go on for approximately 2 seconds
to complete the test and then turns it off to indicate the engine can be started.

resistance
196907 Figure 105

Technical data
Rated voltage 24 V
Pick-up current 160 A to290 A
Constant current 120 A to150 A
Insulating resistance 1 MΩ
540752 Air temperature and pressure sensor TURBO BLOWER AIR PRESSURE AND TEMPERATURE
SENSOR FOR EDC - [85156]
It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the
exact amount of fuel to be injected at each cycle.

Sensor
196905 Figure 106


Supplier: BOSCH
Technical data
Storage temperature −40 to130
Pin - out
1 Earth −
2 Air temperature signal −
4 Air pressure signal −
764251 Oil pressure and temperature sensor TRANSMITTER FOR ENGINE OIL PRESSURE
GAUGE/TRANSMITTER FOR THERMOMETER SIGNALLING THE ENGINE OIL TEMPERAT-
URE - [42030/47032]
The values sent are transmitted to the EDC control unit which, in turn, governs the indicator on the dashboard (indicator/low pres-
sure warning light).
The engine oil temperature is used by the EDC control unit only.

Sensor
196906 Figure 107


SCR SYSTEM (SELECTIVE CATALYTIC REDUCTION) (Euro 4)
Supplier: BOSCH
Technical data
Pin - out
1 Earth −
2 Oil temperature signal −
4 Oil pressure signal −
5074 SCR SYSTEM (SELECTIVE CATALYTIC REDUCTION) (Euro 4)

The operation of this system is described in the "Engine" section of this manual.

DeNOx system diagram

(CAN)
1 2 3
CAN (J1939)
4
(+15)
(+BAT)
PTO
H 2O
6 5
CAN (J1597)
7 8 DCU
UDS 9 10
AdBlue
13
12
11 CAN (J1939)
15
16
14
17
18 19
AIR 21 20
224872 Figure 108

1 Engine water circulation solenoid valve for AdBlue 3 Vehicle interface connector (CAN)
tank heating with SCR 4 Connector for chassis SCR components (STY10)
5 Vehicle interface connector (power supply) 5 Vehicle interface connector (power supply)
2 SCR system interconnection control unit (Box - fuse 6 AdBlue tank temperature and level sensors
and contactors) 7 AdBlue tank
8 AdBlue heating pipes with integrated resistor

(CAN)
1 2 3
CAN (J1939)
4
(+15)
(+BAT)
PTO
H 2O
6 5
CAN (J1597)
7 8 DCU
UDS 9 10
AdBlue
13
12
11 CAN (J1939)
15
16
14
17
18 19
AIR 21 20
224872 Figure 108

9 Compressed air control solenoid valve (metering 15 AdBlue Injector
module) 16 Catalytic converter
10 DCU - SCR dosing module control unit 17 Inlet exhaust gas temperature sensor
11 Dosing module - UDS (Unit Dosing System) 18 Outlet exhaust gas temperature sensor
12 CAN 2 line connector (STY7 - for diagnostics) 19 NOx control unit
13 CAN 1 line connector (STY9 - prearrangement) 20 Nitrogen oxide (NOx) detecting sensor
14 Water separator filter - oil 21 Air reservoir

Location of the SCR system components
1 2
4 3
1 1 3
7 8 12
8 9 10 8 11 12 9 10 8 11
224873 Figure 109
5 Dosing module - UDS (Unit Dosing System) 4 Engine water circulation solenoid valve for AdBlue
1 DCU - SCR dosing module control unit tank heating with SCR
2 Water separator filter - oil 5 Dosing module - UDS (Unit Dosing System)
3 SCR system interconnection control unit (Box - fuse 6 AdBlue tank temperature and level sensors
and contactors) 7 AdBlue Injector
8 Catalytic converter

1 2
4 3
1 1 3
7 8 12
8 9 10 8 11 12 9 10 8 11
224873 Figure 109
9 Inlet exhaust gas temperature sensor 11 Nitrogen oxide (NOx) detecting sensor
10 NOx control unit 12 Outlet exhaust gas temperature sensor

507410 AdBlue metering module
158362 Figure 110

1 Metering module - UDS 5 Mixture output (urea +air)
2 Compressed air control solenoid valve 6 Urea inlet
3 Compressed air intake 7 Urea outlet (return)
4 Metering module (Connector)
The AdBlue pump module consists essentially of a pump that draws the AdBlue from the tank and sends it to the injector when
atomized.
Atomization takes place thanks to the intervention of the compressed air.
The pump module can be equipped with a circuit connected to the engine cooling system that, in case of low temperatures, pre-
vents the freezing of AdBlue.
The amount of AdBlue sent to the injector and the injection pressure are controlled by the DCU and depend on the operating
conditions of the engine and the signals sent by the sensors.
Pin - out (Metering module)

1 - 15 Spare −
16 Power supply (+Batt) 312
17 ÷ 21 Spare −


22 CAN - L line (CAN2) 541
23 Ground 311
24 - 27 Spare −
28 CAN - H line (CAN2) 540
29 - 33 Spare −
34 Positive +15 15
35 Power supply for compressed air control solenoid valve 511
36 Ground for compressed air control solenoid valve 512
37 Spare −
Pin-out (Compressed air control solenoid valve)

1 Power supply for compressed air control solenoid valve 511
2 Ground for compressed air control solenoid valve 512
507411 DCU (Dosing Control Unit)
24 35
13 23
1 12
218396 Figure 111

The DCU acquires various parameters such as engine rpm, fuel consumption and catalytic converter temperature via CAN line and
sensors.
These parameters make it possible to calculate the AdBlue that must be injected into the exhaust pipe.
The system for controlling the injection can adjust its operating parameters to adapt to the real work situation.
DCU control unit pin-out

1 DCU power supply 300


2 DCU control unit ground 311
3 Positive +15 15
4 +15 signal for activation of SCR system (power supplies) 501
5 Spare −
6 Spare −
7 Spare −
8 Spare −
9 CAN - L line (CAN2) 541
10 CAN - H line (CAN2) 540
11 CAN line - L line (CAN1) (prearrangement) 543
12 CAN line - H line (CAN1) (prearrangement) 542
13 Spare −
14 SCR and Urea tank temperature sensor ground 230
15 SCR and Urea tank level sensor ground 231
16 Signal from catalytic converter outlet temperature sensor with SCR 220
17 Signal from catalytic converter inlet temperature sensor with SCR 221
18 Spare −
19 Spare −
20 Spare −
21 Spare −
22 Spare −
23 DCU control unit ground 311
24 Spare −
25 SCR and Urea tank temperature sensor signal 530
26 SCR with Urea tank level sensor signal 531
27 Ground for catalytic converter outlet temperature sensor with SCR 520
28 Ground for catalytic converter inlet temperature sensor with SCR 521
29 Signal from secondary accelerator engagement switch 401
30 Spare −
31 Spare −
32 Spare −
33 Spare −
34 Ground for engine water circulation solenoid valve for Urea tank heating with SCR 510
35 Signal for urea pipe heating control with internal resistor 513

7661 SCR system interconnection control unit

Box - fuses and contactors
A
B
C D E
F1 F2 F3 F4 F5 F6
R1 R2
218394 Figure 112

A Technical view D Output connection B connector (SCR components)
B Wiring Diagram E Fuses and contactors in box view
C Input connection A connector

«ABS - EBL» SYSTEM (ANTI-LOCK BRAKE SYSTEM) - (ELECTRONIC BRAKE LIMITER)
Contactor switches
Ref. Description
R1 Contactor for SCR system activation
R2 Contactor for AdBlue pipe heating engage
Fuses
Ref. Function Capacity (A)
F1 Metering module (UDS) supply 10
F2 SCR system power supply 30
F3 AdBlue Pipes resistors supply 5
F4 NOx control unit supply 10
F5 DCU supply 10
F6 Engine water circulation solenoid valve supply for AdBlue tank heating 5
Connector A pin-out
1 Battery direct positive 300
2 Earth 310
3 Positive +15 501
4 Command for AdBlue pipe heating consent 513
Connector B pin-out
1 DCU supply 301
2 Metering module (UDS) supply 302
3 NOx control unit supply 303
4 Engine water circulation solenoid valve supply for AdBlue tank heating 304
5 Command for AdBlue pipe heating resistors supply 305
6 Command for AdBlue pipe heating resistors ground 311
7 Earth 311
79 «ABS - EBL» SYSTEM (ANTI-LOCK BRAKE SYSTEM) - (ELECTRONIC BRAKE LIM-

ITER)
The EBL function controls the rear axle wheel «skidding» by comparing it to the front axle wheel speed.
On the basis of wheel r.p.m.'s and braking pressure (detected by the sensor upstream from rear axle ABS modulators), the central
unit calculates vehicle speed, rear axle wheel «skidding» and minimum deceleration expected.
«ABS» (Anti-Lock Brake System)

The braking of a moving vehicle and resulting deceleration and stopping distances mainly depend on the grip between the tyres and
the road surface.
With a fully efficient braking system, a further improvement in braking can only be achieved by acting on the friction of the tyres or
on the grade of the road surface.
Even in these optimum conditions, absolute braking safety is in any case not guaranteed when faced with especially difficult situ-
ations, such as poor grip due to a wet or icy road surface. The driver is forced to moderate use of the brakes in order to avoid
partially locking one or more wheels, with the risk of skidding dangerously.

The function of the ABS device is therefore to ensure vehicle stability (under all braking conditions), preventing the wheels from
locking irrespective of the state of the road surface, so as to ensure the available grip is made full use of.
Even in the case of emergency braking, the system makes it possible to keep direction, that is to turn the steering wheel to avoid
obstacles with no risk of skidding.
In short, the anti-lock braking system (ABS):
● Prevents the wheels to lock while braking, irrespectively of the grip condition of the road surface.
● Shortens stopping distances.
● Provides safety for the driver who can keep the vehicle's stability and direction.
EBL (Electronic Brakes Limiter)

The EBL function controls the rear axle wheel skidding by comparing it to the front axle wheel speed.
The input data to the control unit include the wheel speed and braking pressure measured by the pressure sensor installed up-
stream the rear axle ABS modulators.
According to these values, the control unit calculates the speed of the vehicle, the vehicle's deceleration, the rear axle wheel (skid-
ding) slittamento and the minimum deceleration expected.
The EBL function is activated (the rear ABS modulators can keep the preset pressure) when the driver applies an excessive braking
force for the conditions of load on the vehicle, i.e. when the rear axle slip and vehicle deceleration thresholds are exceeded.
Operating logic
The purpose of the electronic control unit is to slow down the vehicle as quickly as possible, ensuring stability and avoiding the
tendency for the wheels to lock.
To achieve this goal, the following data will be sent to the control unit while braking:
● The intensity of braking requested by the driver via the rear axle pressure sensor.
● The deceleration due to the pressures made available via the speed sensor signals.
The continuous monitoring and processing of this information, with reference to the target, will cause the rear axle modulating
valves to activate appropriately and optimise the braking action accordingly.

526711 ABS control unit CONTROL UNIT FOR ABS SYSTEM - [88000]
107016 Figure 113

It has the task of managing the braking system by setting the deceleration values in terms of the parameters measured by the vari-
ous components of the system itself.
It communicates with the on-board electronics via the CAN line and is connected to the vehicle's wiring via two polarised connect-
ors.
Although it has a «blink code »function, displayed through the warning light «ASR», for a preliminary diagnosis, the control unit
has a highly advanced self-testing system that can recognise and memorise, depending on environmental conditions, any failure, in-
cluding those of an intermittent nature, that may occur during system operation, so as to ensure effective and reliable repair inter-
ventions.
Pin – out ABS control unit
X2 X1
107017 Figure 114

Connector X1
2 Spare −
4 ground 0000

X2 X1
107017 Figure 114

5 Ground from switch for ABS exclusion 0049
6 Ground from switch for ASR exclusion 0048
7 Positive +15 8847
8 Positive +30 7710
9 ground 0000
10 K line (diagnostics connector pin 4) 2299
11 Spare –
12 9/15-pin safety jumper (only when connector X1 is not connected) –
13 Spare –
14 Spare –
15 Spare –
Connector X2
1 Positive for "EV" solenoid valve (unloading), front right wheel 9920
2 Positive "EV" (unloaded) solenoid valve command, rear left wheel 9931
3 Positive for "AV" solenoid valve (loading), front left wheel 9919
4 Positive for "AV" solenoid valve (loading), front right wheel 9918
5 Positive "AV" (loaded) solenoid valve command, rear left wheel 9929
6 Positive for "EV" solenoid valve (unloading), front left wheel 9921
7 Ground for ASR solenoid valve 0260
8 Positive "AV" (loaded) solenoid valve command, rear right wheel 9928
9 Positive "EV" (unloaded) solenoid valve command, rear right wheel 9930
16 Positive ASR solenoid valve control 9260

HYDRONIC M-II WATER HEATER
553210 HYDRONIC M-II WATER HEATER

Component location
84000 78237 84014
84005
52003
84006
222571 Figure 115

52003 Switch for engaging additional heater (water recircula- 84000 Water boiler
tion) 84005 Supplementary heater control unit
78237 Solenoid valve for engine water recirculation circuit 84006 Additional heater control panel
closed 84014 Supplementary fuel pump

Additional heater water circuit diagram
223182 Figure 116

1 Additional heater 3 engine
2 Solenoid valve for engine water recirculation circuit 4 Defroster (on the dashboard)
opening 5 Expansion tank
6 Thermostat

553210 HYDRONIC M-II HEATER

Hydronic M-II heater
1
2 3
222577 Figure 117

1 Technical view WA Water outlet
2 Perspective view V Combustion air intake
3 Heater control unit connector B Fuel supply
WE Water inlet A Exhaust gas outlet

Internal Wiring Diagram
222578 Figure 118

1.1 Burner motor 2.1 Burner control unit
1.2 Ignition spark plug 2.12 Water pump
1.2.1 Ignition spark plug (optional) B1 Control unit connector (connection for heater com-
1.5 Overheating sensor ponents)
1.12 Flame sensor B2 Cable connector (vehicle interface)
1.13 Water temperature sensor S2 Control unit connector (vehicle interface)
Heater electronic control unit pin-out

Pin Function Cable
A1 Positive for fuel dosing pump control 7783
A2 Ground 0000
A3 power supply +30 7708
A4 Spare −
B1 Spare −
B2 Spare −
B3 Spare −
B4 Control signal from additional heater control panel 1210
C1 Spare −
C2 Spare −
C3 Spare −
C4 Spare −

AIRTRONIC AIR HEATER (EBERSPACKER)
507570 AIRTRONIC AIR HEATER (EBERSPACKER)

Component location
84000 84014
84005
84006
222576 Figure 119

84000 Air heating unit 84006 Additional heater control panel
84005 Supplementary heater control unit 84014 Supplementary fuel pump

AIRTRONIC AIR HEATER (EBERSPACKER)
507570 Heater control unit connector
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
222579 Figure 120
Pin Description Wire colour

1 power supply +30 7708
2 Spare –
3 Spare –
4 Spare –
5 Fuel pump power supply 7783
6 Shunt pin 7 2300
7 Shunt pin 6 2300
8 Control signal from additional heater control panel 1200
9 Spare –
10 Ground 0000
11 Spare –
12 Spare –
13 Spare –
14 Spare –
15 Spare –
16 Spare –

CIRCUIT BOARDS 165
Contents
Contents CAN line (Euro 4) . . . . . . . . . . . . . . . . . . . . . . 266
Keys to interpretation . . . . . . . . . . . . . . . . . . . 167 Diagnostic connectors . . . . . . . . . . . . . . . . . . . 270
Battery direct positive . . . . . . . . . . . . . . . . . . . 168 Trailer sockets . . . . . . . . . . . . . . . . . . . . . . . . 274
Battery direct positive (Euro 4) . . . . . . . . . . . . . . 172 Refrigerator/Voltage reducer/Reading lights . . . . . . 278
Positive after main current deviator (+30)_01 . . . . . 176 Radio (high roof) / (low roof) . . . . . . . . . . . . . . . 282
Positive after main current deviator (+30)_02 . . . . . 180 Heated filter/Brake air drier . . . . . . . . . . . . . . . . 286
Positive after main current deviator (+30)_03 . . . . . 184 Power windows / Opening roof / Tool compartment
lights / Fifth wheel lights . . . . . . . . . . . . . . . . . . 290
Positive after main current switch (+30) (Euro
4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Central locking . . . . . . . . . . . . . . . . . . . . . . . . 294
Ancillary equipment power supply (+15/1)_ 01 . . . . 192 Adjustable heated rear view mirrors . . . . . . . . . . . 298
Ancillary equipment power supply (+15/1)_ 02 . . . . 196 Manually controlled air conditioning . . . . . . . . . . . 302
Ancillary equipment power supply (+15/2) . . . . . . . 200 Cab tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Services power supply (+15) (Euro 4) . . . . . . . . . . 204 Transversal/longitudinal differential lock - Power
take-off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . 310
Body Controller_01 . . . . . . . . . . . . . . . . . . . . . 208
Power steering . . . . . . . . . . . . . . . . . . . . . . . . 314
Body Controller_02 . . . . . . . . . . . . . . . . . . . . . 212
Manually controlled water heating . . . . . . . . . . . . 318
Body Controller_03 . . . . . . . . . . . . . . . . . . . . . 216
Manually controlled air heating . . . . . . . . . . . . . . 322
Body Controller_04 . . . . . . . . . . . . . . . . . . . . . 220
Heated windscreen / Heated driver's seat . . . . . . . 326
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 224
Diesel heater in tank . . . . . . . . . . . . . . . . . . . . 330
Tachograph Simulator (TSU) / Tachograph . . . . . . . 228
EDC7 (connector B) (Euro 3) . . . . . . . . . . . . . . . 232
EDC7 (connector B) (Euro 4) . . . . . . . . . . . . . . . 234
EDC17 (connector 1) . . . . . . . . . . . . . . . . . . . . 238
EDC7 (Connector A / C) . . . . . . . . . . . . . . . . . 242
EDC17 (Connector 2) . . . . . . . . . . . . . . . . . . . 246
SCR system (Cursor 9) . . . . . . . . . . . . . . . . . . . 250
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Cigarette lighter/Horns/Electric heater . . . . . . . . . 258
CAN line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

166 CIRCUIT BOARDS

CIRCUIT BOARDS 167
Keys to interpretation
CIRCUIT BOARDS
7691 Keys to interpretation
Consider the following as a key to interpretation of the circuit diagrams.
130022 Figure 121

168 CIRCUIT BOARDS
Battery direct positive
7691 Battery direct positive

217821 Figure 121

CIRCUIT BOARDS 169
20000 STARTER BATTERY

25222 THERMOSTARTER CONSENT ENGAGE SWITCH
40011 ELECTRONIC TACHOGRAPH
52600 MAIN POWER SWITCH
53510 SWITCH FOR SWITCHING ON STEP LIGHTS
68000 RADIO RECEIVER
70000 FUSE HOLDER 6
75000 INTERCONNECTION CONTROL UNIT
85031 POTENTIAL DIVIDER FOR POWER SOCKET (MAX. 11A)
85150 EDC CONTROL UNIT
86029 ELECTRONIC CONTROL UNIT FOR CENTRALISED DOOR LOCKING
86116 BODY COMPUTER MULTIPLEX CONTROL UNIT
89000 REFRIGERATOR

682 - Electric/electronic system
170 CIRCUIT BOARDS
Figure 122
86116
222488
F7
F3
70000/3
75000
86029
X
Ø
h
18:28
t 5678.9
40011
89000
180
h
Ø
X
85031
68000
CIRCUIT BOARDS 171
Figure 123
20000
222489
52600
19005
25222
85150 (EDC7)
172 CIRCUIT BOARDS
Battery direct positive (Euro 4)
7691 Battery direct positive (Euro 4)

222587 Figure 123

CIRCUIT BOARDS 173

25818 CONTACTOR FOR HEATED WINDSCREEN ACTIVATION
52036 SWITCH WITH BUILT-IN WARNING LAMP FOR HEATED WINDSCREEN
61106 HEATING ELEMENT FOR HEATED WINDSCREEN
70000 FUSE HOLDER 6
7500Y CONNECTION CONTROL UNIT FOR SCR SYSTEM

174 CIRCUIT BOARDS
Figure 124
86116
222563
F7
F3
70000/3
75000
61106
86029
85031
40011
25818A 25818B
68000
CIRCUIT BOARDS 175
Figure 125
20000
222564
52600
7500Y
19005
25222
85150 (EDC7)
176 CIRCUIT BOARDS
Positive after main current deviator (+30)_01
7691 Positive after main current deviator (+30)_01

217822 Figure 125

CIRCUIT BOARDS 177
03000 SELF-RECTIFYING ALTERNATOR WITH BUILT-IN VOLTAGE REGULATOR

08000 STARTER MOTOR
19005 THERMOSTARTER
22000 HORN
25213 CONTACTOR FOR SUPPLY OF USERS CONNECTED TO IGNITION SWITCH THROUGH +BATTERY
25705 CONTACTOR FOR VEHICLE DIAGNOSIS
25805 HORN CONTROL CONTACTOR
50003 ELECTRONIC INSTRUMENT PANEL WITH MICROPROCESSOR FOR INSTRUMENT AND WARNING
LIGHT DISPLAY
52200 SWITCH FOR ELECTRIC OR PNEUMATIC HORNS
52502 KEY-CONTROLLED SWITCH FOR SERVICES WITH START-UP
54033 6-FUNCTION STEERING COLUMN SWITCH UNIT
72021 30-POLE CONNECTOR FOR ELECTRICAL CONNECTION TO GROUND DIAGNOSTICS
78203 SOLENOID VALVE FOR PNEUMATIC HORNS

178 CIRCUIT BOARDS
25805(E3)
F15
F11
F18 F19 F20

F8
Figure 126
72021
75000
86116
25213(E1)
222490
25705
F10
52200
50003
52502
54033<
CIRCUIT BOARDS 179
Figure 127
20000
222491
52600
25222
03000
22000
19005
78203
85150 (EDC7)
08000
180 CIRCUIT BOARDS

217823 Figure 127

CIRCUIT BOARDS 181
25003 FOG LIGHT ENGAGEMENT CONTACTOR

25813 CONTACTOR FOR HEATED REAR VIEW MIRROR ACTIVATION
25819 CONTACTOR FOR ENGAGING CEILING READING LIGHTS
30011 FOG LIGHT
39022 COURTESY LIGHT FOR ADJUSTABLE CAB INTERIOR SPOT LIGHT
53306 SUN ROOF MOTOR CONTROL SWITCH
70000 FUSE HOLDER 6
72069 16 POLE CONNECTOR FOR OBD (ON-BOARD DIAGNOSTICS)
85000 CIGARETTE LIGHTER
85007 HEATED REARVIEW MIRROR AND ELECTRIC ADJUSTMENT (APPROACH)
85008 HEATED REARVIEW MIRROR AND ELECTRIC ADJUSTMENT (WIDE-ANGLE)
85040 MOTOR FOR ELECTRIC ROOF WITH BUILT-IN SWITCH
86021 HEATED REAR VIEW MIRROR CONTROL UNIT

182 CIRCUIT BOARDS
72069
Figure 128
72021
86116 25813
25003
222492
75000
25213(E1)
70000/1
85000
53306
CIRCUIT BOARDS 183
85008
85006
Figure 129
86021
222493
8500885007 85006
30011
25819
39022
85040
184 CIRCUIT BOARDS

222580 Figure 129

CIRCUIT BOARDS 185
08000 STARTER MOTOR

12032 CAB HYDRAULIC RELEASE PUMP MOTOR
12034 TOOL COMPARTMENT OPENING MOTOR
25200 START-UP CONTACTOR
25810 RELAY FOR DIESEL FUEL HEATING CIRCUIT CONTROL
25847 CONTACTOR FOR CAB TILTING MOTOR
39030 TOOL COMPARTMENT LIGHTS
53061 SWITCH FOR HYDRAULIC CAB RELEASE CONSENT
53063 CAB HYDRAULIC RELEASE PUMP SWITCH (RAISING)
53075 MOMENTARY SWITCH FOR OPENING THE TOOL COMPARTMENT
53512 SWITCH FOR PREVENTING START-UP WITH HANDBRAKE OFF
61101 DIESEL HEATING ELEMENT
70000 FUSE HOLDER 6
72006 7-POLE CONNECTOR FOR TRACTOR TRAILER ABS/EBS ELECTRICAL CONNECTION
88000 CONTROL UNIT FOR ABS SYSTEM

186 CIRCUIT BOARDS
Figure 130
70000/2
88000
222494
86116 25810
72006
75000
F2
25213(E1)
25847
70000/3
53061
39030
12034
25200
53075
CIRCUIT BOARDS 187
61101
Figure 131
222495
52600
53512/B
53063
12032
08000
188 CIRCUIT BOARDS
Positive after main current switch (+30) (Euro 4)
7691 Positive after main current switch (+30) (Euro 4)

222588 Figure 131

CIRCUIT BOARDS 189
25356 CONTACTOR FOR DIESEL HEATING IN TANK
25YYY CONTACTOR FOR ACTIVATING DRIVER'S HEATED SEAT
44047 FUEL LEVEL INDICATOR TRANSMITTER WITH RESISTOR FOR HEATING DIESEL
52223 SWITCH FOR DIESEL HEATING IN TANK
52YYY SWITCH FOR ACTIVATION OF DRIVER'S HEATED SEAT
70000 FUSE HOLDER 6
70051 1-WAY 5A FUSE HOLDER
84000 WATER BOILER
84001 AIR HEATING UNIT
84005 SUPPLEMENTARY HEATER CONTROL UNIT
84006 ADDITIONAL HEATER INDICATOR AND CONTROL UNIT

190 CIRCUIT BOARDS
Figure 132
70000/2
86116
222565
75000
F2
25213(E1)
70000/3
25356A
25356B
25YYY
84006
52223
52YYY
CIRCUIT BOARDS 191
Figure 133
84005
222566
84001
85036
84006
44047
84000
84005
192 CIRCUIT BOARDS
Ancillary equipment power supply (+15/1)_ 01
7691 Ancillary equipment power supply (+15/1)_ 01

222589 Figure 133

CIRCUIT BOARDS 193

25868 CONTACTOR FOR WARNING LIGHT CONTROL SIGNALLING POWER STEERING FAULT
25903 CONTACTOR FOR EDC DEACTIVATION
LIGHT DISPLAY
52324 ENGINE BRAKE PREFITTING SWITCH
53511 SWITCH FOR SIGNALLING CAB DISCONNECTED
61104 HEATING ELEMENT FOR BRAKING SYSTEM AIR DRYER
86013 SENSOR FOR SIGNALLING WATER IN FUEL FILTER

194 CIRCUIT BOARDS
Figure 134
86116 25810
72021
86116
F16
222496
25705
F2
25213(E1) 75000
F1
F5
68000
25868
50003
52324
25903
40011
52502
CIRCUIT BOARDS 195
Figure 135
20000
222497
52600
03000
86013
61104
53511
85150 (EDC7)
196 CIRCUIT BOARDS
7691 Ancillary equipment power supply (+15/1)_ 02

222583 Figure 135

CIRCUIT BOARDS 197
12012 AIR CONDITIONING SYSTEM COMPRESSOR

22047 SIGNAL SOUND FOR ACC (ADAPTIVE CRUISE CONTROL)
25007 REMOTE REVERSING LIGHT SWITCH
25326 CONTACTOR FOR BRIEF ACTIVATION OF AIR-CONDITIONING SYSTEM
25327 CONTACTOR FOR CONNECTION OF AIR-CONDITIONING SYSTEM
34000 MULTIFUNCTION REAR LIGHT
34011 FIFTH WHEEL LIGHT
42608 3-SWITCH ASSEMBLY SIGNALLING COOLANT PRESSURE
52009 SWITCH WITH BUILT IN WARNING LIGHT FOR TRAILER LIGHT
52045 SWITCH FOR ENGAGING FRONT WHEEL DRIVE
53022 FRONT DIFFERENTIAL LOCK CONTROL SWITCH
53039 REAR DIFFERENTIAL LOCK ACTIVATION SWITCH
53503 REVERSE LIGHT SWITCH
61001 HOUSING FOR 3 x 1A DIODES (2 WITH COMMON ANODE)
70000 FUSE HOLDER 6
72000 STANDARD 7-POLE CONNECTOR FOR ELECTRICAL CONNECTION TO TRAILER
72001 SUPPLEMENTARY 7-POLE CONNECTOR FOR ELECTRICAL CONNECTION TO TRAILER
78206 SOLENOID VALVE FOR LONGITUDINAL DIFFERENTIAL LOCK
78263 SOLENOID VALVE FOR REAR TRANSVERSE DIFFERENTIAL LOCK
78264 SOLENOID VALVE FOR FRONT TRANSVERSE DIFFERENTIAL LOCK
82000 ELECTRIC WINDSCREEN DEFROSTER CONTROL UNIT

198 CIRCUIT BOARDS
Figure 136
70000/2
70000/1
88000
222498
34011
72000
86116
75000
F14
25213(E1)
53022
25007
52009
6100125326
82000
52502
52045
25327
53039
CIRCUIT BOARDS 199
Figure 137
22047
7200072001
222499
X12
34000
78263
78206
53503
42608
12012
200 CIRCUIT BOARDS
Ancillary equipment power supply (+15/2)
7691 Ancillary equipment power supply (+15/2)

222584 Figure 137

CIRCUIT BOARDS 201
30100 HEADLIGHT ADJUSTER SWITCH
52312 HEADLIGHT LEVELLING CONTROL SWITCH
53300 ELECTRIC WINDOW SWITCH - DRIVER SIDE
53302 ELECTRIC WINDOW SWITCH - PASSENGER SIDE
80000 PASSENGER DOOR POWER WINDOW MOTOR
80001 DRIVER DOOR POWER WINDOW MOTOR

202 CIRCUIT BOARDS
F14
F6
Figure 138
25213(E1) 75000
82000
86116
86116
222500
F13
F9
53302/2
52502
53300
53302
52312
CIRCUIT BOARDS 203
Figure 139
30100
222501
80001
30001
72006
80000
204 CIRCUIT BOARDS
Services power supply (+15) (Euro 4)
7691 Services power supply (+15) (Euro 4)

222590 Figure 139

CIRCUIT BOARDS 205
84010 METERING DEVICE
85140 SCR (SELECTIVE CATALYTIC REDUCTION) PUMP UNIT ELECTRONIC CONTROL UNIT

206 CIRCUIT BOARDS
Figure 140
75000 86116
222567
F14 F2
25213(E1)
F5
25YYY
84006
52223
52502
25818A 25818B
52YYY
52036
CIRCUIT BOARDS 207
7500Y
Figure 141
222568
84010
84006
85140
208 CIRCUIT BOARDS
Body Controller_01
7691 Body Controller_01

Body Controller_01
217828 Figure 141

CIRCUIT BOARDS 209
Body Controller_01

25200 START-UP CONTACTOR
53006 SWITCH FOR START-UP FROM ENGINE COMPARTMENT
53508 SWITCH FOR PREVENTING START-UP WITH GEARS ENGAGED AND TURNING ON REVERSING LIGHT
53511 SWITCH FOR SIGNALLING CAB DISCONNECTED
70000 FUSE HOLDER 6

210 CIRCUIT BOARDS
Body Controller_01
Figure 142
20000
222502
52600
53512/B
53006
53508
08000
CIRCUIT BOARDS 211
Body Controller_01
Figure 143
72021
86116
86116
222503
70000/2
F15
F20
F3
F8
F2
25213(E1) 75000
F11
25847
F1
F10
53511
52502
53512/A
25200
212 CIRCUIT BOARDS
Body Controller_02

Body Controller_02
217829 Figure 143

CIRCUIT BOARDS 213
Body Controller_02

30001 LOW BEAM AND HIGH BEAM WITH SIDE LIGHT
30011 FOG LIGHT
30100 HEADLIGHT ADJUSTER SWITCH
32002 FRONT DIRECTION INDICATOR LIGHT
33001 SIDE DIRECTION INDICATOR
37001 FRONT CLEARANCE LIGHT
52307 SWITCH FOR EXTERIOR LIGHTS
52312 HEADLIGHT LEVELLING CONTROL SWITCH
52321 SWITCH WITH INCORPORATED INDICATOR LIGHT FOR FOG LIGHTS AND REAR FOG LIGHTS CON-
SENT
70000 FUSE HOLDER 6

214 CIRCUIT BOARDS
Body Controller_02
Figure 144
52321
25003
70000/1
86116
222504
75000
25213(E1)
F6
54033<
52307
52312
CIRCUIT BOARDS 215
Body Controller_02
Figure 145
20000
222505
52600
30100
30011
30001
32002
37001
216 CIRCUIT BOARDS
Body Controller_03

Body Controller_03
217830 Figure 145

CIRCUIT BOARDS 217
Body Controller_03

52007 SWITCH WITH INCORPORATED INDICATOR FOR REAR FOG LIGHT
52302 EMERGENCY LIGHT SWITCH WITH INCORPORATED INDICATOR
52307 SWITCH FOR EXTERIOR LIGHTS
53501 STOP SIGNALLING SWITCH
70000 FUSE HOLDER 6

218 CIRCUIT BOARDS
Body Controller_03
Figure 146
52007
86116
86116
222506
75000
25213(E1)
25007
54033>
52302
52307
CIRCUIT BOARDS 219
Body Controller_03
Figure 147
72000
34000>
22047
72001
X12
222507
35000
34000<
53503
20000
53501
85150 (EDC7)
52600
220 CIRCUIT BOARDS
Body Controller_04

Body Controller_04
226009 Figure 147

CIRCUIT BOARDS 221
Body Controller_04

25819 CONTACTOR FOR ENGAGING CEILING READING LIGHTS
30011 FOG LIGHT
39003 OVERHEAD LIGHT FOR STEP LIGHTING
39022 COURTESY LIGHT FOR ADJUSTABLE CAB INTERIOR SPOT LIGHT
39027 BUNK CEILING LIGHT TOOL
42031 TRANSMITTER FOR FRONT BRAKE AIR PRESSURE
42032 TRANSMITTER FOR REAR BRAKE AIR PRESSURE GAUGE
42393 SPEED LIMITER ADJUSTMENT SWITCH
52094 SWITCH FOR SPOT LIGHT
52324 ENGINE BRAKE PREFITTING SWITCH
53504 FRONT DIFFERENTIAL LOCKING ENGAGED INDICATOR SWITCH
53507 SWITCH FOR SIGNALLING LOW GEARS ENGAGED
53509 INTERNAL LIGHT SWITCH
53517 SWITCH FOR SIGNALLING TRANSVERSAL LOCK ENGAGED
53521 SWITCH FOR SIGNALLING LONGITUDINAL LOCK ENGAGED
53567 SWITCH FOR SIGNALLING (SIDE) POWER TAKEOFF 2 ENGAGED
53568 SWITCH FOR SIGNALLING (REAR) POWER TAKEOFF 1 ENGAGED
64000 ELECTRIC WINDSCREEN WASHER PUMP
65000 WINDSCREEN WIPER UNIT
70000 FUSE HOLDER 6

222 CIRCUIT BOARDS
Body Controller_04
Figure 148
72069
86116
222508
75000
F2
25213(E1)
39003
39022
72021
70000/1
54033<
54033>
52324
25819
52094
53510
39027
CIRCUIT BOARDS 223
Body Controller_04
Figure 149
20000
52600
222509
53517
53521
53509
44037
42032
42031
65000
64000
224 CIRCUIT BOARDS
Instrument Cluster
7691 Instrument Cluster

Instrument Cluster
226010 Figure 149

CIRCUIT BOARDS 225
Instrument Cluster

25903 CONTACTOR FOR EDC DEACTIVATION
42351 SWITCH FOR SIGNALLING CLOGGED AIR FILTER
44031 FUEL LEVEL INDICATOR TRANSMITTER WITH CONTACT FOR RESERVE WARNING LIGHT
LIGHT DISPLAY
53400 CLUSTER MENU CONTROL SWITCH (UP)
53401 CLUSTER MENU CONTROL SWITCH (DOWN)
53402 CLUSTER MENU CONTROL SWITCH (C)
53403 CLUSTER MENU CONTROL SWITCH (OK)
53538 BODY TIPPED INDICATOR SWITCH

226 CIRCUIT BOARDS
Instrument Cluster
Figure 150
72021
86116
86116
222510
F18 75000
40011
F1 F2
50003
25903
53401
53400
53402
53403
CIRCUIT BOARDS 227
Instrument Cluster
Figure 151
20000
44031
222511
52600
86013
85150 (EDC7)
72006
03000
228 CIRCUIT BOARDS
Tachograph Simulator (TSU) / Tachograph
7691 Tachograph Simulator (TSU) / Tachograph

Tachograph
226011 Figure 151

CIRCUIT BOARDS 229

40032 TRANSMITTERS FOR TACHOMETER AND TACHOGRAPH

230 CIRCUIT BOARDS
Figure 152
72021
40011 (TSU)
222512
86116
X
Ø
h
18:28
t 5678.9
40011
180
h
Ø
X
F3
25213(E1) 75000
F1
CIRCUIT BOARDS 231
Figure 153
20000
222513
52600
40032
232 CIRCUIT BOARDS
EDC7 (connector B) (Euro 3)
7691 EDC7 (connector B) (Euro 3)

EDC7 (B connector B)
217834 Figure 153

CIRCUIT BOARDS 233
19005 THERMOSTARTER
42374 EDC CLUTCH SWITCH
LIGHT DISPLAY
53007 SWITCH FOR STOPPING ENGINE FROM ENGINE COMPARTMENT
53310 TOTAL PTO ON GEARBOX ENGAGEMENT SIGNALLING SWITCH
61071 CAB 20-POLE CONNECTOR FOR FITTERS
78050 ENGINE BRAKE CONTROL SOLENOID VALVE
85152 LOAD SENSOR ON ACCELERATOR FOR EDC

234 CIRCUIT BOARDS
7691 EDC7 (connector B) (Euro 4)

EDC7 (B connector B)
222582 Figure 153

CIRCUIT BOARDS 235
19005 THERMOSTARTER
LIGHT DISPLAY
55101 ELECTRONIC SWITCH SIGNALLING ADDITIONAL TANK
85030 ACCELERATOR PEDAL POSITION TRANSDUCER

236 CIRCUIT BOARDS
Figure 154
72021
86116
222514
75000
F5 F19
70000/1
25213(E1)
85152
42374
50003
53501
52502
53310
55101
CIRCUIT BOARDS 237
Figure 155
20000
222515
52600
19005
25222
86013
53007
53006
85150 (EDC7)
238 CIRCUIT BOARDS
EDC17 (connector 1)
7691 EDC17 (connector 1)

EDC17 (connector 1)
217835 Figure 155

CIRCUIT BOARDS 239
EDC17 (connector 1)
19005 THERMOSTARTER
LIGHT DISPLAY

240 CIRCUIT BOARDS
EDC17 (connector 1)
Figure 156
72021
86116
222516
75000
F5 F19
25213(E1)
85152
50003
42374
53501
52502
53310
55101
CIRCUIT BOARDS 241
EDC17 (connector 1)
Figure 157
20000
222517
52600
19005
25222
86013
85150 (EDC17)
53007
53006
242 CIRCUIT BOARDS
EDC7 (Connector A / C)
7691 EDC7 (Connector A / C)

217836 Figure 157

CIRCUIT BOARDS 243
42030 TRANSMITTER FOR ENGINE OIL PRESSURE GAUGE

47032 SENDER FOR TEMPERATURE GAUGE SHOWING ENGINE OIL TEMPERATURE
47042 FUEL TEMPERATURE SENSOR
48035 ENGINE RPM SENSOR
48042 ENGINE SPEED SENSOR ON TIMING SYSTEM
78013 PRESSURE REGULATOR SOLENOID VALVE
78247 ELECTRONIC INJECTION SOLENOID VALVE
85153 COOLANT TEMPERATURE SENSOR FOR EDC
85156 TURBO BLOWER AIR PRESSURE AND TEMPERATURE SENSOR FOR EDC
85157 PRESSURE ADJUSTMENT SENSOR

244 CIRCUIT BOARDS
Figure 158
48042
222518
78013
48035
85150 (EDC7)
85153
CIRCUIT BOARDS 245
Figure 159
222519
85156
78247
78247
85157
42030
47032
47042
246 CIRCUIT BOARDS
EDC17 (Connector 2)
7691 EDC17 (Connector 2)

EDC17 (Connector 2)
217837 Figure 159

CIRCUIT BOARDS 247
EDC17 (Connector 2)
42030 TRANSMITTER FOR ENGINE OIL PRESSURE GAUGE

47032 SENDER FOR TEMPERATURE GAUGE SHOWING ENGINE OIL TEMPERATURE
47042 FUEL TEMPERATURE SENSOR
48035 ENGINE RPM SENSOR
48042 ENGINE SPEED SENSOR ON TIMING SYSTEM
78013 PRESSURE REGULATOR SOLENOID VALVE
78247 ELECTRONIC INJECTION SOLENOID VALVE
85153 COOLANT TEMPERATURE SENSOR FOR EDC
85156 TURBO BLOWER AIR PRESSURE AND TEMPERATURE SENSOR FOR EDC
85157 PRESSURE ADJUSTMENT SENSOR

248 CIRCUIT BOARDS
EDC17 (Connector 2)
Figure 160
85150 (EDC17)
47042
222520
78013
85156
48035
CIRCUIT BOARDS 249
EDC17 (Connector 2)
Figure 161
85153
48042
222521
78247
42030
47032
78247
85157
250 CIRCUIT BOARDS
SCR system (Cursor 9)
7691 SCR system (Cursor 9)

SCR system/Cursor 9)
222591 Figure 161

CIRCUIT BOARDS 251

52071 SWITCH FOR PTO 1 ENGAGE (REAR)
70000 FUSE HOLDER 6
78266 SCR (SELECTIVE CATALYTIC REDUCTION) METERING MODULE SOLENOID VALVE
78267 ENGINE WATER CIRCULATION VALVE FOR UREA TANK HEATING WITH SCR (SELECTIVE CATALYTIC
REDUCTION)

252 CIRCUIT BOARDS
85150 (EDC7)
Figure 162
72021
222522
86116
75000
20000
F5
25213(E1)
70000/3
52071
52600
CIRCUIT BOARDS 253
85142
7500Y
78267
Figure 163
85144
85141
222523
78266
84010
85140
85143
85144
254 CIRCUIT BOARDS
ABS
7691 ABS
ABS
217838 Figure 163

CIRCUIT BOARDS 255
ABS
LIGHT DISPLAY
52057 A.B.S. CUT-OUT SWITCH
70000 FUSE HOLDER 6
78052 ABS/EBS SOLENOID VALVE
88001 ABS/EBS SYSTEM SENSOR

256 CIRCUIT BOARDS
ABS
Figure 164
72021
222524
86116
75000
F9
88000
70000/2
52057
50003
CIRCUIT BOARDS 257
ABS
Figure 165
72006
222525
88001
78052
78052
85150 (EDC7)
53501
258 CIRCUIT BOARDS
Cigarette lighter/Horns/Electric heater
7691 Cigarette lighter/Horns/Electric heater

222585 Figure 165

CIRCUIT BOARDS 259
22000 HORN
25805 HORN CONTROL CONTACTOR
52200 SWITCH FOR ELECTRIC OR PNEUMATIC HORNS
70000 FUSE HOLDER 6
78203 SOLENOID VALVE FOR PNEUMATIC HORNS

260 CIRCUIT BOARDS
25805(E3)
F12
Figure 166
75000
F14
86116
222526
52200
54033<
CIRCUIT BOARDS 261
Figure 167
82000
222527
85000
78203
22000
262 CIRCUIT BOARDS
CAN line
7691 CAN line

CAN line
217840 Figure 167

CIRCUIT BOARDS 263
CAN line

LIGHT DISPLAY
72XXX 7-PIN TELEMATIC CONNECTOR

264 CIRCUIT BOARDS
CAN line
72069
Figure 168
72021
86116
222528
88000
50003
40011
72XXX
86021
86029
CIRCUIT BOARDS 265
CAN line
Figure 169
85150 (EDC17)
222529
85150 (EDC7)
266 CIRCUIT BOARDS
CAN line (Euro 4)
7691 CAN line (Euro 4)

CAN line (Euro 4)
222592 Figure 169

CIRCUIT BOARDS 267
CAN line (Euro 4)

LIGHT DISPLAY
85144 NOx DETECTION SENSOR WITH SCR

268 CIRCUIT BOARDS
CAN line (Euro 4)
72069
Figure 170
72021
86116
222528
88000
50003
40011
72XXX
86021
86029
CIRCUIT BOARDS 269
CAN line (Euro 4)
85150 (EDC7)
Figure 171
222530
84010
85140
85144
270 CIRCUIT BOARDS
Diagnostic connectors
7691 Diagnostic connectors

226013 Figure 171

CIRCUIT BOARDS 271

LIGHT DISPLAY
70000 FUSE HOLDER 6

272 CIRCUIT BOARDS
72069
Figure 172
72021
25705
86116
222531
75000
70000/1
F18
25213(E1)
88000
F01
50003
40011
52502
72XXX
CIRCUIT BOARDS 273
Figure 173
20000
222532
52600
19005
25222
85150 (EDC17)
CURSOR 9
CURSOR 13
53006
85150 (EDC7)
53006
274 CIRCUIT BOARDS
Trailer sockets
7691 Trailer sockets

Trailer sockets
217842 Figure 173

CIRCUIT BOARDS 275
Trailer sockets

34000 MULTIFUNCTION REAR LIGHT
LIGHT DISPLAY
70000 FUSE HOLDER 6

276 CIRCUIT BOARDS
Trailer sockets
Figure 174
70000/2
86116
86116
222533
75000
25213(E1)
F9
70000/1
25007
50003
CIRCUIT BOARDS 277
Trailer sockets
Figure 175
34000>
22047
72006
X12
222534
34000<
72000
53503
72001
20000
52600
278 CIRCUIT BOARDS
Refrigerator/Voltage reducer/Reading lights
7691 Refrigerator/Voltage reducer/Reading lights

217843 Figure 175

CIRCUIT BOARDS 279

39009 COURTESY LIGHT FOR READING LIGHTS
70000 FUSE HOLDER 6
72054 6 AMP POWER SOCKET
89000 REFRIGERATOR

280 CIRCUIT BOARDS
Figure 176
39009
222535
F7
75000
70000/3
89000
85031
CIRCUIT BOARDS 281
Figure 177
20000
222536
52600
72054
282 CIRCUIT BOARDS
Radio (high roof) / (low roof)
7691 Radio (high roof) / (low roof)

173700 Figure 177

CIRCUIT BOARDS 283

68001 LOUDSPEAKER
68002 ANTENNA

284 CIRCUIT BOARDS
Figure 178
86116
222537
F7
F2
75000
68000
CIRCUIT BOARDS 285
Figure 179
68001
222538
68001
68001
68002
286 CIRCUIT BOARDS
Heated filter/Brake air drier
7691 Heated filter/Brake air drier

217844 Figure 179

CIRCUIT BOARDS 287

61101 DIESEL HEATING ELEMENT
61104 HEATING ELEMENT FOR BRAKING SYSTEM AIR DRYER
70000 FUSE HOLDER 6

288 CIRCUIT BOARDS
F16
Figure 180
25810
75000
222539
F2
70000/3
CIRCUIT BOARDS 289
Figure 181
20000
222540
61104
61101
52600
290 CIRCUIT BOARDS
Power windows / Opening roof / Tool compartment lights / Fifth wheel lights
7691 Power windows / Opening roof / Tool compartment lights / Fifth wheel lights
217845 Figure 181

CIRCUIT BOARDS 291
12034 TOOL COMPARTMENT OPENING MOTOR

34011 FIFTH WHEEL LIGHT
39030 TOOL COMPARTMENT LIGHTS
52009 SWITCH WITH BUILT IN WARNING LIGHT FOR TRAILER LIGHT
53075 MOMENTARY SWITCH FOR OPENING THE TOOL COMPARTMENT
53300 ELECTRIC WINDOW SWITCH - DRIVER SIDE
53302 ELECTRIC WINDOW SWITCH - PASSENGER SIDE
53306 SUN ROOF MOTOR CONTROL SWITCH
70000 FUSE HOLDER 6
80000 PASSENGER DOOR POWER WINDOW MOTOR
80001 DRIVER DOOR POWER WINDOW MOTOR
85040 MOTOR FOR ELECTRIC ROOF WITH BUILT-IN SWITCH

292 CIRCUIT BOARDS
80001
Figure 182
53302/2
222541
34011
53300
53302
80000
CIRCUIT BOARDS 293
53306
Figure 183
70000/1
70000/2
222542
86116
75000
F13
52009
39030
12034
53075
294 CIRCUIT BOARDS
Central locking
7691 Central locking

Central locking
173703 Figure 183

CIRCUIT BOARDS 295
Central locking
12010 MOTOR FOR LOCKING OR UNLOCKING DOOR ON PASSENGER SIDE

12011 MOTOR FOR LOCKING OR UNLOCKING DOOR ON DRIVER SIDE

296 CIRCUIT BOARDS
Central locking
Figure 184
86116
222543
F7
75000
86029
CIRCUIT BOARDS 297
Central locking
Figure 185
53510
12010
222544
12011
53510
298 CIRCUIT BOARDS
Adjustable heated rear view mirrors
7691 Adjustable heated rear view mirrors

217846 Figure 185

CIRCUIT BOARDS 299
25813 CONTACTOR FOR HEATED REAR VIEW MIRROR ACTIVATION

52004 SWITCH FOR HEATED REAR VIEW MIRRORS
70000 FUSE HOLDER 6
85006 HEATED REARVIEW MIRROR AND ELECTRIC ADJUSTMENT (MAIN)
85007 HEATED REARVIEW MIRROR AND ELECTRIC ADJUSTMENT (APPROACH)
85008 HEATED REARVIEW MIRROR AND ELECTRIC ADJUSTMENT (WIDE-ANGLE)
85010 REARVIEW MIRROR CONTROL
85011 CONTROL FOR REAR VIEW MIRROR SELECTION AND REAR VIEW HEATED MIRROR ACTIVATION

300 CIRCUIT BOARDS
F16
Figure 186
8611625813
70000/1
75000
86116
222545
85010
85011
52004
CIRCUIT BOARDS 301
Figure 187
86021
222546
85008
85006
8500885007 85006
302 CIRCUIT BOARDS
Manually controlled air conditioning
7691 Manually controlled air conditioning

222586 Figure 187

CIRCUIT BOARDS 303

12012 AIR CONDITIONING SYSTEM COMPRESSOR
25326 CONTACTOR FOR BRIEF ACTIVATION OF AIR-CONDITIONING SYSTEM
25327 CONTACTOR FOR CONNECTION OF AIR-CONDITIONING SYSTEM
42608 3-SWITCH ASSEMBLY SIGNALLING COOLANT PRESSURE
LIGHT DISPLAY
61001 HOUSING FOR 3 x 1A DIODES (2 WITH COMMON ANODE)
70000 FUSE HOLDER 6

304 CIRCUIT BOARDS
Figure 188
70000/1
222547
86116
75000
F14
6100125326
82000
25327
50003
CIRCUIT BOARDS 305
Figure 189
20000
222548
52600
03000
42608
12012
306 CIRCUIT BOARDS
Cab tilting
7691 Cab tilting

Cab tilting
217847 Figure 189

CIRCUIT BOARDS 307
Cab tilting
12032 CAB HYDRAULIC RELEASE PUMP MOTOR

53061 SWITCH FOR HYDRAULIC CAB RELEASE CONSENT
53063 CAB HYDRAULIC RELEASE PUMP SWITCH (RAISING)
70000 FUSE HOLDER 6

308 CIRCUIT BOARDS
Cab tilting
Figure 190
86116
222549
75000
70000/3
25847
53061
CIRCUIT BOARDS 309
Cab tilting
Figure 191
53512/B
222550
53063
12032
310 CIRCUIT BOARDS
Transversal/longitudinal differential lock - Power take-off (PTO)
7691 Transversal/longitudinal differential lock - Power take-off (PTO)

Longitudinal/transverse differential lock - PTO
226014 Figure 191

CIRCUIT BOARDS 311
52071 SWITCH FOR PTO 1 ENGAGE (REAR)

53022 FRONT DIFFERENTIAL LOCK CONTROL SWITCH
53039 REAR DIFFERENTIAL LOCK ACTIVATION SWITCH
53504 FRONT DIFFERENTIAL LOCKING ENGAGED INDICATOR SWITCH
53517 SWITCH FOR SIGNALLING TRANSVERSAL LOCK ENGAGED
53521 SWITCH FOR SIGNALLING LONGITUDINAL LOCK ENGAGED
53568 SWITCH FOR SIGNALLING (REAR) POWER TAKEOFF 1 ENGAGED
70000 FUSE HOLDER 6
78206 SOLENOID VALVE FOR LONGITUDINAL DIFFERENTIAL LOCK
78252 SOLENOID VALVE FOR ENGAGING (TRANSMISSION REAR) POWER TAKEOFF 1
78263 SOLENOID VALVE FOR REAR TRANSVERSE DIFFERENTIAL LOCK
78264 SOLENOID VALVE FOR FRONT TRANSVERSE DIFFERENTIAL LOCK

312 CIRCUIT BOARDS
Figure 192
70000/1
86116
222551
75000
53022 52071
52502
52045
53039
CIRCUIT BOARDS 313
53517
Figure 193
53521
222552
78252
78263
78206
314 CIRCUIT BOARDS
Power steering
7691 Power steering

Power steering
222593 Figure 193

CIRCUIT BOARDS 315
Power steering

25868 CONTACTOR FOR WARNING LIGHT CONTROL SIGNALLING POWER STEERING FAULT
42622 CIRCUIT 2 HYDRAULIC OIL FLOW INDICATOR SWITCH
42623 ELECTRIC SWITCH IN FRONT POWER STEERING SWITCHING VALVE (ZF CIRC.1.5)
42624 ELECTRIC SWITCH IN FRONT POWER STEERING LOCK VALVE (ZF CIRC.1.5)
44037 POWER STEERING LOW FLUID LEVEL INDICATOR CONTROL
LIGHT DISPLAY

316 CIRCUIT BOARDS
Power steering
Figure 194
86116
222553
75000
25213(E1)
F1
25868
50003
CIRCUIT BOARDS 317
Power steering
Figure 195
20000
222554
52600
42622
44037
42624
42623
318 CIRCUIT BOARDS
Manually controlled water heating
7691 Manually controlled water heating

222594 Figure 195

CIRCUIT BOARDS 319
52003 SWITCH WITH INCORPORATED INDICATOR FOR THE SUPPLEMENTARY HEATER
70000 FUSE HOLDER 6
78237 SOLENOID VALVE FOR ENGINE WATER RECIRCULATION CIRCUIT CLOSED
84000 WATER BOILER
84014 SUPPLEMENTARY FUEL PUMP

320 CIRCUIT BOARDS
F2
Figure 196
70000/2
25213(E1) 75000
86116
86116
222555
F17
84006
52003
CIRCUIT BOARDS 321
Figure 197
84014
222556
78237
84000
84005
322 CIRCUIT BOARDS
Manually controlled air heating
7691 Manually controlled air heating

222595 Figure 197

CIRCUIT BOARDS 323
70000 FUSE HOLDER 6
70051 1-WAY 5A FUSE HOLDER
84001 AIR HEATING UNIT
84014 SUPPLEMENTARY FUEL PUMP

324 CIRCUIT BOARDS
Figure 198
86116
222557
75000
F2
25213(E1)
70000/3
84006
CIRCUIT BOARDS 325
Figure 199
84014
222558
84005
84001
326 CIRCUIT BOARDS
Heated windscreen / Heated driver's seat
7691 Heated windscreen / Heated driver's seat

222596 Figure 199

CIRCUIT BOARDS 327

61106 HEATING ELEMENT FOR HEATED WINDSCREEN
70000 FUSE HOLDER 6
85036 HEATED PNEUMATIC SEAT (DRIVER SIDE)

328 CIRCUIT BOARDS
Figure 200
86116
222559
75000
F14
25213(E1)
25YYY
70000/3
25818A 25818B
52YYY
52036
CIRCUIT BOARDS 329
Figure 201
20000
222560
52600
61106
85036
330 CIRCUIT BOARDS
Diesel heater in tank
7691 Diesel heater in tank

222597 Figure 201

CIRCUIT BOARDS 331

44047 FUEL LEVEL INDICATOR TRANSMITTER WITH RESISTOR FOR HEATING DIESEL
LIGHT DISPLAY
52223 SWITCH FOR DIESEL HEATING IN TANK
70000 FUSE HOLDER 6

332 CIRCUIT BOARDS
Figure 202
86116
222561
75000
F14
25213(E1)
25356B 25356A
70000/3
50003
52223
CIRCUIT BOARDS 333
Figure 203
20000
222562
52600
44047
334 DIAGNOSTICS

DIAGNOSTICS 335
Contents
Contents
Main electronic - electric malfunctions . . . . . . . . . 337

DTC INSTRUMENT CLUSTER control unit . . . . 338
DTC IBC2 control unit . . . . . . . . . . . . . . . . . 340

336 DIAGNOSTICS

DIAGNOSTICS 337
DIAGNOSTICS

DTC INSTRUMENT CLUSTER control unit
338
DTC FMI Faulty compon- Error type Visible fault Possible Cause Repair opera- Controls to Measuring Values Notes

DIAGNOSTICS
ent tion be carried conditions to be
out detected
0x0001 ELECTRONIC EEPROM FAULTY
– – – – – – – –
(1) CONTROL UNIT
0x0004 STEPPER MOTOR INSTRUMENT INDIC-
– – – – – – – –
(4) ATORS
0x0005 SENSORS FUEL LEVEL GAUGE
– – – – – – – –
(5) SENSOR
0x0006 ELECTRONIC ELECTRONIC CON-
– – – – – – – –
(6) CONTROL UNIT TROL UNIT
0x0007 SENSORS AMBIENT TEMPERAT-
– – – – – – – –
(7) URE SENSOR
0x0008 WARNING FAULT OF THE EOBD
– – – – – – – –
(8) LIGHTS INDICATOR LAMP
0x0009 ELECTRONIC OIL LEVEL SENSOR
– – – – – – – –
(9) CONTROL UNIT
0x000C COMMUNICA- NO COMMUNICA-
– – – – – – – –
(12) TION LINES TION ON CAN LINE
0x000D COMMUNICA- NO COMMUNICA-
– – – – – – – –
(13) TION LINES TION WITH IBC ECU
0x000E COMMUNICA- NO COMMUNICA-
– – – – – – – –
(14) TION LINES TION WITH EDC ECU
0x000F COMMUNICA- NO COMMUNICA-
(15) – TION LINES TION WITH TACHO- – – – – – – –
GRAPH ECU
0x0010 COMMUNICA- NO COMMUNICA-
(16) – TION LINES TION WITH ALLISON – – – – – – –
GEARBOX ECU

– – – – – – – –
(17) TION LINES TION WITH ABS ECU
– – – – – – – –
(18) TION LINES TION WITH ECAS
0x0013 COMMUNICA- NO COMMUNIC-
(19) – TION LINES ATION WITH RE- – – – – – – –
TARDER ECU
0x0014 COMMUNICA- NO COMMUNIC-
(20) – TION LINES ATION WITH ECU – – – – – – –
“MIRRORS CHECK”
DTC FMI Faulty compon- Error type Visible fault Possible Cause Repair opera- Controls to Measuring Values Notes
ent tion be carried conditions to be
out detected
(21) – TION LINES TION WITH EXPAN- – – – – – – –
SION MODULE

DIAGNOSTICS
339
DTC IBC2 control unit
340

DIAGNOSTICS
out detected
0x0001 ELECTRONIC CON- CHECK-SUM WRONG
– – – – – – – –
(1) TROL UNIT
0x0002 ELECTRONIC CON- OVERHEATING
– – – – – – – –
(2) TROL UNIT
0x0003 POWER SUPPLY TGC PIN C2 VOLTAGE
– – – – – – – –
(3) (+30)
0x0004 POWER SUPPLY TGC PIN D12 VOLTAGE
– – – – – – – –
(4)
– – – – – – – –
(5)
– – – – – – – –
(6)
0x0007 POWER SUPPLY TGC PIN C14 VOLTAGE
– – – – – – – –
(7)
0x0008 DIRECTION INDIC- RIGHT TURN INDIC-
– – – – – – – –
(8) ATORS ATOR
0x0009 DIRECTION INDIC- TRAILER RH INDIC-
– – – – – – – –
(9) ATORS ATOR
0x000A DIRECTION INDIC- TRAILER RH TURN
– – – – – – – –
(10) ATORS LIGHT CONTROL
0x000B DIRECTION INDIC- LEFT TURN INDICATOR
– – – – – – – –
(11) ATORS
0x000C DIRECTION INDIC- TRAILER LH INDIC-
– – – – – – – –
(12) ATORS ATOR
0x000D DIRECTION INDIC- TRAILER LH TURN
– – – – – – – –
(13) ATORS LIGHT CONTROL
0x000E PARK- LEFT PARKING LIGHTS /

(14) – ING/CLEARANCE RIGHT CLEARANCE – – – – – – –
LIGHTS
0x000F PARK- REAR RIGHT PARKING
(15) – ING/CLEARANCE LIGHT – – – – – – –
LIGHTS
0x0010 PARK- LEFT/RIGHT NUMBER
(16) – ING/CLEARANCE PLATE LIGHTS – – – – – – –
LIGHTS
out detected
0x0011 PARK- FRONT LH PARKING /
(17) ING/CLEARANCE RIGHT CLEARANCE /
– LIGHTS RIGHT REAR PARKING / – – – – – – –
RH-LH NUMBER PLATE
/ RH TRAILER LIGHTS
0x0012 PARK- RIGHT PARKING LIGHTS
(18) – ING/CLEARANCE / LEFT CLEARANCE – – – – – – –
LIGHTS
0x0013 PARK- REAR LEFT PARKING
(19) – ING/CLEARANCE LIGHT – – – – – – –
LIGHTS
0x0014 PARK- REAR LH/RH DIMEN-
(20) – ING/CLEARANCE SION LIGHTS – – – – – – –
LIGHTS
0x0015 PARK- FRONT RH PARKING
(21) ING/CLEARANCE / LEFT CLEARANCE /
LIGHTS LEFT REAR PARKING
– – – – – – – –
/ REAR LH TRAILER
CLEARANCE LIGHTS
CONTROLS
0x0016 REAR FOG LIGHTS LEFT / RIGHT
– – – – – – – –
(22)

0x0017 REAR FOG LIGHTS LEFT / RIGHT VEHICLE-
– – – – – – – –
(23) TRAILER
0x0018 STOP LIGHTS LEFT
– – – – – – – –

(24)
0x0019 STOP LIGHTS RIGHT
– – – – – – – –
(25)
0x001A STOP LIGHTS STOP LIGHT CONTROL
– – – – – – – –
(26)
0x001B SWITCHES RIGHT/LEFT TURN
– – – – – – – –
DIAGNOSTICS
(27) INDICATOR
0x001C SWITCHES WINDSCREEN WIPER
– – – – – – – –
(28)
0x001D SWITCHES ENGINE BRAKE
(29) – PRESELECTION – – – – – – –
BUTTON
341
342
out detected

DIAGNOSTICS
0x001E SWITCHES LONGITUDINAL DIF-
– – – – – – – –
(30) FERENTIAL LOCKING
0x001F SENSORS FRONT BRAKES AIR
– – – – – – – –
(31) PRESSURE
0x0020 SENSORS REAR BRAKES AIR PRES-
– – – – – – – –
(32) SURE
0x002B SENSORS POWER SUPPLY FOR
(43) – BRAKE SYSTEM AIR – – – – – – –
PRESSURE SENSOR
0x002C COMMUNICATION NO COMMUNICATION
– – – – – – – –
(44) LINES ON CAN LINE
0x002D ELECTRONIC CON- NOT PROGRAMMED
– – – – – – – –
(45) TROL UNIT

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682

Images and text: IVECO S.p.A. 2015

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

SYMBOLS - SERVICE OPERATIONS . . . . . . . . . . . . 6

GENERAL WARNINGS REGARDING THE

Grounding and screening . . . . . . . . . . . . . . . . . . . 11

Optional electrical and mechanical parts

Conversions between the main units of measurement

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

Danger for persons

Risk of serious damage to the vehicle

NOTE Indicates an additional explanation for a piece of information.

– printed 603.95.857 – base 02/2015 - 2nd ED.

SYMBOLS - SERVICE OPERATIONS

Tighten to the specified torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

– printed 603.95.857 – base 02/2015 - 2nd ED.

40 Chassis cross members

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

Grounding and screening

– printed 603.95.857 – base 02/2015 - 2nd ED.

Optional electrical and mechanical parts installations

Revolutions per time unit

Where accuracy is not particularly required:

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

VEHICLE IDENTIFICATION DATA . . . . . . . . . . . . . 5

DECODING VCB EURO III VEHICLE . . . . . . . . . . . 8

DECODING VCB EURO IV VEHICLE . . . . . . . . . . . 9

COMPOSITION OF EURO III MODELS . . . . . . . . . 10

COMPOSITION OF EURO IV MODELS . . . . . . . . . 11

– printed 603.95.857 – base 02/2015 - 2nd ED.

– printed 603.95.857 – base 02/2015 - 2nd ED.

Vehicle identification plate

– printed 603.95.857 – base 02/2015 - 2nd ED.

1. The vehicle VIN

Vehicle identification number (V.I.N.) punched on the chassis

– printed 603.95.857 – base 02/2015 - 2nd ED.

Positions 12-13-14-15-16-17: Progressive production number

● SC 430 G 34 H T S ‒ Cab type

● SC 430 G 34 H T S ‒ Total ground

● SC 430 G 34 H T S ‒ Iveco range code 682

● SC 430 G 34 H T S ‒ Type of use

● SC 430 G 34 H T S ‒ Type of rear axle

– printed 603.95.857 – base 02/2015 - 2nd ED.

DECODING VCB EURO III VEHICLE

● A A A B B C C D ‒ AXLE CONFIGURATION - TOTAL GROUND MASS

● A A A B B C C D ‒ TYPE OF REAR AXLE - TYPE OF SUSPENSION

– printed 603.95.857 – base 02/2015 - 2nd ED.

● A A A B B C C D ‒ CAB TYPE - STEERING - BRAKE COMBINATION

DECODING VCB EURO IV VEHICLE

● A A A B B C C D ‒ AXLE CONFIGURATION - TOTAL GROUND MASS